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Hour of manufacture. The bar code that appears on the bottom of the label is your Vehicle Identification Number (VIN). Gross Vehicle Weight Rating (GVWR) The GVWR is the total permissible weight of your vehicle including driver, passengers, vehicle, options and cargo. The label also specifies maximum capacities of front and rear axle systems (GAWR). Total load must be limited so GVWR and front and rear GAWR are not exceeded. Payload The payload of a vehicle is defined as the allowable load weight a truck can carry, including the weight of the driver, all passengers, options and cargo.
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Gross Axle Weight Rating (GAWR) The GAWR is the maximum permissible load on the front and rear axles. The load must be distributed in the cargo area so that the GAWR of each axle is not exceeded. Each axle GAWR is determined by the components in the system with the lowest load carrying capacity (axle, springs, tires or wheels). Heavier axles or suspension components sometimes specified by purchasers for in- creased durability does not necessarily increase the vehi- cle’s GVWR. Tire Size The tire size on the Label represents the actual tire size on your vehicle. Replacement tires must be equal to the load capacity of this tire size. Rim Size This is the rim size that is appropriate for the tire size listed.
Inflation Pressure This is the cold tire inflation pressure for your vehicle for all loading conditions up to full GAWR. Curb Weight The curb weight of a vehicle is defined as the total weight of the vehicle with all fluids, including vehicle fuel, at full capacity conditions, and with no occupants or cargo loaded into the vehicle. The front and rear curb weight values are determined by weighing your vehicle on a commercial scale before any occupants or cargo are added. Loading The actual total weight and the weight of the front and rear of your vehicle at the ground can best be determined by weighing it when it is loaded and ready for operation. The entire vehicle should first be weighed on a commer- cial scale to insure that the GVWR has not been exceeded. The weight on the front and rear of the vehicle should
then be determined separately to be sure that the load is properly distributed over front and rear axle. Weighing the vehicle may show that the GAWR of either the front or rear axles has been exceeded but the total load is within the specified GVWR. If so, weight must be shifted from front to rear or rear to front as appropriate until the specified weight limitations are met. Store the heavier items down low and be sure that the weight is distributed equally. Stow all loose items securely before driving. Improper weight distributions can have an adverse effect on the way your vehicle steers and handles and the way the brakes operate.
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CAUTION!
Do not load your vehicle any heavier than the GVWR or the maximum front and rear GAWR. If you do, parts on your vehicle can break, or it can change the way your vehicle handles. This could cause you to lose control. Also overloading can shorten the life of your vehicle.
TRAILER TOWING In this section you will find safety tips and information on limits to the type of towing you can reasonably do with your vehicle. Before towing a trailer carefully re- view this information to tow your load as efficiently and safely as possible. To maintain warranty coverage, follow the requirements and recommendations in this manual concerning ve- hicles used for trailer towing.
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Common Towing Definitions The following trailer towing related definitions will assist you in understanding the following information: Gross Vehicle Weight Rating (GVWR) The GVWR is the total allowable weight of your vehicle. This includes driver, passengers, cargo and tongue weight. The total load must be limited so that you do not exceed the GVWR. Gross Trailer Weight (GTW) The GTW is the weight of the trailer plus the weight of all cargo, consumables and equipment (permanent or tem- porary) loaded in or on the trailer in its ⬙loaded and ready for operation⬙ condition. The recommended way to measure GTW is to put your fully loaded trailer on a vehicle scale. The entire weight of the trailer must be supported by the scale.
Gross Combination Weight Rating (GCWR) The GCWR is the total permissible weight of your vehicle and trailer when weighed in combination. NOTE: The GCWR rating includes a 150 lbs (68 kg) allowance for the presence of a driver. Gross Axle Weight Rating (GAWR) The GAWR is the maximum capacity of the front and rear axles. Distribute the load over the front and rear axles evenly. Make sure that you do not exceed either front or rear GAWR.
WARNING!
It is important that you do not exceed the maximum front or rear GAWR. A dangerous driving condition can result if either rating is exceeded. You could lose control of the vehicle and have an accident.
Tongue Weight (TW) The tongue weight is the downward force exerted on the hitch ball by the trailer. In most cases it should not be less than 10% or more than 15% of the trailer load. You must consider this as part of the load on your vehicle. Frontal Area The frontal area is the maximum height and maximum width of the front of a trailer. Trailer Sway Control The trailer sway control is a telescoping link that can be installed between the hitch receiver and the trailer tongue that typically provides adjustable friction associated with the telescoping motion to dampen any unwanted trailer swaying motions while traveling. Weight-Carrying Hitch A weight-carrying hitch supports the trailer tongue weight, just as if it were luggage located at a hitch ball or some other connecting point of the truck. These kind of
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hitches are the most popular on the market today and they’re commonly used to tow small- and medium-sized trailers. Weight-Distributing Hitch A weight-distributing system works by applying lever- age through spring (load) bars. They are typically used for heavier loads, to distribute trailer tongue weight to the tow vehicle’s front axle and the trailer axle(s). When used in accordance with the manufacturers’ directions, it provides for a more level ride, offering more consistent steering and brake control thereby enhancing towing safety. The addition of a friction / hydraulic sway control also dampens sway caused by traffic and crosswinds and contributes positively to tow vehicle and trailer stability. Trailer sway control and a weight distributing (load equalizing) hitch are recommended for heavier Tongue Weights (TW) and may be required depending on Vehicle and Trailer configuration / loading to comply with gross axle weight rating (GAWR) requirements.
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WARNING!
• An improperly adjusted Weight Distributing Hitch system may reduce handling, stability, brak- ing performance, and could result in an accident. • Weight Distributing Systems may not be compat- ible with Surge Brake Couplers. Consult with your hitch and trailer manufacturer or a reputable Rec- reational Vehicle dealer for additional information.
