2004 CHEVROLET KODIAK manual transmission

Starting Your DURAMAX™ Diesel
Engine
Your diesel engine starts differently than a gasoline
engine.
Automatic Transmission
Move your shift lever to PARK (P) or NEUTRAL (N).
Your engine won’t start in any other position – that’s a
safety feature. To restart when you’re already moving,
use NEUTRAL (N) only.
Notice:Do not try to shift to PARK (P) if your
vehicle is moving. If you do, you could damage the
transmission. Shift to PARK (P) only when your
vehicle is stopped.
Manual Transmission
Move your shift lever to neutral and hold the clutch
pedal to the floor while starting the engine. Your
vehicle won’t start if the clutch pedal is not all the way
down –that’s a safety feature.
Starting Your Engine
1. Turn your ignition key to RUN.
Observe the wait to start light. SeeWait to Start
Indicator on page 3-36. (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.
If your vehicle is equipped with the RPO LLY
engine, it has a fast warm-up glow plug system.
The wait to start light will illuminate for a much
shorter time than most diesel engines, due to the
rapid heating of the glow plug system.
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.
Notice:If the WAIT TO START light stays on, it
means that your vehicle could have one of several
problems, so you should have it serviced right away.
3. If the engine does not start after 15 seconds of
cranking, turn the ignition key to OFF. Wait one
minute for the starter to cool, then try the same
steps again.
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When the engine is started, it will slowly ramp up to the
high idle speed after a delay of a few seconds up to
about two minutes. For this method to work properly
there must be no throttle or brake pedal faults, and the
throttle pedal must not fall below 75 percent of wide
open throttle while pressing the brake pedal.
The engine idle speed will return to normal once the
following conditions are met:
•Once engine coolant temperature reaches
150°F (65°C).
•Air intake temperature reaches 41°F (5°C).
The high idle speed will be temporarily interrupted and
the engine speed will return to normal if any of the
following conditions occur:
•The brake pedal is applied.
•The accelerator pedal is pressed.
•The automatic transmission is shifted out of
PARK (P) or NEUTRAL (N).
•The clutch pedal on the manual transmission is
pressed.
•Vehicle speed is detected.
Once these inputs are removed, the engine idle speed
will slowly ramp back up to high idle after the normal
delay, if the conditions for engine coolant temperature
and air intake temperature are still met.
Engine Checks Before Operating
When you’ve started your engine, let it run for
20 to 30 seconds before you put a load on the engine.
Butdon’tleave the vehicle while the engine is running.
Avoid unnecessary idling of diesel engine equipped
vehicles.
If the engine idles too long, the temperature of the
engine coolant will fall below the normal operating
range. Low engine operating temperature causes
several conditions which affect engine operation and
reduce engine life.
The engine should be permitted to go through a
warm-up period. Operate the vehicle at a minimum of
600 rpm during the warm-up period. During this
period and during operation, the following observations
should be made.
During this warm-up period, check your warning lights
and gages:
•If oil pressure doesn’t begin to rise within
15 seconds of starting, stop the engine and find the
cause.
•If the engine coolant temperature gage needle goes
into the hot area on the gage, stop the engine and
find the cause of the overheating.
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Two-Speed Rear Axle Electric
Shift Control
If your vehicle is equipped with this feature, you’ll find a
label on the headliner above the windshield or in
another place near the driver that shows how to use it.
Be sure to follow the directions carefully.
Use the following directions based on the type of shift
control you have.
Manual Transmission
The rear axle shift control
switch for a manual
transmission is located on
the shift lever.
When the switch is up, the rear axle is in the high
range. Push the switch down to change to low range.The two-speed axle should be in low when you park the
vehicle. You’ll need to engage the transmission, even
move the vehicle a little, to be sure the axle is in the low
range. Then apply the parking brake, shift into
NEUTRAL and shut off the engine.
