2002 CHEVROLET C3500 HD clutch

2-15 Manual Transmission
The gear selector should be in neutral and the parking
brake engaged. Hold the clutch pedal to the floor and
start the engine. Your vehicle won't start if the clutch
pedal is not all the way down
-- that's a safety feature.
1. With your foot off the accelerator pedal, turn the
ignition key to START. When the engine starts, let
go of the key. The idle speed will go down as your
engine gets warm.
NOTICE:
Holding your key in START for longer than
15 seconds at a time will cause your battery to
be drained much sooner. And the excessive heat
can damage your starter motor. Wait about
15 seconds between each try to help avoid
draining your battery or damaging your starter.
2. If it doesn't start within 10 seconds, push the
accelerator pedal all the way to the floor, while you
hold the ignition key in START. When the engine
starts, let go of the key and let up on the accelerator
pedal. Wait about 15 seconds between each try.When starting your engine in very cold weather
(below 0
F or
-18
C), do this:
1. With your foot off the accelerator pedal, turn the
ignition key to START and hold it there up to
15 seconds. When the engine starts, let go of the key.
2. If your engine still won't start (or starts but then
stops), it could be flooded with too much gasoline.
Try pushing your accelerator pedal all the way to the
floor and holding it there as you hold the key in
START for about three seconds. When the engine
starts, let go of the key and accelerator. If the vehicle
starts briefly but then stops again, do the same
thing, but this time keep the pedal down for five or
six seconds. This clears the extra gasoline from
the engine.
NOTICE:
Your engine is designed to work with the
electronics in your vehicle. If you add electrical
parts or accessories, you could change the way
the engine operates. Before adding electrical
equipment, check with your dealer. If you don't,
your engine might not perform properly.

2-21
Manual Transmission Operation
Five-Speed
Here's how to operate your
manual transmission.
FIRST (1) is intended only for heavy loads and is not
recommended for normal driving.
During the first 500 miles (805 km) of vehicle use, start
your vehicle moving in FIRST (1). This allows clutch
components to break
-in properly.FIRST (1): Press the clutch pedal and shift into
FIRST (1). Then, slowly let up on the clutch pedal as
you press the accelerator pedal. Shift into FIRST (1)
only when the vehicle is below 5 mph (8 km/h).
SECOND (2): Press the clutch pedal and shift into
SECOND (2). Then, slowly let up on the clutch pedal
as you press the accelerator pedal.
You can shift into SECOND (2) when you're going less
than 20 mph (32 km/h). If you've come to a complete
stop and it's hard to shift into SECOND (2), put the shift
lever into NEUTRAL and let up on the clutch. Press the
clutch pedal back down.
THIRD (3): Press the clutch pedal and shift
into THIRD (3).
FOURTH (4) and FIFTH (5): Shift into the higher
forward gears the same way you do for THIRD (3).
Slowly let up on the clutch pedal as you press the
accelerator pedal.
To stop, let up on the accelerator pedal and press
the brake pedal. Just before the vehicle stops, press
the clutch pedal and the brake pedal, and shift
to NEUTRAL.

2-22
NEUTRAL: Use this position when you start or idle
your engine.
REVERSE (R): To back up, first press down the clutch
pedal. Then shift into REVERSE (R). Let up on the
clutch pedal slowly while pressing the accelerator pedal.
NOTICE:
Shift to REVERSE (R) only after your vehicle
speed is below 5 mph. Shifting to REVERSE (R)
while your vehicle speed is above 5 mph could
damage your transmission.
Also, use REVERSE (R), along with the parking brake,
when turning off your engine and parking your vehicle.
Shift Speeds
CAUTION:
If you skip a gear when you downshift, you could
lose control of your vehicle. You could injure
yourself or others. Don't shift down more than
one gear at a time when you downshift.
If your speed drops below 20 mph (32 km/h), or if the
engine is not running smoothly, you should downshift to
the next lower gear. You may have to downshift two or
more gears to keep the engine running smoothly or for
good performance.

2-27
Shifting Out of PARK (P)
(Automatic Transmission Only)
Your vehicle has an automatic transmission shift lock
control system, you have to fully apply your regular
brakes before you can shift from PARK (P) when the
ignition is in RUN. See ªAutomatic Transmissionº in
the Index.
If you cannot shift out of PARK (P), ease pressure on
the shift lever and push the shift lever all the way up
into PARK (P) as you maintain brake application.
Then, move the shift lever to any gear you want.
If you ever hold the brake pedal down but still can't
shift out of PARK (P), try this:
1. Turn the key to OFF.
2. Apply and hold the brake until the end of Step 4.
3. Shift to NEUTRAL (N).
4. Start the vehicle and shift to the drive gear you want.
5. Have the system fixed as soon as you can.
Parking Your Vehicle
(Manual Transmission Models Only)
Before you get out of your vehicle, move the shift lever
into REVERSE (R), and firmly apply the parking brake.
Once the shift lever has been placed into REVERSE (R)
with the clutch pedal pressed in, you can turn the
ignition key to OFF, remove the key and release
the clutch.
If you are parking on a hill, or if you are pulling a
trailer, see ªTowing a Trailerº in the Index.
CAUTION:
Shifting the transfer case to NEUTRAL can
cause your vehicle to roll even if the manual
transmission is in gear. You or someone else could
be seriously injured. Be sure to set the parking
brake before placing the transfer case in
NEUTRAL. See ªParking Brakeº in the Index.