EXAMPLE — Without Weight-Distributing Hitch
(Incorrect)
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EXAMPLE — With Weight-Distributing Hitch (Correct)
EXAMPLE — Improper Adjustment of Weight-
Distributing Hitch (Incorrect)
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Fifth-Wheel Hitch A special high platform with a coupling that mounts over the rear axle of the tow vehicle in the truck bed. Connects a vehicle and fifth-wheel trailer with a coupling king pin. Gooseneck Hitch The gooseneck hitch employs a pivoted coupling arm which attaches to a ball mounted in the bed of a pickup truck. The coupling arm connects to the hitch mounted over the rear axle in the truck bed. Trailer Hitch Classification The rear bumper is intended to tow trailers up to 2,000 lbs (907 kg) without added equipment or alter- ations to the standard equipment. Your vehicle may be factory equipped for safe towing of trailers weighing over 2,000 lbs (907 kg) with the optional Trailer Tow Prep Package. See your dealer for package content. The following chart provides the industry standard for the maximum trailer weight a given trailer hitch class can
tow and should be used to assist you in selecting the correct trailer hitch for your intended towing condition.
Trailer Hitch Classification Definitions
Class
Max. Trailer Hitch Industry
Standards
Class I - Light Duty Class II - Medium Duty Class III - Heavy Duty Class IV - Extra Heavy Duty Fifth Wheel/Gooseneck
2,000 lbs (907 kg) 3,500 lbs (1587 kg) 5,000 lbs (2268 kg) 10,000 lbs (4540 kg)
Greater than 10,000 lbs
(4540 kg)
Refer to “Trailer Towing Weights (Maximum Trailer Weight Ratings)” for the website address that con- tains the necessary information for your specific drivetrain. All trailer hitches should be professionally installed on your vehicle.
Trailer Towing Weights (Maximum Trailer Weight Ratings)
Never exceed the maximum tongue weight stamped on your bumper or trailer hitch.
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NOTE: For additional trailer towing information (maxi- mum trailer weight ratings) refer to the following website addresses: • http:// www.dodge.com/towing. • http:// www.dodge.ca (Canada). Trailer and Tongue Weight Always load a trailer with 60% to 65% of the weight in the front of the trailer. This places 10% to 15% of the Gross Trailer Weight (GTW) on the tow hitch of your vehicle. Loads balanced over the wheels or heavier in the rear can cause the trailer to sway severely side to side which will cause loss of control of vehicle and trailer. Failure to load trailers heavier in front is the cause of many trailer accidents.
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put in or on your vehicle.
Consider the following items when computing the weight on the rear axle of the vehicle: • The tongue weight of the trailer. • The weight of any other type of cargo or equipment • The weight of the driver and all passengers. NOTE: Remember that everything put into or on the trailer adds to the load on your vehicle. Also, additional factory-installed options, or dealer-installed options, must be considered as part of the total load on your vehicle. Refer to the Tire and Loading Information plac- ard in the “Tire Safety Information” section of this manual.
Towing Requirements To promote proper break-in of your new vehicle drive- train components the following guidelines are recom- mended:
CAUTION!
• Avoid towing a trailer for the first 500 miles (805 km) of vehicle operation. Doing so may dam- age your vehicle. • During the first 500 miles (805 km) of trailer
towing, limit your speed to 50 mph (80 km/h).
Perform the maintenance listed in Section 8 of this manual. When towing a trailer, never exceed the GAWR, or GCWR, ratings.
WARNING!
Improper towing can lead to an injury accident. Follow these guidelines to make your trailer towing as safe as possible: Make certain that the load is secured in the trailer and will not shift during travel. When trailering cargo that is not fully secured, dynamic load shifts can occur that may be difficult for the driver to control. You could lose control of your vehicle and have an accident. • When hauling cargo or towing a trailer, do not over- load your vehicle or trailer. Overloading can cause a loss of control, poor performance or damage to brakes, axle, engine, transmission, steering, suspension, chas- sis structure or tires. • Safety chains must always be used between your vehicle and trailer. Always connect the chains to the
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frame or hook retainers of the vehicle hitch. Cross the chains under the trailer tongue and allow enough slack for turning corners. • Vehicles with trailers should not be parked on a grade. When parking, apply the parking brake on the tow vehicle. Put the tow vehicle automatic transmission in PARK. With four-wheel-drive vehicles, make sure the transfer case is not in neutral. Always, block or ⬙chock⬙ the trailer wheels.
• GCWR must not be exceeded. • Total weight must be distributed between the tow vehicle and the trailer such that the following four ratings are not exceeded: 1. GVWR 2. GTW 3. GAWR
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4. Tongue weight rating for the trailer hitch utilized (This requirement may limit the ability to always achieve the 10% to 15% range of tongue weight as a percentage of total trailer weight).
− When replacing tires, refer to “Tires–General Informa- tion” for proper tire replacement procedures. Replac- ing tires with a higher load carrying capacity will not increase the vehicle’s GVWR and GAWR limits.
Towing Requirements — Tires − Do not attempt to tow a trailer while using a compact
spare tire.
− Proper tire inflation pressures are essential to the safe and satisfactory operation of your vehicle. Refer to “Tires–General Information” for proper tire inflation procedures.
− Check the trailer tires for proper tire inflation pres-
sures before trailer usage.
− Check for signs of tire wear or visible tire damage before towing a trailer. Refer to “Tires–General Infor- mation” for the proper inspection procedure.
Towing Requirements — Trailer Brakes − Do not interconnect the hydraulic brake system or vacuum system of your vehicle with that of the trailer. This could cause inadequate braking and possible personal injury.
− An electronically actuated trailer brake controller is required when towing a trailer with electronically actuated brakes. When towing a trailer equipped with a hydraulic surge actuated brake system, an electronic brake controller is not required.
− Trailer brakes are recommended for trailers over 1,000 lbs (454 kg) and required for trailers in excess of 2,000 lbs (907 kg).
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CAUTION!
If the trailer weighs more than 1,000 lbs (454 kg) loaded, it should have its own brakes and they should be of adequate capacity. Failure to do this could lead to accelerated brake lining wear, higher brake pedal effort, and longer stopping distances.
WARNING! (Continued)
• Towing any trailer will increase your stopping distance. When towing you should allow for addi- tional space between your vehicle and the vehicle in front of you. Failure to do so could result in an accident.
