Segment:
Full-size SUV / Light Duty Truck Crossover
Competitors:
Ford Explorer Sport Trac, Dodge Ramcharger, Nissan Titan Crew Cab, Toyota Tundra Access Cab (competing on utility and passenger capacity)
Unique Selling Proposition:
Segment-defining Midgate system allowing conversion from a closed SUV cabin to an open-bed pickup truck configuration, combining the benefits of both vehicle types.
Years Covered:
2002, 2003, 2004, 2005, 2006
Models Covered:
All Chevrolet Avalanche models, all trim levels, all configurations
Engine Coverage:
5.3L V8 (LM7), 6.0L V8 (LQ4)
Transmission Coverage:
4L60-E (4-speed automatic), 4L80-E (4-speed automatic)
Estimated Page Count:
Likely 2000+ pages (typical for a complete workshop manual)
Type:
Complete Workshop Service Repair Manual
Digital Format:
Downloadable PDF
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, engine performance, transmission (automatic), transfer case (4WD models)
Chassis:
Suspension (front and rear), steering system, braking system (ABS, DRL, rear drum/disc), wheels and tires
Electrical:
Body control module (BCM), powertrain control module (PCM), chassis control module (CCM), lighting (interior and exterior), instrument cluster, audio system, HVAC controls, power windows/locks/mirrors, cruise control, trailer wiring
Body:
Exterior body panels, interior trim, seats, cargo management system (Midgate, Midgate panel, bed cover), doors, windows, bumpers, tailgate
Maintenance:
Oil changes, filter replacements, fluid checks and changes, belt and hose inspection/replacement, spark plug replacement, brake pad/rotor replacement, tire rotation
Repair:
Engine overhaul, transmission rebuild, suspension component replacement, brake caliper/master cylinder replacement, alternator/starter replacement, power steering pump replacement, fuel pump replacement, radiator replacement, exhaust system repair, body panel repair/replacement, interior component repair
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), wiring diagrams, component testing procedures
Specifications:
Torque specifications, fluid capacities, clearances, measurements, diagnostic parameters
Depth:
Comprehensive, covering all aspects from routine maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and wiring diagrams.
Requirements:
Adobe Reader (free download available), compatible with PC, MAC, tablets, and smartphones.
Printability:
High quality, allows printing of individual pages, chapters, or the entire manual.
Digital Binding:
N/A (Digital Download)
Digital Paper Type:
N/A (Digital Download)
Engine Displacement 1:
5.3 Liters (327 cu in)
Engine Type 1:
V8, Vortec 5300, OHV, 16-valve
Horsepower 1:
285 hp @ 5200 rpm (approximate)
Torque 1:
325 lb-ft @ 4000 rpm (approximate)
Fuel System 1:
Sequential Electronic Fuel Injection (SEFI)
Engine Displacement 2:
6.0 Liters (364 cu in)
Engine Type 2:
V8, Vortec 6000, OHV, 16-valve
Horsepower 2:
300 hp @ 4800 rpm (approximate)
Torque 2:
360 lb-ft @ 4000 rpm (approximate)
Fuel System 2:
Sequential Electronic Fuel Injection (SEFI)
Type 1:
4-speed Automatic Overdrive
Type 2:
4-speed Automatic Overdrive
Model 2:
4L80-E (typically with 6.0L engine)
Drive Options:
Rear-Wheel Drive (RWD), All-Wheel Drive (AWD, with a 2-speed transfer case on most models)
Overall Length:
221.0 inches
Overall Width:
79.7 inches
Overall Height:
76.7 inches
Cargo Volume Midgate Closed:
Approximately 57.7 cubic feet (behind the second row)
Cargo Volume Midgate Open:
Approximately 108.9 cubic feet (behind the first row, bed length extended)
Curb Weight Rwd 5.3L:
Approximately 5,545 lbs
Curb Weight AWD 5.3L:
Approximately 5,756 lbs
Gross Vehicle Weight Rating Gvw:
7,000 - 7,200 lbs (depending on configuration)
NHTSA Rollover Resistance:
3-star rating (typical for this era of large SUVs)
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Traction Control:
Available Traction Control System (TCS).
Airbags:
Frontal airbags for driver and front passenger.
Seat Belts:
Three-point seat belts for all seating positions.
Audio System:
Factory AM/FM stereo with CD player. Optional premium sound systems, Bose audio, and in-dash CD changers available.
Navigation:
Optional factory navigation system was available on higher trim levels.
Cruise Control:
Standard cruise control.
Trailer Package:
Optional towing packages included trailer wiring harnesses and upgraded cooling.
Oil Change Interval:
Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specific recommendations).
Engine Air Filter:
Inspect every 15,000 miles, replace as needed.
Cabin Air Filter:
Replace every 12,000-15,000 miles or annually.
Transmission Fluid:
Replace fluid and filter every 30,000-100,000 miles depending on usage and fluid type (consult manual).
Engine Oil 5.3L:
SAE 5W-30, API SN or newer certified. Capacity: 6 quarts with filter.
Engine Oil 6.0L:
SAE 5W-30, API SN or newer certified. Capacity: 6 quarts with filter.
Transmission Fluid:
Dexron III/VI (or equivalent), check manual for exact specification. Capacity varies by transmission model.
Coolant:
Dex-Cool (orange) extended life antifreeze coolant, 50/50 mixture with distilled water. Capacity: 14.1 - 15.2 quarts.
Transmission Reliability:
Some reports of 4L60-E transmission wear and failure, particularly with heavy use or towing. Fluid and filter changes are critical.
Rear Main Seal:
Potential for rear main seal leaks on some Vortec engines.
Intermediate Shaft Bearing:
Some AWD models can experience wear or failure of the intermediate shaft bearing.
Interior Rattles:
Common in large SUVs of this era, various interior trim panels can develop rattles.
Manufacturer:
Chevrolet, a division of General Motors (GM), known for its broad range of vehicles from trucks to sports cars.
Platform:
Built on the GMT800 platform, shared with Chevrolet Silverado/GMC Sierra pickups, Tahoe/Yukon SUVs.
Major Updates:
Minor styling updates, powertrain enhancements, and feature additions throughout its first generation lifecycle (2002-2006).
Manufacturing Plant:
Janesville, Wisconsin, USA