This is a theorem of Hassler Whitney:
For $0<k<\infty$ and any $n$-dimensional $C^k$ manifold the maximal atlas contains a $C^\infty$ atlas on the same underlying set.
It seems to me that this theorem says every $C^{k}$ manifold can be thought of as if it were a $C^{\infty}$ manifold proceeding like this:
Start with a given a $C^{k}$ atlas $\mathcal{A}$ on a topological manifold $M$
Consider the maximal $C^{k}$ atlas $\overline{\mathcal{A}}$ containing $\mathcal{A}$ (i.e. the atlas containing every $C^{k}$ chart on $M$ compatible with $\mathcal{A}$)
Extract a $C^{\infty}$ subatlas $\mathcal{A}_{\infty}$ of $\overline{\mathcal{A}}$ (it can be done because of Whitney's theorem)
Now make $M$ a $C^{\infty}$ manifold considering the atlas $\mathcal{A}_{\infty}$
After this maneuver we ended up with two differentiable structures over the same underlying topological manifold $M$: one of $C^{k}$ type given by $\mathcal{A}$ and the other of $C^{\infty}$ type given by $\mathcal{A}_{\infty}$.
My questions are:
Up to what extent are this two differentiable manifolds, $(M,\mathcal{A})$ and $(M,\mathcal{A}_{\infty})$, the same?
Is it true that the maximal atlas $\overline{\mathcal{A}_{\infty}}$ generated by $\mathcal{A}_{\infty}$ is the same as $\overline{\mathcal{A}}$ with all the non $C^{\infty}$ charts removed?
Are there examples of $C^{k}$ manifolds for which exists a $C^{k}$ atlas such that none of its charts is $C^{r}$ for some $r>k$?
When studying functions defined on a $C^{k}$ manifold $M$ we can consider differentials up to order $k$, with this limit $k$ imposed by the $C^{k}$ differentiable structure. Is the theorem of Whitney telling us that this restriction is artificial since we can get a $C^{\infty}$ atlas for $M$?
Thanks.
(1) The identity map from the $C^k$-manifold to its $C^\infty$-refinement is a $C^k$-diffeomorphism.
(2) I don't understand your question.
(3) This question does not make sense to me. What does it mean for a map to be more differentiable than the maximum-definable level of differentiability?
(4) You're asking a vague question here. Could you be more specific.