WARNING!
• Do not connect trailer brakes to your vehicle’s hydraulic brake lines. It can overload your brake system and cause it to fail. You might not have brakes when you need them and could have an accident.
(Continued)
Towing Requirements — Trailer Lights & Wiring Whenever you pull a trailer, regardless of the trailer size, stop lights and turn signals on the trailer are required for motoring safety. The Trailer Tow Package may include a 4 and 7–pin wiring harness. Use a factory approved trailer harness and connector. NOTE: Do not cut or splice wiring into the vehicles wiring harness.
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The electrical connections are all complete to the vehicle but you must mate the harness to a trailer connector. Refer to the following illustrations.
1 — Female Pins 2 — Male Pin 3 — Ground
4-Pin Connector 4 — Park 5 — Left Stop/Turn 6 — Right Stop/Turn
1 — Battery 2 — Backup Lamps 3 — Right Stop/Turn 4 — Electric Brakes
7-Pin Connector
5 — Ground 6 — Left Stop/Turn 7 — Running Lamps
WARNING!
Any work done to the vehicles electrical system, or wiring, should be performed by a qualified automo- tive technician, if done improperly it may cause damage to the electrical system wiring and could result in serious or fatal injury.
Towing Tips Before setting out on a trip, practice turning, stopping and backing the trailer in an area away from heavy traffic. Automatic Transmission The “DRIVE” range can be selected when towing. How- ever, if frequent shifting occurs while in this range, the “TOW HAUL” or “OD/OFF” range should be selected.
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NOTE: Using the “TOW HAUL” or “OD/OFF” range while operating the vehicle under heavy operating con- ditions will improve performance and extend transmis- sion life by reducing excessive shifting and heat build up. This action will also provide better engine braking. The automatic transmission fluid and filter should be changed if you REGULARLY tow a trailer for more than 45 minutes of continuous operation. Refer to the “Main- tenance Schedule” in Section 8 for the proper mainte- nance intervals. NOTE: Check the automatic transmission fluid level before towing. Tow/Haul — If Equipped To reduce potential for automatic transmission overheat- ing, turn the “TOW HAUL OD/OFF” feature ON when driving in hilly areas or shift the transmission to Drive position 2 on more severe grades.
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Electronic Speed Control — If Equipped − Do not use in hilly terrain or with heavy loads. − When using the speed control, if you experience speed drops greater than 10 mph (16 km/h), disengage until you can get back to cruising speed.
− Use speed control in flat terrain and with light loads to
maximize fuel efficiency.
Cooling System To reduce potential for engine and transmission over- heating, take the following actions: NOTE: Engine power may be temporarily reduced in order to maintain oil and coolant temperatures under extreme trailer tow operating conditions. − City Driving When stopped for short periods of time, put transmission in neutral and increase engine idle speed.
− Highway Driving Reduce speed. − Air Conditioning Turn off temporarily.
SNOWPLOW Snowplow Prep Packages are available as a factory- installed option. These packages include components necessary to equip your vehicle with a snowplow. NOTE: Before installation of a snowplow, it is highly recommended that the owner/installer obtain and follow the recommendations contained within the current Dodge Body Builder’s Guide. See your authorized dealer, installer or snowplow manufacturer for this information. There are unique electrical systems that must be con- nected to properly assure operator safety, and to prevent overloading vehicle systems.
WARNING!
Attaching a snowplow to this vehicle could adversely affect performance of the airbag system in an acci- dent. Do not expect that the airbag will perform as described earlier in this manual
RECREATIONAL TOWING (BEHIND MOTORHOME, ETC.)
CAUTION!
Front or rear wheel lifts should not be used. Internal damage to the transmission or transfer case will occur if a front or rear wheel lift is used when recreational towing.
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Recreational Towing – Two-Wheel Drive Models
Recreational towing of two-wheel drive models is not allowed. Towing with the rear wheels on the ground can result in severe transmission damage. Recreational Towing – Four-Wheel Drive Models
CAUTION!
Failure to follow these requirements can cause severe damage to the transmission and/or transfer case.
NOTE: Both the manual shift and electronic shift trans- fer cases must be shifted into NEUTRAL for recreational towing. Automatic transmissions must be shifted into the PARK position for recreational towing. Refer to the following for the proper transfer case NEUTRAL shifting procedure for your vehicle.
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Recreational Towing Procedure — Manual Shift Transfer Case — If Equipped Use the following procedure to prepare your vehicle for recreational towing:
CAUTION!
It is necessary to follow these steps to be certain that the transfer case is fully in NEUTRAL before recre- ational towing to prevent damage to internal parts.
1. Bring the vehicle to a complete stop. 2. Shut OFF the engine. 3. Depress the brake pedal. 4. Shift the transmission into NEUTRAL. 5. Shift the transfer case lever into NEUTRAL.
6. Start the engine. 7. Shift the transmission into REVERSE. 8. Release the brake pedal for five seconds and ensure that there is no vehicle movement. 9. Repeat steps 7 and 8 with the transmission in DRIVE. 10. Shut OFF the engine and place the ignition key in the unlocked OFF position. 11. Shift the transmission into PARK. 12. Apply the parking brake. 13. Attach the vehicle to the tow vehicle with the tow bar. 14. Release the parking brake.
CAUTION!
Damage to the transmission may occur if the trans- mission is shifted into PARK with the transfer case in NEUTRAL and the engine running. With the transfer case in NEUTRAL ensure that the engine is OFF prior to shifting the transmission into PARK.
Returning to Normal Operation — Manual Shift Transfer Case Use the following procedure to prepare your vehicle for normal usage: 1. Bring the vehicle to a complete stop. 2. Apply the parking brake. 3. Shut OFF the engine. 4. Depress the brake pedal.
STARTING AND OPERATING 399
5. Shift the transmission into NEUTRAL. 6. Shift the transfer case lever into desired position. 7. Shift the transmission into PARK.
WARNING!
