2002 CHEVROLET C3500 HD manual transmission

Long Trip/Highway Scheduled Maintenance
7-43
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
the cooling system and pressure cap.
An Emission Control Service.
ACTUAL
SERVICED BY:MILEAGE
DATE
ACTUAL
SERVICED BY:MILEAGE
DATE

7-45
Cassette Deck Service
Clean cassette deck. Cleaning should be done every
50 hours of tape play. See ªAudio Systemsº in the
Index for further details.
At Least Twice a Year
Restraint System Check
Make sure the safety belt reminder light and all your
belts, buckles, latch plates, retractors and anchorages are
working properly. Look for any other loose or damaged
safety belt system parts. If you see anything that might
keep a safety belt system from doing its job, have it
repaired. Have any torn or frayed safety belts replaced.
Wiper Blade Check
Inspect wiper blades for wear or cracking. Replace blade
inserts that appear worn or damaged or that streak or
miss areas of the windshield. Also see ªWiper Blades,
Cleaningº in the Index.
Spare Tire Check
At least twice a year, after the monthly inflation check
of the spare tire determines that the spare is inflated to
the correct tire inflation pressure, make sure that the
spare tire is stored securely.Engine Air Cleaner Filter Restriction
Indicator Check
Your vehicle has an indicator located on the air cleaner
in the engine compartment that lets you know when the
air cleaner filter is dirty and needs to be changed. Check
indicator at least twice a year or when your engine oil is
changed, whichever occurs first. See ªAir Cleanerº in
the Index for more information. Inspect your air cleaner
filter restriction indicator more often if the vehicle is
used in dusty areas or under off road conditions.
Weatherstrip Lubrication
Silicone grease on weatherstrips will make them last
longer, seal better, and not stick or squeak. Apply
silicone grease with a clean cloth. During very cold,
damp weather more frequent application may be
required. See ªRecommended Fluids and Lubricantsº
in the Index.
Manual Transmission Check
Check the transmission fluid level; add if needed. See
ªManual Transmission Fluidº in the Index. Check for
leaks. A fluid leak is the only reason for fluid loss. Have
the system inspected and repaired if needed.

7-46
Automatic Transmission Check
Check the transmission fluid level; add if needed. See
ªAutomatic Transmission Fluidº in the Index. A fluid
loss may indicate a problem. Check the system and
repair if needed.
Hydraulic Clutch System Check
Check the fluid level in the clutch reservoir. See
ªHydraulic Clutch Fluidº in the Index. A fluid loss in
this system could indicate a problem. Have the system
inspected and repaired at once.
At Least Once a Year
Key Lock Cylinders Service
Lubricate the key lock cylinders with the lubricant
specified in Part D.
Body Lubrication Service
Lubricate all body hood and body door hinges, latches,
locks and folding seat hardware. Part D tells you what to
use. More frequent lubrication may be required when
exposed to a corrosive environment.Starter Switch Check
CAUTION:
When you are doing this check, the vehicle could
move suddenly. If it does, you or others could be
injured. Follow the steps below.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the regular
brake. See ªParking Brakeº in the Index if necessary.
Do not use the accelerator pedal, and be ready to turn
off the engine immediately if it starts.
3. On automatic transmission vehicles, try to start the
engine in each gear. The starter should work only in
PARK (P) or NEUTRAL (N). If the starter works in
any other position, your vehicle needs service.
On manual transmission vehicles, put the shift lever
in NEUTRAL (N), push the clutch down halfway
and try to start the engine. The starter should work
only when the clutch is pushed down all the way to
the floor. If the starter works when the clutch isn't
pushed all the way down, your vehicle needs service.

7-47
Automatic Transmission Shift Lock Control
System Check
CAUTION:
When you are doing this check, the vehicle could
move suddenly. If it does, you or others could be
injured. Follow the steps below.
1. Before you start, be sure you have enough
room around the vehicle. It should be parked
on a level surface.
2. Firmly apply the parking brake. See ªParking Brakeº
in the Index if necessary.
Be ready to apply the regular brake immediately if
the vehicle begins to move.3. With the engine off, turn the key to the RUN
position, but don't start the engine. Without applying
the regular brake, try to move the shift lever out of
PARK (P) with normal effort. If the shift lever
moves out of PARK (P), your vehicle needs service.
Ignition Transmission Lock Check
While parked, and with the parking brake set, try to turn
the ignition key to LOCK in each shift lever position.

With an automatic transmission, the key should turn
to LOCK only when the shift lever is in PARK (P).

With a manual transmission, the key should turn to
LOCK only when you press the key release button.
On all vehicles, the key should come out only in LOCK.

7-52
USAGEFLUID/LUBRICANT
Hydraulic Brake
SystemDelco Supreme 11
Brake Fluid
(GM Part No. 12377967 or
equivalent DOT
-3 brake fluid).
Windshield
Washer SolventGM Optikleen
Washer Solvent
(GM Part No. 1051515) or
equivalent.
Hydraulic Clutch
SystemHydraulic Clutch Fluid (GM Part
No. 12345347 or equivalent
DOT
-3 brake fluid).
Parking Brake
Cable GuidesChassis Lubricant (GM Part
No. 12377985 or equivalent)
or lubricant meeting requirements
of NLGI # 2, Category LB
or GC
-LB.
Power Steering
SystemGM Power Steering Fluid
(GM Part No. 1052884
- 1 pint,
1050017
- 1 quart, or equivalent).
USAGEFLUID/LUBRICANT
Manual
TransmissionGM Goodwrench Synthetic
Manual Transmission Fluid
(GM Part No. 12346190
- 1 qt.)
or equivalent SAE 75W
-85 GL-4
gear oil.
Automatic
TransmissionDEXRON
-III Automatic
Transmission Fluid.
Key Lock
CylindersMulti-Purpose Lubricant,
Superlube
(GM Part
No. 12346241 or equivalent).
Floor Shift
LinkageLubriplate
Lubricant Aerosol
(GM Part No. 12346293 or
equivalent) or lubricant meeting
requirements of NLGI # 2
Category LB or GC
-LB.

8-12
SERVICE PUBLICATIONS ORDERING INFORMATION
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Service Manuals have the diagnosis and repair
information on engines, transmission, axle, suspension,
brakes, electrical, steering, body, etc.
RETAIL SELL PRICE: $120.00
Transmission, Transaxle, Transfer Case
Unit Repair Manual
This manual provides information on unit repair
service procedures, adjustments and specifications
for GM transmissions, transaxles and transfer cases.
RETAIL SELL PRICE: $50.00
Service Bulletins
Service Bulletins give technical service information
needed to knowledgeably service General Motors cars
and trucks. Each bulletin contains instructions to assist
in the diagnosis and service of your vehicle.
Owner's Information
Owner publications are written specifically for owners
and intended to provide basic operational information
about the vehicle. The owner's manual will include the
Maintenance Schedule for all models.
In
-Portfolio: Includes a Portfolio, Owner's Manual and
Warranty Booklet.
RETAIL SELL PRICE: $35.00
Without Portfolio: Owner's Manual only.
RETAIL SELL PRICE: $25.00
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Service Publications are available for current and
past model GM vehicles. To request an order form,
please specify year and model name of the vehicle.
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