4-38 Power Take-Off (PTO) Engine Speed
Control (If Equipped)
NOTICE:
If you have a PTO that will exceed 35 hp
installed on your vehicle, it could damage the
transmission. When having a PTO installed
on your vehicle, make sure that it will not
exceed 35 hp.
Before using a PTO, refer to the manufacturer's or
installer's instructions.
NOTICE:
Using a PTO while operating in one place
before the vehicle has reached normal operating
temperature can damage the transmission.
If you will be using the PTO while operating in
one place, drive and warm up the vehicle before
using the PTO.
To engage PTO for stationary applications
(manual transmission):
1. Hold the clutch pedal down.
2. Set the parking brake.
3. Shift the transmission into NEUTRAL.
4. Engage the PTO. Refer to the manufacturer's or
installer's instructions on electrically engaged PTOs.
5. For mobile operations, shift the transmission into the
gear you want, apply the regular brakes and release
the parking brake. For stationary operations, leave
the parking brake applied.
6. Release the clutch and regular brakes as you
normally would. When the clutch is released,
the PTO will start.
7. Turn the PTO rotary switch to ON.

4-39
NOTICE:
Using a PTO for more than four hours without
driving your vehicle can damage the transmission.
If using a PTO for more than four hours without
driving your vehicle, drive your vehicle for a while
to allow the transmission to cool.
Preset Mode: PTO speed control mode is used for
stationary applications. This mode provides a default
standby speed of 850 rpm (800 rpm with automatic
transmission) and two default PTO operation speeds
which follow:
1. PTO Set Speed of 1250 rpm, or
2. PTO Resume Speed of 1700 rpm.
The standby speed (800/850 rpm) is not to be used
as a PTO control speed. Vehicles not equipped with
cruise control will not have the resume speed capability.Using PTO speed control in Preset Mode
(Factory Setting):
1. Engage the PTO.
2. Select PARK (P) or NEUTRAL (N) range.
Apply the parking brake if NEUTRAL (N)
is selected.
3. Make sure your foot is off the brake pedal
(and off the clutch on vehicles equipped with
a manual transmission). Select the desired
engine speed for PTO operation. Be sure to
read the following Preset Mode information
regarding operation.
To engage PTO for mobile applications
(manual transmission):
If you are going to drive the vehicle, shift the
transmission into the gear you want, apply the
regular brakes and release the parking brake.
Release the clutch (and the regular brakes) as you
normally would. When you release the clutch,
the PTO will start.

4-40
To engage a PTO while the vehicle is moving:
1. Hold the clutch pedal down.
2. Shift the transmission into NEUTRAL.
3. Engage the PTO.
4. Shift the transmission into the gear you want.
5. Release the clutch as you normally would.
When you release the clutch, the PTO will start.
Variable Mode: PTO speed control mode can be used
for both stationary and mobile applications. This mode
allows PTO to be controlled in a fashion similar to how
cruise control sets vehicle speed. The operator can set an
rpm (between 800 and 2200) with the cruise control
feature or with the SET position on the PTO switch.
The operator is then able to increase rpm in increments
of 100, or ªtap,º with the resume position on the
cruise control. Or, the operator can decrease rpm in
increments of 100 with either of the SET switches on
the PTO or the cruise control. Vehicles not equipped
with cruise control will not be able to increase in
100 rpm increments.Using PTO speed control in Variable Mode:
1. Engage the PTO.
2. Make sure your foot is off the brake pedal
(and off the clutch for vehicles equipped with
a manual transmission).
3. Select the desired engine speed (with the foot pedal)
and select SET on the PTO switch or with the
cruise control.
Engine speed will be governed to the PTO maximum
engine speed (2,200 rpm) while in either the preset or
variable PTO modes. All engine speed values listed
above are factory preset values. With the exception of
the ªtapº increment (100 rpm), all of these values are
programmable and can be adjusted by your GM dealer
or body upfitter. If the PTO software settings do not
match the settings shown here, then they may have
already been altered in order to satisfy the requirements
of the installed PTO system and body equipment.

5-21
Engine Fan Noise
Your vehicle has a clutched engine cooling fan. When
the clutch is engaged, the fan spins faster to provide
more air to cool the engine. In most everyday driving
conditions, the fan is spinning slower and the clutch is
not fully engaged. This improves fuel economy and
reduces fan noise. Under heavy vehicle loading, trailer
towing and/or high outside temperatures, the fan speed
increases as the clutch more fully engages. So you may
hear an increase in fan noise. This is normal and should
not be mistaken as the transmission slipping or making
extra shifts. It is merely the cooling system functioning
properly. The fan will slow down when additional
cooling is not required and the clutch disengages.
You may also hear this fan noise when you start the
engine. It will go away as the fan clutch partially
disengages.
If a Tire Goes Flat
It's unusual for a tire to ªblow outº while you're driving,
especially if you maintain your tires properly. If air goes
out of a tire, it's much more likely to leak out slowly.
But if you should ever have a ªblowout,º here are a few
tips about what to expect and what to do:
If a front tire fails, the flat tire will create a drag that
pulls the vehicle toward that side. Take your foot off the
accelerator pedal and grip the steering wheel firmly.
Steer to maintain lane position, and then gently brake to
a stop well out of the traffic lane.
A rear blowout, particularly on a curve, acts much like a
skid and may require the same correction you'd use in a
skid. In any rear blowout, remove your foot from the
accelerator pedal. Get the vehicle under control by
steering the way you want the vehicle to go. It may be
very bumpy and noisy, but you can still steer. Gently
brake to a stop
-- well off the road if possible.
If a tire goes flat, avoid further tire and wheel damage
by driving slowly to a level place and turn on your
hazard warning flashers. The next part tells you what
to do.