You or others could be injured if you leave the vehicle unattended with the transfer case in the NEUTRAL position without first fully engaging the parking brake. The transfer case NEUTRAL position disengages both the front and rear driveshafts from the powertrain and will allow the vehicle to move, regardless of the transmission position. The parking brake should always be applied when the driver is not in the vehicle.
400 STARTING AND OPERATING
CAUTION!
• Do not use a bumper-mounted clamp-on tow bar on your vehicle. The bumper face bar will be damaged. • Do not disconnect the rear driveshaft because fluid will leak from the transfer case and damage the internal parts.
Recreational Towing Procedure — Electronic Shift Transfer Case — If Equipped Use the following procedure to prepare your vehicle for recreational towing:
CAUTION!
It is necessary to follow these steps to be certain that the transfer case is fully in NEUTRAL before recre- ational towing, to prevent damage to internal parts.
1. Bring the vehicle to a complete stop. 2. Shut OFF the engine. 3. Turn the ignition key to the ON position, but do not start the engine. 4. Depress the brake pedal. 5. Shift the transmission into NEUTRAL. 6. Using the point of a ballpoint pen or similar object, depress the recessed transfer case NEUTRAL button for four seconds. 7. After shift is completed and the NEUTRAL light comes on, release the NEUTRAL button. 8. Start the engine. 9. Shift the transmission into REVERSE. 10. Release the brake pedal for five seconds and ensure that there is no vehicle movement.
11. Repeat steps 9 and 10 with the transmission in DRIVE. 12. Shut the engine OFF and place ignition key in the unlocked OFF position. 13. Shift the transmission into PARK. 14. Apply the parking brake. 15. Attach the vehicle to the tow vehicle with the tow bar. 16. Release the parking brake. NOTE: • Steps 1 through 5 are requirements that must be met prior to depressing the NEUTRAL selection button, and must continue to be met until the four seconds elapses and the shift has been completed. If any of these requirements (with the exception of 3 - Key ON) are not met prior to depressing the NEUTRAL button or are no longer met during the four second timer, then
STARTING AND OPERATING 401
the NEUTRAL indicator light will flash continuously until all requirements are met or until the NEUTRAL button is released. • The ignition key must be ON for a shift to take place and for the position indicator lights to be operable. If the key in not ON, the shift will not take place and no position indicator lights will be on or flashing. • Flashing NEUTRAL position indicator light indicates
that shift requirements have not been met.
CAUTION!
Damage to the transmission may occur if the trans- mission is shifted into PARK with the transfer case in NEUTRAL and the engine running. With the transfer case in NEUTRAL, ensure that the engine is OFF prior to shifting the transmission into PARK.
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Returning to Normal Operation — Electronic Shift Transfer Case Use the following procedure to prepare your vehicle for normal usage: 1. Bring the vehicle to a complete stop. 2. Shut OFF the engine. 3. Turn the ignition key to the ON position, but do not start the engine. 4. Depress the brake pedal. 5. Shift the transmission into NEUTRAL. 6. Using the point of a ballpoint pen or similar object, depress the recessed transfer case Neutral (N) button for one second. 7. After the Neutral indicator light turns off, release the Neutral (N) button.
from the 4AUTO (if equipped) position.
8. After the Neutral (N) button has been released, the transfer case will shift into the position identified by the selector switch. 9. Shift the transmission into PARK. NOTE: • The transfer case cannot be shifted into NEUTRAL • Steps 1 through 5 are requirements that must be met prior to depressing the transfer case Neutral (N) button, and must continue to be met until one second elapses and the shift has been completed. If any of these requirements (with the exception of step 3 - key ON) are not met prior to depressing the Neutral (N) button, or are no longer met during the one second time, then all of the mode position indicator lights will flash continuously until all requirements are met, or until the Neutral (N) button is released.
• The ignition key must be ON for a transfer case shift to take place and for the position indicator lights to be operable. If the key is not ON, the shift will not take place and no position indicator lights will be on or flashing. • Flashing Neutral position indicator light indicates that
shift requirements have not been met.
WARNING!
You or others could be injured if you leave the vehicle unattended with the transfer case in the NEUTRAL position without first fully engaging the parking brake. The transfer case NEUTRAL position disengages both the front and rear driveshafts from the powertrain and will allow the vehicle to move despite the transmission position. The parking brake should always be applied when the driver is not in the vehicle.
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CAUTION!
• Do not use a bumper-mounted clamp-on tow bar on your vehicle. The bumper face bar will be damaged. • Do not disconnect the rear driveshaft because fluid will leak from the transfer case and fluid loss will damage internal parts.
EQUIPMENT IDENTIFICATION PLATE The equipment Identification Plate is located on the hood inner surface. The following information about your vehicle is dis- played on this plate: Model, Wheelbase, Vehicle Identifi- cation Number, Truck Order Number, and code numbers with descriptions of all production and special equip- ment on the truck as shipped from the factory. NOTE: Always refer to the Equipment Identification Plate When Ordering Parts.
WHAT TO DO IN EMERGENCIES
CONTENTS
䡵 Hazard Warning Flasher 䡵 Jacking Instructions
. . . . . . . . . . . . . . . 406
. . . . . . . . . . . . . . . . . . . 407
. . . . . . . . . . . . . . . . . . . . . . 407
. . . . . . . . . . . . . 408
. . . . . . . . . . . . . . 409
. . . . . . . . . . . . . . . . . . . . . . . 409
. . . . . . . . . . . . . . . . . . . . . . . 410
. . . . . . . . . . . . . 414▫ Jack Location ▫ Removing The Spare Tire ▫ Tire Changing Procedure ▫ Preparations ▫ Instructions ▫ Hub Caps/Wheel Covers
䡵 Hoisting 䡵 Jump-Starting Procedures 䡵 Freeing A Stuck Vehicle 䡵 Emergency Tow Hooks — If Equipped 䡵 Towing A Disabled Vehicle
. . . . . . . . . . . . . . . . . . . . . . . . . . . 418
. . . . . . . . . . . . . . . 419
. . . . . . . . . . . . . . . . 421
. . . . . 422
. . . . . . . . . . . . . . 422
. . . . . . . . . . . . . . . 423
. . . . . . . . . . . . . . . 423▫ 4-Wheel Drive Vehicles ▫ 2–Wheel Drive Vehicles
406 WHAT TO DO IN EMERGENCIES
HAZARD WARNING FLASHER The Hazard Warning flasher switch is mounted on the top of the steering column.