Also, always start the vehicle in motion with the
two-speed axle in the low range. To shift up from low to
high, do the following:
1. Move the switch up for the high range,
2. disengage the clutch, and
3. after a brief pause, engage the clutch and then
press down on the accelerator.
To shift down from high to low, do the following:
1. Move the switch down to low,
2. release the accelerator and then quickly apply
it again.
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Rear Air Suspension Dump Control
If your vehicle is equipped with the Hendrickson HAS
Series single-axle air suspension, you have this control.
The air suspension dump control allows the operator
to lower the deck height approximately 4.5 inches
(11.5 cm) from the normal frame height.
The switch to deflate and
inflate the air suspension
is located in the instrument
panel switchbank.
Press the bottom of the switch to deflate the air
suspension and lower the deck height. Press the top of
the switch to return the suspension to normal deck
height.
An indicator light will come on and stay on whenever
the switch is in the dumped position.
Automatic Transmission Operation
We build vehicles with five and six-speed automatic
transmissions. This part of the manual covers the basics
of these. With some of the transmissions, you will find
another manual in your vehicle that goes into more
detail. On the headliner, in front of and above the driver,
or in some other place near the driver, you will see a
label that describes important operating facts about the
automatic transmission in your vehicle. Make sure
you follow the instructions on this label.
Be sure to keep your parking brake set until you are
ready to shift into DRIVE (D), and press the brake pedal
while shifting from NEUTRAL (N) or PARK (P) to a
drive gear.
All vehicles equipped with automatic transmissions can
be started in PARK (P), if equipped, or in NEUTRAL (N).
See the Allison
®Transmission Operator’s Manual in
your vehicle for more information about this.
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Manual Transmission Operation
Using the Clutch
When you are starting to move the vehicle, it is
important to begin with the engine speed at idle. Then
start to engage the clutch and listen for an engine speed
drop of about 100 rpm. At this point, the clutch is
engaging, so you should increase the engine speed and
fully engage the clutch. It is important not to increase
the engine speed sooner or before the clutch begins it’s
engagement. If you do, you can cause damage to
your vehicle.
Double-Clutching
You must use the double-clutching method when you
shift 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 speed
match. When downshifting, accelerate the engine
until the engine rpm and road speed match. Then
quickly disengage the clutch and move the shift lever to
the next gear position and engage the clutch.
Eaton®Fuller®Five and Six-Speed
Transmissions and TTC Spicer
Seven-Speed Transmissions
These transmissions have gears that automatically
synchronize when you shift up or down (except
FIRST (1) gear on the five-speed and seven-speed
transmission which is unsynchronized). Choose the gear
that will maintain the road speed you want while
keeping the engine above two-thirds of the governed
speed. When the engine speed drops below two-thirds
of the governed speed, shift into the next lower gear
before your engine begins to lug. When you shift down,
be sure to double-clutch if required.
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ZF Six-Speed Transmission
Here’s how to operate your
transmission.
This six-speed pattern is unique to GM manual
transmissions. The transmission always repositions the
shift lever to neutral, which is located between
FOURTH (4) and FIFTH (5) gear.
To prevent unintentional gear selections, additional
force is required to move the shift lever into
REVERSE (R) or FIRST (1). Use FIRST (1) when trailer
towing, driving with a heavier payload or launching
on a grade. Otherwise, start in SECOND (2) gear. Only
shift into FIRST (1) when the vehicle has stopped
moving.
During the first 500 miles (805 km) of vehicle use, start
the vehicle moving in FIRST (1) gear. This allows
the clutch components to wear-in properly.FIRST (1):With the vehicle at a stop, release the
brake, press the clutch pedal and shift into FIRST (1).
Then, slowly let up on the clutch pedal as you press the
accelerator pedal. Only downshift into FIRST (1)
when the vehicle has come to a complete stop. If the
shift lever will not go into FIRST (1), put the lever
in neutral and let up on the clutch pedal to fully engage
the clutch. Press the clutch pedal again. Then, shift
into FIRST (1).
