Home/Chevrolet/Cab & Chassis Silverado 3500/Chevrolet Cab & Chassis Silverado 3500 (2003-2007)/Repair manual
Repair manual
Chevrolet Cab & Chassis Silverado 3500 Repair Manual
Step-by-step repair and maintenance instructions for the Chevrolet Cab & Chassis Silverado 3500 (2003–2007): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
81sections
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- Transmission Fluid Temperature Sensor Specifications
- Fastener Tightening Specifications
- Transmission General Specifications
- Fluid Capacity Specifications
- Range Reference
- Shift Solenoid Valve State and Gear Ratio
- Shift Speed
- Transmission Range Switch Logic
- Transmission Fluid Pressure Manual Valve Position Switch Logic
- Line Pressure
- Component Resistance
- End Play Specifications
- Overrun Clutch Housing Selective Thrust Washer Specifications
- Output Shaft Selective Thrust Washer Specifications
- Oil Pump Specifications
- Automatic Transmission Schematic Icons
- C103 Engine Side to Transmission Side
- Torque Converter Clutch Pulse Width Modulated (TCC PWM) Solenoid Valve, Wiring Harness Side
- Automatic Transmission Output Speed Sensor (OSS)
- DIAGNOSTIC CODE INDEX
- Removal Procedure
- Installation Procedure
- Range Selector Lever Cable Adjustment
- Cable Re-Adjustment
- Tools Required
- Park/Neutral Position Switch Adjustment
- Third and Fourth Clutch Accumulator Disassembly
- Third and Fourth Clutch Accumulator Assembly
- Valve Body and Pressure Switch Replacement
- Transmission Extension Housing Rear Oil Seal Replacement
- Torque Converter Assembly Removal
- Torque Converter End Play Inspection
- Transmission Holding Fixture Installation
- Transmission Fluid Draining
- Speed Sensor Assembly Removal
- Case Extension Assembly Removal
- Transmission Fluid Pan Removal
- Transmission Fluid Filter Assembly Removal
- Transmission Wire Harness Removal
- Control Valve Body Assembly Removal
- Manual 2-1 Band Servo Assembly Removal
- Low and Reverse Band Servo Assembly Removal
- Low and Reverse Band Servo Piston Pin Check
- Manual Shift Shaft Removal
- Parking System Components Removal
- Front End Play Check
- Rear Unit End Play Check
- Transmission Oil Pump Assembly Removal
- 4th Clutch Assembly Removal
- Forward Clutch Assembly Removal
- Manual 2-1 Band Assembly Removal
- Intermediate Clutch Assembly Removal
- Center Support and Gear Unit Assembly Removal
- Low and Reverse Band Removal
- Output Shaft Seal Removal
- Transmission Case Inspection
- Output Shaft Seal Installation
- Parking System Components Installation
- Low and Reverse Band/Thrust Washer Installation
- Center Support and Gear Unit Assembly Disassemble
- Center Support Assembly Disassemble
- Center Support Assembly Reconditioning Repair
- Center Support Assembly Assemble
- Center Support and Gear Unit Assembly Assemble
- Center Support and Gear Unit Assembly Installation
- Center Support Bolt and Transmission Fluid Cooler Pipe Fitting Installation
- Intermediate Clutch Assembly Installation
- Direct Clutch Assembly Disassemble
- Direct Clutch Assembly Assemble
- Direct Clutch Assembly Installation
- Direct Clutch Piston Travel Check
- Forward Clutch Assembly Disassemble
- Forward Clutch Assembly Assemble
- Forward Clutch Piston Travel Check
- Forward Clutch Hub Assemble
- Forward Clutch Assembly Installation