Hazard Warning Flasher Switch
Press the switch to turn on the Hazard Warning flasher. When the switch is activated, all directional turn signals will flash on and off to warn oncoming traffic of an emergency. Press the switch a second time to turn off the Hazard Warning flasher. This is an emergency warning system and should not be used when the vehicle is in motion. Use it when your vehicle is disabled and is creating a safety hazard for other motorists. When you must leave the vehicle to seek assistance, the Hazard Warning flasher will continue to operate even though the ignition switch is OFF. NOTE: With extended use, the Hazard Warning flasher may discharge your battery.
JACKING INSTRUCTIONS
WARNING!
• Being under a jacked-up vehicle is dangerous. The vehicle could slip off the jack and fall on you. You could be crushed. Never put any part of your body under a vehicle that is on a jack. Never start or run the engine while the vehicle is on a jack. If you need to get under a raised vehicle, take it to an authorized service center where it can be raised on a lift. • The jack is designed to use as a tool for changing tires only. The jack should not be used to lift the vehicle for service purposes. The vehicle should be jacked on a firm level surface only. Avoid ice or slippery areas.
WHAT TO DO IN EMERGENCIES 407
Jack Location The jack and jack tools are stored under the front passenger seat. Lift the flap on the side of the seat for access. Remove the jack and tools by removing the wing bolt and sliding the assembly from under the seat.
Jack Location
408 WHAT TO DO IN EMERGENCIES
Removing The Spare Tire Remove the spare tire before attempting to jack the truck. Attach the wheel wrench to the jack extension tube. Insert the tube through the access hole between the lower tailgate and the top of the bumper and into the winch mechanism tube. Rotate the wheel wrench handle coun- terclockwise until the spare tire is on the ground with enough cable slack to allow you to pull it out from under the vehicle. When the spare is clear, tilt the retainer at the end of the cable and pull it through the center of the wheel. NOTE: Always stow the spare tire with the valve stem facing the ground.
Removing the Spare Tire
1 — Lower 2 — Raise It is recommended that you stow the flat or spare to avoid tangling the loose cable.
NOTE: The winch mechanism is designed for use with the jack extension tube only. Use of an air wrench or other power tools is not recommended and can damage the winch. Tire Changing Procedure
WARNING!
• Getting under a jacked-up vehicle is dangerous. The vehicle could slip off the jack and fall on you. You could be crushed. Never get any part of your body under a vehicle that is on a jack. Never start or run the engine while the vehicle is on a jack. If you need to get under a raised vehicle, take it to an authorized service center where it can be raised on a lift.
(Continued)
WHAT TO DO IN EMERGENCIES 409
WARNING! (Continued)
• Do not raise this vehicle using a bumper jack. The jack is designed as a tool for changing tires on this vehicle only. It is not recommended that the jack be used for service purposes or to lift more than one wheel at a time.
Preparations
1. Park the vehicle on a firm, level surface. Avoid ice or slippery areas.
WARNING!
Do not attempt to change a tire on the side of the vehicle close to moving traffic. Pull far enough off the road to avoid the danger of being hit when operating the jack or changing the wheel.
2. Set the parking brake.
410 WHAT TO DO IN EMERGENCIES
3. Place the shift lever into PARK. On four-wheel drive vehicles, shift the transfer case to the 4L position. 4. Turn the ignition OFF. 5. Turn on the Hazard Warning flasher.
6. Block both the front and rear of the wheel diagonally opposite the jacking position. For example, if the right front wheel is being changed, block the left rear wheel.
NOTE: Passengers should not remain in the vehicle when the vehicle is being jacked.
Instructions
WARNING!
Carefully follow these tire changing warnings to help prevent personal injury or damage to your vehicle: • Always park on a firm, level surface as far from the edge of the roadway as possible before raising the vehicle. • Block the wheel diagonally opposite the wheel to • Set the parking brake firmly and set an automatic transmission in PARK; a manual transmission in REVERSE. • Never start or run the engine with the vehicle on a • Do not let anyone sit in the vehicle when it is on a
be raised.
jack.
jack.
(Continued)
WARNING! (Continued)
for lifting this vehicle during a tire change.
• Do not get under the vehicle when it is on a jack. • Only use the jack in the positions indicated and • If working on or near a roadway, be extremely • To assure that spare tires, flat or inflated, are securely stowed, spares must be stowed with the valve stem facing the ground.
careful of motor traffic.
• Turn on the Hazard Warning flasher.
WHAT TO DO IN EMERGENCIES 411
2. Using the wheel wrench, loosen, but do not remove, the wheel nuts by turning them counterclockwise one turn while the wheel is still on the ground. 3. Placement of the Jack: • For 2500/3500 4x2 series trucks, when changing a front wheel, place the bottle jack under the frame rail behind the wheel. Locate the jack as far forward as possible on the straight part of the frame.
1. Remove the spare wheel, jack, and tools from storage.
Jack Warning Label
4x2 Jacking Location
412 WHAT TO DO IN EMERGENCIES
• Operate the jack using the jack drive tube and the wheel wrench. The tube extension, may be used, but is not required. • For 2500/3500 4x4 series trucks, when changing the front wheel, assemble the jack drive tube to the jack and connect the drive tube to the extension tube. Place the jack under the axle as close to the tire as possible with the drive tubes extending to the front. Connect the jack tube extension and wheel wrench.
4x4 Jacking Location
• For all trucks, when changing a rear wheel, as- semble the jack drive tube to the jack and connect the drive tube to the extension tube. Place the jack under the axle between the spring and the shock absorber with the drive tubes extending to the rear.