SECOND (2):With the vehicle at a stop, release the
brake, press the clutch pedal and shift into SECOND (2).
Then, slowly let up on the clutch pedal as you press
the accelerator pedal. With the vehicle moving, press the
clutch pedal and upshift into SECOND (2) from
FIRST (1) while applying light pressure to the right on
the shifter. Then, slowly let up on the clutch pedal
as you press the accelerator pedal. If you come to a
complete stop and the shift lever will not go into
SECOND (2), put the lever in neutral and let up on the
clutch pedal to fully engage the clutch. Press the
clutch pedal again. Then, shift into SECOND (2).
THIRD (3):Press the clutch pedal and upshift into
THIRD (3). Then, slowly let up on the clutch pedal as
you press the accelerator pedal.
FOURTH (4), FIFTH (5) and SIXTH (6):Upshift into the
higher forward gears the same way as you do
THIRD (3). Slowly let up on the clutch pedal as you
press the accelerator pedal.
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NEUTRAL:Use this position when you start or idle
your engine.
REVERSE (R):To back up, press the clutch pedal.
Wait for the vehicle to stop moving and then, shift
to REVERSE (R). Let up on the clutch slowly while
pressing the accelerator pedal. Also, use REVERSE (R),
along with the parking brake, when turning off your
engine and parking your vehicle.
Eaton®Fuller®Nine and Ten-Speed
Non-Synchronized Manual
Transmissions
If your vehicle has one of these transmissions the
engine rpm and road speed must match when upshifting
and downshifting. The label above the windshield will
tell you the operating basics you need to know.
The following are driving tips.
•Always choose an initial starting gear suitable for
the load and terrain.
•Always use double-clutching procedures when
shifting.
•Never move the range shift lever to the LO speed
gear position after HI range preselection, or
anytime the transmission is in the HI range.
•Never move the range knob or lever with the shift
lever in neutral while the vehicle is moving.
•Never make a range shift while moving in
REVERSE (R).
Clutch Brake (Vehicles with
Non-Synchronized Transmission)
A clutch brake is used to stop transmission input shaft
rotation so that FIRST (1) or REVERSE (R) gear
selection can be initiated when the vehicle is at a
standstill and the engine is idling.
Press the clutch pedal all the way down to the floorboard
to apply the clutch brake.
When using the clutch brake, disengage the clutch
pedal and shift the transmission into either the initial
starting gear or REVERSE (R). If the tooth-butting
occurs between the clutching teeth, re-engage the clutch
while applying light pressure to the shift lever. This
will provide for a smooth shift into either FIRST (1) or
REVERSE (R) gear.
Notice:Using the clutch brake for shifting into any
gear other than FIRST (1) or REVERSE (R) may
cause premature wear of the clutch brake and make
gear shift effort more difficult. Do not use the
clutch brake for shifting after engaging FIRST (1) or
REVERSE (R).
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Cruise Control
If your vehicle has this
feature, it is located at the
end of the multifunction
lever.
T(Set):Pressing in this button at the end of the
lever sets the cruise control speed.
9(Off):Moving the switch to this position turns off
the cruise control.
R(On):Moving the switch to this position turns on the
cruise control.
S(Resume/Accelerate):Moving the switch to this
position turns on resume/accelerate.With cruise control, you can maintain a speed of about
30 mph (48 km/h) or more without keeping your foot
on the accelerator. Cruise control does not work
at speeds below about 30 mph (48 km/h).
If you have an automatic transmission and you apply
your brakes, the cruise control will shut off.
If you have a manual transmission and you apply your
brakes or push the clutch pedal, the cruise control
will shut off.
{CAUTION:
Cruise control can be dangerous where you
can not drive safely at a steady speed. So, do
not use your cruise control on winding roads
or in heavy traffic.
Cruise control can be dangerous on slippery
roads. On such roads, fast changes in tire
traction can cause needless wheel spinning,
and you could lose control. Do not use cruise
control on slippery roads.
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