- 4th Clutch Assembly Disassemble
- 4th Clutch Assembly Assemble
- 4th Clutch Assembly Installation
- Overrun Clutch Assembly Disassemble
- Overrun Clutch Assembly Assemble
- Overdrive Carrier Assembly Disassemble
- Overdrive Carrier Assembly Assemble
- Turbine Shaft Disassemble
- Turbine Shaft Assemble
- Overdrive Carrier Assemble
- Turbine Shaft/Overdrive Carrier Installation
- 4th Clutch Plate Installation
- Transmission Oil Pump Disassemble
- Transmission Oil Pump Cover Disassemble
- Transmission Oil Pump Cover Assemble
- Transmission Oil Pump Body to Gear Face Clearance Check
- Transmission Oil Pump Body Disassemble
- Transmission Oil Pump Body Assemble
- Transmission Oil Pump Assemble
- Transmission Oil Pump Assembly Installation
- Manual 2-1 Band Servo Assembly Disassemble
- Manual 2-1 Band Servo Assembly Assemble
- Manual 2-1 Band Servo Assembly Installation
- Low and Reverse Band Servo Apply Piston Pin Check
- Low and Reverse Band Servo Assembly Disassemble
- Low and Reverse Band Servo Assembly Assemble
- Low and Reverse Band Servo Assembly Installation
- Third and Fourth Clutch Accumulator Housing Removal
- Third and Fourth Clutch Accumulator Housing Disassemble
- Third and Fourth Clutch Accumulator Housing Assemble
- Control Valve Body Assembly Disassemble
- Control Valve Body Cleaning and Inspection
- Control Valve Body Assembly Assemble
- Third/Fourth Clutch Accumulator Housing Installation
- Control Valve Body Assembly Installation
- Wiring Harness Installation
- Transmission Fluid Filter Assembly Installation
- Transmission Fluid Pan Installation
- Speed Sensor Assembly Installation
- Case Extension Assembly Installation
- Torque Converter Assembly Installation
- Holding Fixture Removal
- How to Use This Section
- Basic Knowledge
- Diagnosis
- Transmission General Description
- Transmission Component and System Description
- Transmission Adaptive Functions
- Clearing Transmission Adaptive Pressure (TAP)
- Transmission Indicators and Messages
- Park or Neutral - Engine Running
- Reverse
- Overdrive Range, First Gear
- Overdrive Range, Second Gear
- Overdrive Range, Third Gear - Torque Converter Clutch Applied
- Overdrive Range, Fourth Gear - Torque Converter Clutch Applied
- Overdrive Range, 4-3 Downshift
- Overdrive Range, 3-2 Downshift
- Manual Third Gear
- Manual Second Gear
- Manual First Gear
- Special Tools
- Temperature Versus Resistance
- Altitude Versus Barometric Pressure
- Ignition System Specifications
- Fastener Tightening Specifications
- Fuel Injector 2
- Fuel Injector 3
- Fuel Injector 4
- Fuel Injector 5
- Fuel Injector 6
- Fuel Injector 7
- Fuel Injector 8
- Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1
- Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2
- Ignition Coil 2
- Ignition Coil 3
- Ignition Coil 4
- Ignition Coil 5
- Ignition Coil 6
- Ignition Coil 7
- Ignition Coil 8
- Knock Sensor (KS) - 2
- Manifold Absolute Pressure (MAP) Sensor
- DIAGNOSTIC CODE INDEX
- Engine Control Module Replacement
- Removal Procedure
- Installation Procedure
- Crankshaft Position System Variation Learn
- Description
- Conditions for Running the Throttle Learn Procedure
- Throttle Learn
- Throttle Body Cleaning
- Tools Required
- Special Tools
- Fuel Pressure Relief (Without CH 48027)
- Tool Required
- Disconnect Procedure
- Connect Procedure
- Fuel Tank Draining