WHAT TO DO IN EMERGENCIES 413
If the 2500/3500 bottle jack will not lower by NOTE: turning the dial (thumbwheel) by hand, it may be neces- sary to use the jack drive tube in order to lower the jack. 4. By rotating the wheel wrench clockwise, raise the vehicle until the wheel just clears the surface.
WARNING!
Raising the vehicle higher than necessary can make the vehicle unstable and cause an accident. It could slip off the jack and hurt someone near it. Raise the vehicle only enough to remove the tire.
5. Remove the wheel nuts and pull the wheel off. Install the spare wheel and wheel nuts with the cone shaped end of the nuts toward the wheel on 2500/3500 single rear- wheel (SRW) models. On 3500 dual rear-wheel models (DRW) the lug nuts are a two-piece assembly with a flat
Rear Jacking Location (All)
• Connect the jack tube extension and wheel wrench. Before raising the wheel off the ground, make sure that the jack will not damage surrounding truck parts and adjust the jack position as required.
414 WHAT TO DO IN EMERGENCIES
face. Lightly tighten the nuts. To avoid risk of forcing the vehicle off the jack, do not fully tighten the nuts until the vehicle has been lowered. 6. Using the wheel wrench, finish tightening the nuts using a crisscross pattern. The correct nut tightness is 135 ft lbs (183 N·m) torque for 2500/3500 single-rear wheel (SRW) models, and 145 ft lbs (197 N·m) for 3500
dual rear-wheel models. If in doubt about the correct tightness, have them checked with a torque wrench by your authorized dealer or at a service station.WARNING!
A loose tire or jack thrown forward in a collision or hard stop could injure someone in the vehicle. Al- ways stow the jack parts and the extra tire and wheel in the places provided.
7. Install wheel center cap and remove wheel blocks. Do not install chrome or aluminum wheel center caps on the spare wheel. This may result in cap damage. 8. Lower the jack to its fully closed position. If the bottle jack will not lower by turning the dial (thumbwheel) by hand, it may be necessary to use the jack drive tube in order to lower the jack. Stow the replaced tire, jack, and tools as previously described. 9. Adjust the tire pressure when possible. NOTE: Do not oil wheel studs. For chrome wheels, do not substitute with chrome plated wheel nuts. Hub Caps/Wheel Covers The hub caps must be removed before raising the vehicle off the ground. For 2500/3500 single rear-wheel (SRW) models, use the blade on the end of the lug wrench to pry the hub cap off.
Insert the blade end into the pry-off notch and carefully pop off the hub cap with a back-and-forth motion. On 3500 models with dual rear wheels (DRW), you must first remove the hub caps. The jack handle driver has a hook at one end that will fit in the pry off notch of the rear hub caps. Position the hook and pull out on the ratchet firmly. The hub cap should pop off. The wheel skins can now be removed. For the front hub cap on 3500
models use the blade on the end of the lug wrench to pry the caps off. The wheel skin can now be removed.CAUTION!
• Use a back-and-forth motion to remove the hub cap. Do not use a twisting motion when removing the hub cap, damage to the hub cap finish may occur.
(Continued)
WHAT TO DO IN EMERGENCIES 415
CAUTION! (Continued)
• The rear hub caps on the dual rear wheel has two pry-off notches. Make sure that the hook of the jack handle driver is located squarely in the cap notch before attempting to pull off.
You must use the flat end of the lug wrench to pry off the wheel skins. Insert the flat tip completely and using a back-and-forth motion, loosen the wheel skin. Repeat this procedure around the tire until the skin pops off. Replace the wheel skins first using a rubber mallet. When replacing the hub caps, tilt the cap retainer over the lugnut bolt circle and strike the high side down with a rubber mallet. Be sure that the hub caps and wheel skins are firmly seated around the wheel.
416 WHAT TO DO IN EMERGENCIES
8-Stud — Dual Rear Wheels Dual wheels are flat-mounted and center-piloted. The lug nuts are a two-piece assembly. When the tires are being rotated or replaced, clean these lug nuts and add two drops of oil at the interface between the hex and the washer.
Oiling Location
Slots in the wheels will assist in properly orienting the inner and outer wheels. Align these slots when assem- bling the wheels for best access to the tire valve on the inner wheel. The tires of both dual wheels must be completely off the ground when tightening, to ensure wheel centering and maximum wheel clamping. Dual wheel models require a special heavy-duty lug nut tightening adapter (included with the vehicle) to cor- rectly tighten the lug nuts. Also, when it is necessary to remove and install dual rear wheels, use a proper vehicle lifting device. NOTE: When installing a spare tire as part of a dual rear wheel end combination, the tire diameter of the two individual tires must be compared. If there is a significant difference, the larger tire should be installed in a front location. The correct direction of rotation for dual tire installations must also be observed.
These dual rear wheels should be tightened as follows:
Tightening Pattern
1. Tighten the wheel nuts in the numbered sequence to a snug fit.
WHAT TO DO IN EMERGENCIES 417
2. Retighten the wheel nuts in the same sequence to the torques listed in the table. Go through the sequence a second time to verify that specific torque has been achieved. Retighten to specifications at 100 miles (160 km) and after 500 miles (800 km). It is recommended that wheel stud nuts be kept torqued to specifications at all times. Torque wheel stud nuts to specifications at each lubrication interval. Wheel Nuts All wheel nuts should be tightened occasionally to elimi- nate the possibility of wheel studs being sheared or the bolt holes in the wheels becoming elongated. This is especially important during the first few hundred miles/ kilometers of operation to allow the wheel nuts to become properly set. All nuts should first be firmly seated against the wheel. The nuts should then be tightened to recommended torque. Tighten the nuts to final torque in increments. Progress around the bolt
418 WHAT TO DO IN EMERGENCIES
circle, tightening the nut opposite to the nut just previ- ously tightened until final torque is achieved. Recom- mended torques are shown in the following chart. Disc Wheels
Type Nut Stud Size Torque Ft. Lbs.
Cone Flanged
9/16-18
9/16-18120-150
130-160To Stow The Flat Or Spare
WARNING!
A loose tire thrown forward in a collision or hard stop could injure the occupants in the vehicle. Have the deflated (flat) tire repaired or replaced immedi- ately.
Torque Newton Meters 160-200
190-220Turn the wheel so that the valve stem is down. Slide the wheel retainer through the center of the wheel and position it properly across the wheel opening. For convenience in checking the spare tire inflation, stow with the valve stem toward the rear of the vehicle. Attach the wheel wrench to the extension tube. Rotate the winch mechanism until the wheel is drawn into place against the underside of the vehicle. Continue to rotate until you feel the winch mechanism slip, or click three or four times. It cannot be overtightened. Push against the tire several times to be sure it is firmly in place.
HOISTING A conventional floor jack may be used at the jacking locations. Refer to the graphics that show jacking loca- tions. However, a floor jack or frame hoist must never be used on any other parts or the underbody.
CAUTION!
Never use a floor jack directly under the differential housing of a loaded truck or damage to your vehicle may result.
JUMP-STARTING PROCEDURES Do not attempt to push or tow your vehicle to get it started. Vehicles equipped with an automatic transmis- sion cannot be started this way. Also, there is a greater risk of an accident when a vehicle is being pushed or towed. If the vehicle has a discharged battery, booster cables may be used to obtain a start from a booster battery or the battery in another vehicle. This type of start can be dangerous if done improperly, so follow this procedure carefully.
WHAT TO DO IN EMERGENCIES 419
WARNING!
• Battery fluid is a corrosive acid solution; do not allow battery fluid to contact eyes, skin or cloth- ing. Don’t lean over battery when attaching clamps or allow the clamps to touch each other. If acid splashes in eyes or on skin, flush contami- nated area immediately with large quantities of water. • A battery generates hydrogen gas which is flam- mable and explosive. Keep flame or spark away from the vent holes. • Do not use a booster battery or any other booster source that has a greater than 12-Volt system, i.e., do not use a 24-Volt power source.
1. Remove all metal jewelry such as watch bands or bracelets which might make an unintended electrical contact.
420 WHAT TO DO IN EMERGENCIES
2. Park the booster vehicle within cable reach but with- out letting the vehicles touch. Set the parking brake on both vehicles, place the automatic transmission in PARK and turn the ignition OFF. 3. Turn off the heater, radio, and all unnecessary electri- cal loads. 4. Connect one end of a jumper cable to the positive terminal of the booster battery. Connect the other end of the same cable to the positive terminal of the discharged battery.
WARNING!
Do not permit vehicles to touch each other as this could establish a ground connection and personal injury could result.
5. Connect the other cable; first to the negative terminal of the booster battery, and then to the engine of the vehicle with the discharged battery. Make sure you have a good contact on the engine.
WARNING!
or towing.
• You should not try to start your vehicle by pushing • Do not connect the cable to the negative post of the discharge battery. The resulting electrical spark could cause the battery to explode. • During cold weather when temperatures are be- low freezing point, electrolyte in a discharged battery may freeze. Do not attempt jump-starting because the battery could rupture or explode. The battery temperature must be brought up above freezing point before attempting jump-start.
6. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery. 7. When removing the jumper cables, reverse the above sequence exactly. Be careful of the moving belts and fan.
WARNING!
the battery vent.
Any procedure other than above could result in: • Personal injury caused by electrolyte squirting out • Personal injury or property damage due to battery • Damage to charging system of booster vehicle or
explosion.
of immobilized vehicle.
WHAT TO DO IN EMERGENCIES 421
FREEING A STUCK VEHICLE If the vehicle becomes stuck in snow, sand, or mud, it can often be moved by a rocking motion. Move the shift lever rhythmically between DRIVE and REVERSE, while ap- plying slight pressure to the accelerator. In general, the least amount of accelerator pedal pressure to maintain the rocking motion without spinning the wheels or racing the engine, is most effective. Racing the engine or spinning the wheels, due to the frustration of not freeing the vehicle, may lead to transmission over- heating and failure. Allow the engine to idle with the shift lever in NEUTRAL for at least one minute after every five rocking-motion cycles. This will minimize overheating and reduce the risk of transmission failure during prolonged efforts to free a stuck vehicle.
422 WHAT TO DO IN EMERGENCIES
EMERGENCY TOW HOOKS — IF EQUIPPED Your vehicle may be equipped with emergency tow hooks. NOTE: For off-road recovery, it is recommended to use both of the front tow hooks to minimize the risk of damage to the vehicle.
WARNING!
• Chains are not recommended for freeing a stuck vehicle. Chains may break, causing serious injury or death. • Stand clear of vehicles when pulling with tow hooks. Tow straps and chains may break, causing serious injury.
CAUTION!
Tow hooks are for emergency use only to rescue a vehicle stranded off-road. Do not use tow hooks for tow truck hookup or highway towing. You could damage your vehicle.
TOWING A DISABLED VEHICLE Proper towing or lifting equipment is required to prevent damage to your vehicle. Use only tow bars and other equipment designed for the purpose, following equip- ment manufacturer’s instructions. Use of safety chains is mandatory. Attach a tow bar or other towing device to the main structural members of the vehicle, not to bumpers or associated brackets. State and local laws applying to vehicles under tow must be observed.
4-Wheel Drive Vehicles
CAUTION!
To avoid damage to the transfer case while towing, always use one of the following methods. • The transfer case must be in the neutral position, and the transmission must be in PARK to tow a 4-Wheel Drive vehicle with one end of the vehicle raised. • The manufacturer recommends towing with all wheels OFF the ground. Acceptable methods are to tow the vehicle on a flatbed or with one end of vehicle raised and the opposite end on a towing dolly.
WHAT TO DO IN EMERGENCIES 423
2–Wheel Drive Vehicles Provided that the transmission is operable, tow with the transmission in NEUTRAL and the ignition key in the OFF position along with the front wheels raised and the rear wheels on the ground. Speed must not exceed 30 mph (50 km/h) and distance must not exceed 15 miles (25 km). If the vehicle is to be towed faster than 30 mph (50 km/h) or more than 15 miles (25 km) the vehicle must be towed with the rear wheels raised and the front wheels on the ground. It may also be towed on a flatbed or with the front wheels raised and the rear wheels on a dolly.