- Fuel System Cleaning
- Fuel Injector Cleaning
- Inspection Procedure
- EVAP Cleaning Procedure
- Spark Plug Wire Inspection
- Spark Plug Inspection
- Visual Inspection
- Engine Control Module Description
- Malfunction Indicator Lamp (MIL) Operation
- Cylinder Deactivation (Active Fuel Management) System Description
- Valve Lifter Oil Manifold (VLOM) Assembly
- Engine Control Module (ECM)
- Cylinder Deactivation Inhibit Reasons
- Purpose
- Accelerator Pedal Position (APP) Sensor
- Throttle Body Assembly
- Engine Control Module
- Normal Mode
- Reduced Engine Power Mode
- Camshaft Position (CMP) Actuator System
- CMP Actuator System Operation
- CMP Actuator Solenoid Circuit Diagnostics
- CMP Actuator System Performance Diagnostic
- Fuel System Overview
- E85 Flex Fuel Description
- Switching Between Gasoline and E85
- Fuel Pump Control Module (FPCM) - L76, L92, LH6, LY2, LY5
- Electronic Returnless Fuel System (ERFS) - L76, L92, LH6, LY2, LY5
- Liquid Fuel Pressure Sensor - With FPCM
- Fuel Tanks
- Fuel Fill Pipe
- Fuel Level Sensor
- Fuel Pump
- Rear Fuel Pump (Dual Tank Applications Only)
- Fuel Strainer
- Fuel Filter
- Nylon Fuel Pipes
- Quick-Connect Fittings
- On-Board Refueling Vapor Recovery System (ORVR)
- Fuel Pipe O-Rings
- Fuel Injectors
- Fuel Pressure Regulator
- Fuel Metering Modes of Operation
- Starting Mode
- Clear Flood Mode
- Run Mode
- Acceleration Mode
- Deceleration Mode
- Battery Voltage Correction Mode
- Fuel Cutoff Mode
- Fuel Trim
- EVAP System Operation
- Large Leak Test
- Small Leak Test
- Canister Vent Restriction Test
- Purge Solenoid Valve Leak Test
- Check Gas Cap Message
- EVAP System Components
- EVAP Canister
- EVAP Purge Solenoid Valve
- EVAP Vent Solenoid Valve
- Fuel Tank Pressure Sensor
- Electronic Ignition (EI) System Description
- Crankshaft Reluctor Wheel
- Crankshaft Position (CKP) Sensor
- Camshaft Reluctor Wheel
- Camshaft Position (CMP) Sensor
- Ignition Coils
- Modes of Operation
- Sensor Description
- Temperature Versus Resistance
- Altitude Versus Barometric Pressure
- Ignition System Specifications
- Fastener Tightening Specifications
- Emissions Related DTCs
- Non-Emissions Related DTCs
- Engine Controls Schematic Icons
- Powertrain Control Module (PCM) C2
- Fuel Injector 2 (Except L59)
- Fuel Injector 2 (L59)
- Fuel Injector 3 (Except L59)
- Fuel Injector 3 (L59)
- Fuel Injector 4 (Except L59)
- Fuel Injector 4 (L59)
- Fuel Injector 5 (Except L59)
- Fuel Injector 5 (L59)
- Fuel Injector 6 (Except L59)
- Fuel Injector 6 (L59)
- Fuel Injector 7 (Except L59)
- Fuel Injector 7 (L59)
- Fuel Injector 8 (Except L59)
- Fuel Injector 8 (L59)
- Fuel Tank Pressure (FTP) Sensor
- Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (4.8/5.3L)
- Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1 (6.0L)
- Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (4.8/5.3L)
- Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (6.0L)
- Ignition Coil 2
- Ignition Coil 3
- Ignition Coil 4
- Ignition Coil 5
- Ignition Coil 6
- Ignition Coil 7
- Ignition Coil 8
- Knock Sensor (KS) 2
- DIAGNOSTIC CODE INDEX
- Powertrain Control Module Replacement
- Removal Procedure
- Installation Procedure
- Crankshaft Position System Variation Learn
- Throttle Body Cleaning
- Fuel Pressure Relief (With CH 48027)
- Fuel Pressure Relief (Without CH 48027)
- Tools Required
- Metal Collar Quick Connect Fitting Service
- Fuel Tank Draining (4.8L, 5.3L, and 6.0L Engine)
- Fuel Tank Draining (5.3L (L59) Engine)
- Fuel Tank Cleaning
- Fuel Injector Cleaning
- Inspection Procedure
- EVAP Cleaning Procedure
- Spark Plug Wire Inspection
- Spark Plug Inspection
- Visual Inspection
- Powertrain
- Powertrain Control Module Function
- Malfunction Indicator Lamp (MIL) Operation
- Trip
- Warm-Up Cycle
- Diagnostic Trouble Codes (DTCs)
- DTC Status
- Throttle Actuator Control (TAC) System Description
- Accelerator Pedal Position (APP) Sensor
- Throttle Body Assembly
- Throttle Actuator Control Module
- Powertrain Control Module
- Normal Mode
- Reduced Engine Power Mode
- Fuel System Overview
- E85 Flex Fuel Description
- Switching Between Gasoline and E85
- Fuel Tanks
- Fuel Fill Pipe
- Fuel Level Sensor
- Fuel Pump
- Rear Fuel Pump (Dual Tank Applications Only)
- Fuel Strainer
- Fuel Filter
- Nylon Fuel Pipes
- Quick-Connect Fittings
- On-Board Refueling Vapor Recovery System (ORVR)
- Fuel Pipe O-Rings
- Fuel Injectors
- Fuel Pressure Regulator
- Fuel Metering Modes of Operation
- Starting Mode
- Clear Flood Mode
- Run Mode
- Acceleration Mode
- Deceleration Mode
- Battery Voltage Correction Mode
- Fuel Cutoff Mode
- Fuel Trim
- Fuel Tank
- Secondary Fuel Pump - Dual Tanks
- Fuel Feed and Return Pipes
- EVAP System Operation
- Large Leak Test
- Small Leak Test
- Canister Vent Restriction Test
- Purge Solenoid Valve Leak Test
- Check Gas Cap Message
- EVAP System Components
- EVAP Canister
- EVAP Purge Solenoid Valve
- EVAP Vent Solenoid Valve
- Fuel Tank Pressure Sensor
- Electronic Ignition (EI) System Description
- Crankshaft Position (CKP) Sensor
- Crankshaft Reluctor Wheel
- Camshaft Position (CMP) Sensor
- Camshaft Reluctor Wheel
- Ignition Coils
- Powertrain Control Module (PCM)
- Modes of Operation
- Purpose
- Sensor Description
- Air Intake System Description
- Special Tools
- Temperature Versus Resistance
- Altitude Versus Barometric Pressure
- Ignition System Specifications
- Fastener Tightening Specifications
- Emissions Related DTCs
- Non-Emissions Related DTCs
- Conditions for Clearing the DTC - Type X
- Engine Controls Schematic Icons
- Powertrain Control Module (PCM) - C2
- Evaporative Emission (EVAP) Canister Vent Solenoid
- Fuel Injector 2
- Fuel Injector 3
- Fuel Injector 4
- Fuel Injector 5
- Fuel Injector 6
- Fuel Injector 7
- Fuel Injector 8
- Fuel Pump and Sender Assembly - Secondary (Except NQZ)
- Fuel Tank Pressure (FTP) Sensor
- Heated Oxygen Sensor (HO2S) Bank 2 Sensor 1
- Heated Oxygen Sensor (HO2S) Bank 2 Sensor 2 (NC1/NC8)
- Ignition Coil 2
- Ignition Coil 3
- Ignition Coil 4
- Ignition Coil 5
- Ignition Coil 6
- Ignition Coil 7
- Ignition Coil 8
- Knock Sensor (KS) 2
- Powertrain Control Module Replacement
- Removal Procedure
- Installation Procedure
- Crankshaft Position System Variation Learn
- Throttle Body Cleaning
- Fuel Pressure Relief (With CH 48027)
- Fuel Pressure Relief (Without CH 48027)
- Tools Required
- Metal Collar Quick Connect Fitting Service
- Fuel Tank Draining
- Fuel System Cleaning
- Fuel Injector Cleaning
- Inspection Procedure
- EVAP Cleaning Procedure
- Spark Plug Wire Inspection
- Spark Plug Inspection
- Visual Inspection
- Powertrain
- Powertrain Control Module Function
- Malfunction Indicator Lamp (MIL) Operation
- Trip
- Warm-Up Cycle
- Diagnostic Trouble Codes (DTCs)
- DTC Status
- Fuel System Overview
- Fuel Tanks
- Fuel Pump
- Rear Fuel Pump - Dual Tank Applications Only
- Fuel Strainer
- Nylon Fuel Pipes
- Quick-Connect Fittings
- On-Board Refueling Vapor Recovery (ORVR) System
- Fuel Pipe O-Rings
- Fuel Pulsation Damper
- Fuel Pressure Regulator Assembly
- Fuel Metering Modes of Operation
- Starting Mode
- Clear Flood Mode
- Run Mode
- Acceleration Mode
- Deceleration Mode
- Battery Voltage Correction Mode
- Fuel Cutoff Mode
- Short Term Fuel Trim
- Long Term Fuel Trim
- EVAP System Operation
- Large Leak Test
- Small Leak Test
- Canister Vent Restriction Test
- Purge Solenoid Valve Leak Test
- Check Gas Cap Message
- EVAP System Components
- Electronic Ignition (EI) System Description
- Crankshaft Position (CKP) Sensor
- Crankshaft Reluctor Wheel
- Camshaft Position (CMP) Sensor
- Camshaft Reluctor Wheel
- Ignition Coils
- Powertrain Control Module (PCM)
- Modes of Operation
- Purpose
- Sensor Description
- Air Intake System Description
- Special Tools
- Fastener Tightening Specifications
- Axle Preload and Backlash Specifications
- Sealers, Adhesives, and Lubricants
- Noise Diagnosis
- Classifying the Symptom
- Visual/Physical Inspection
- Symptoms List
- Gear Noise
- Bearing Noise
- Front Wheel Bearing Noise
- Knock at Low Speeds
- Backlash Clunk
- Noisy in Drive
- Noisy When Coasting
- Intermittent Noise
- Constant Noise
- Noisy on Turns
- Straight Roller Bearing Diagnosis
- Tapered Roller Bearing Diagnosis
- Front Axle Lubricant Leak Diagnosis
- Determining the Cause
- Front Axle Lubricant Level Inspection
- Removal Procedure
- Installation Procedure
- Inner Axle Shaft Shim Adjustment
- Alternate Adjustment Method
- Front Differential Drive Pinion Flange/Yoke, Seal, and Dust Deflector Replacement
- Differential Carrier Assembly Bushing Replacement
- Differential Carrier Assembly Disassemble (8.25 Inch Axles)
- Inspection Procedure
- Disassembly Procedure
- Differential Carrier Assembly Disassemble (9.25 Inch Axle)
- Differential Case Assembly Disassemble (8.25 Inch Axle)
- Differential Case Assembly Disassemble (9.25 Inch Axle)
- Differential Case Bearings Inspection
- Differential Case and Gears Inspection
- Pinion and Ring Gear Inspection
- Thrust Washers, Shims, and Adjuster Sleeves Inspection
- Differential Case Assembly Assemble (8.25 Inch Axle)
- Differential Case Assembly Assemble (9.25 Inch Axle)
- Pinion Bearing Cup Installation (8.25 Inch Axle w/J 45858)
- Pinion Bearing Cup Installation (8.25/9.25 Inch Axles w/J 36598)
- Pinion Bearing Cup Installation (9.25 Inch Axle w/J 45754)
- Pinion Depth Adjustment
- Differential Carrier Assembly Assemble
- Backlash Inspection and Adjustment
- Differential Carrier Assembly Final Assembly (8.25 F4WD Axle)
- Differential Carrier Assembly Final Assembly (8.25 S4WD and 9.25 Axles)
- Gear Tooth Contact Pattern Inspection
- Adjustments Affecting Tooth Contact
- Testing Procedure
- Correct Contact Pattern
- Selectable Four Wheel Drive (S4WD) Front Axle Description and Operation
- Full-Time Four Wheel Drive (F4WD) Front Axle Description and Operation
- Special Tools
- Fastener Tightening Specifications
- Backup Lamp - Right
- Clearance Lamp - Left Rear (RO5)
- Clearance Lamp - Right Front (RO5)
- Clearance Lamp - Right Rear (RO5)
- Clearance Lamp (U01)
- Daytime Running Lamp (DRL) - Left
- Daytime Running Lamp (DRL) - Right
- Dome Lamp - Rear (Except Crew Cab w/YE9 or Y91)
- Door Courtesy Lamp - Left Front (YE9 or Y91)
- Door Courtesy Lamp - Right Front (YE9/Y91)
- Door Latch Assembly (Door Jamb Switch) - Left Rear - C2 (Crew Cab Only)
- Door Latch Assembly (Door Jamb Switch) - Right Rear -C2 (Crew Cab Only)
- Fog Lamp - Right Front
- Headlamp - High Beam - Left
- Headlamp - High Beam - Right
- Headlamp - Low Beam - Right
- License Lamp - Right
- Marker Lamp - Left Front
- Marker Lamp - Left Rear (X88)
- Marker Lamp - Right Front
- Marker Lamp - Right Rear (X88)
- Park/Turn Signal Lamp - Right Front
- Roof Marker Lamp - Left (U01)
- Roof Marker Lamp - Right (U01)
- Tail/Stop Lamp - Left (GMC)
- Tail/Stop Lamp - Right (Chevy)
- Tail/Stop Lamp - Right (GMC)
- Turn Signal - Left Rear (Chevy)
- Turn Signal - Left Rear (GMC)
- Turn Signal - Right Rear (Chevy)
- Turn Signal - Right Rear (GMC)
- Vanity Mirror Lamp - Right (Y91)
- Wrecker Relay (5X7)
- DIAGNOSTIC CODE INDEX
- Scan Tool Output Controls
- Scan Tool Data List
- Circuit Description
- DTC Descriptor
- Conditions for Running the DTC
- Conditions for Setting the DTC
- Action Taken When the DTC Sets
- Conditions for Clearing the MIL/DTC
- Diagnostic Aids
- Test Description
- Conditions for Clearing the DTC
- Visual/Physical Inspection
- Intermittent
- Symptom List
- Backup Lamps Always On
- Backup Lamps Inoperative
- Cargo Lamp Always On
- Cargo Lamp Inoperative
- Clearance Lamps Inoperative
- Courtesy Lamps Always On
- Courtesy Lamps Inoperative
- Daytime Running Lamps (DRL) Always On
- Daytime Running Lamps (DRL) Defeat Inoperative
- Daytime Running Lamps (DRL) Inoperative
- Exterior Courtesy Lamp(s) Always On
- Exterior Courtesy Lamp(s) Inoperative
- Fog Lamp Indicator Inoperative
- Fog Lamps Always On
- Fog Lamps Inoperative
- Hazard Lamps Always On
- Hazard Lamps Inoperative
- Headlamp Low or High Beams Always On
- Headlamps Inoperative - High Beams
- Headlamps Inoperative - Low Beams
- Low and High Beams Headlamps Inoperative
- Headlamps Flash to Pass Inoperative
- High Beam Indicator Always On
- High Beam Indicator Inoperative
- Interior Backlighting Does Not Dim
- Interior Backlighting Inoperative
- Park, License, and Tail Lamps Always On
- Park, License, and Tail Lamps Inoperative
- Reading Lamp(s) Inoperative
- Roof Beacon Lamp Always On
- Roof Beacon Lamp Inoperative
- Stop Lamps Always On
- Stop Lamps Inoperative
- Turn Signal Lamps and/or Indicators Always On or Flashing
- Turn Signal Lamps and/or Indicators Inoperative
- Vanity Mirror Lamp(s) Inoperative
- Removal Procedure
- Installation Procedure
- Headlamp Aiming
- Screen Method for Headlamp Aiming (Visual Aim)
- Headlamp Aiming Procedure
- Fog Lamp Aiming
- Preparation Procedure
- Aiming Procedure
- Exterior Lamps
- Headlamps
- High Beams
- Low Beams
- Daytime Running Lamps (DRL)
- Fog Lamps
- Park, Tail and Marker Lamps
- Exterior Courtesy Lamps
- Turn Signal/Hazard Lamps
- Stop Lamps
- Backup Lamps - Automatic Transmission
- Backup Lamps - Allison Transmission
- Backup Lamps - Manual Transmission
- Cargo Lamps
- Clearance Lamps
- Roof Beacon Lamp
- Interior Lamps
- Courtesy/Illuminated Entry Lamps
- Keyless Entry Interior Illumination
- Vanity Lamps
- Reading Lamps
- Battery Rundown Protection/Inadvertent Power
- Interior Lamps Dimming