CAUTION!
Towing faster than 30 mph (50 km/h) or for more than 15 miles (25 km) can cause severe damage to the transmission.
MAINTAINING YOUR VEHICLE
CONTENTS
䡵 Engine Compartment— 5.7L . . . . . . . . . . . . . 427
䡵 Onboard Diagnostic System (OBD II) . . . . . . 428
. . . . . . . . . . 428▫ Loose Fuel Filler Cap Message
䡵 Emissions Inspection And Maintenance
䡵 Replacement Parts 䡵 Dealer Service 䡵 Maintenance Procedures
Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
. . . . . . . . . . . . . . . . . . . . 430
. . . . . . . . . . . . . . . . . . . . . . . 430
. . . . . . . . . . . . . . . . 431
. . . . . . . . . . . . . . . . . . . . . . . . 431
. . . . . . . . . . . . . . . . . . . . 433▫ Engine Oil ▫ Engine Oil Filter
▫ Engine Air Cleaner Filter ▫ Maintenance-Free Battery ▫ Air Conditioner Maintenance ▫ Front Prop Shaft Lubrication — 2500/3500
. . . . . . . . . . . . . . 434
. . . . . . . . . . . . . 434
. . . . . . . . . . . 435(4X4) Models . . . . . . . . . . . . . . . . . . . . . . . 436
▫ Body Lubrication . . . . . . . . . . . . . . . . . . . 437
▫ Windshield Wiper Blades . . . . . . . . . . . . . 437
▫ Adding Washer Fluid . . . . . . . . . . . . . . . . 438
▫ Exhaust System . . . . . . . . . . . . . . . . . . . . 438426 MAINTAINING YOUR VEHICLE
▫ Cooling System . . . . . . . . . . . . . . . . . . . . 441
▫ Brake System . . . . . . . . . . . . . . . . . . . . . . 447
▫ Rear Axle And 4X4 Front Driving Axle FluidLevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
. . . . . . . . . . . . . . . . . . . . . . 449
. . . . . . . . . . . . . . 449▫ Transfer Case ▫ Automatic Transmission ▫ Appearance Care And Protection From
䡵 Fuses
▫ Integrated Power Module
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . 452
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
. . . . . . . . . . . . . 458
. . . . . . . . . . . . . . . . . . . . . . 463
. . . . . . . . . . . . . . . 464
. . . . . . . . . . . . . . . . . . . . 465䡵 Vehicle Storage 䡵 Replacement Light Bulbs 䡵 Bulb Replacement
▫ Headlight (Halogen)/Front Park And Turn
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
▫ Fog Lights ▫ Tail, Stop, Turn And Backup Lights ▫ Center High-Mounted Stoplight (CHMSL)
. . . . . . . . . . . . . . . . . . . . . . . . 468
. . . . . . 469With Cargo Light
. . . . . . . . . . . . . . . . . . . . 472
. . 473▫ Cab Top Clearance Lights — If Equipped ▫ Tailgate ID Lights (Dual Rear Wheels) —
If Equipped . . . . . . . . . . . . . . . . . . . . . . . . 475
▫ Rear Light Bar ID Marker
▫ Side Marker Lights (Dual Rear Wheels)
䡵 Fluids And Capacities 䡵 Fluids, Lubricants And Genuine Parts
(Dual Rear Wheel) — If Equipped . . . . . . . . 476
. . . 477
. . . . . . . . . . . . . . . . . 478
. . . . . . 479
. . . . . . . . . . . . . . . . . . . . . . . . . . . 479
. . . . . . . . . . . . . . . . . . . . . . . . . . 480▫ Engine ▫ Chassis
ENGINE COMPARTMENT— 5.7L
MAINTAINING YOUR VEHICLE 427
1 — Air Cleaner Filter 2 — Automatic Transmission Dipstick 3 — Engine Oil Fill 4 — Brake Fluid Reservoir 5 — Battery 6 — Integrated Power Module
7 — Power Steering Fluid Reservoir 8 — Engine Oil Dipstick 9 — Washer Fluid Reservoir 10 — Engine Coolant Reservoir 11 — Coolant Pressure Cap
428 MAINTAINING YOUR VEHICLE
ONBOARD DIAGNOSTIC SYSTEM (OBD II) Your vehicle is equipped with a sophisticated onboard diagnostic system called OBDII. This system monitors the performance of the emissions, engine, and automatic transmission control systems. When these systems are operating properly, your vehicle will provide excellent performance and fuel economy, as well as engine emis- sions well within current government regulations. If any of these systems require service, the OBD II system will turn on the Malfunction Indicator Light (MIL). It will also store diagnostic codes and other information to assist your service technician in making repairs. Al- though your vehicle will usually be drivable and not need towing, see your authorized dealer for service as soon as possible.
CAUTION!
• Prolonged driving with the MIL on could cause further damage to the emission control system. It could also affect fuel economy and drivability. The vehicle must be serviced before any emissions tests can be performed. • If the MIL is flashing, severe catalytic converter damage and power loss will soon occur. Immedi- ate service is required.
Loose Fuel Filler Cap Message
If the vehicle’s diagnostic system determines that the fuel filler cap in loose, improperly installed, or damaged, a GASCAP message will be displayed in the instrument cluster. Tighten the gas cap until a “clicking” sound is heard. This is an indication that the gas cap is properly tightened. Press the odometer reset button to turn the message off. If the problem persists, the message will
appear the next time the vehicle is started. This might indicate a damaged cap. If the problem is detected twice in a row, the system will turn on the MIL. Resolving the problem will turn the MIL light off.
EMISSIONS INSPECTION AND MAINTENANCE PROGRAMS In some localities, it may be a legal requirement to pass an inspection of your vehicle’s emissions control system. Failure to pass could prevent vehicle registration.
For states that require an Inspection and Mainte- nance (I/M), this check verifies the Malfunction Indicator Light (MIL) is functioning and is not on when the engine is running, and that the OBD II system is ready for testing. Normally, the OBD II system will be ready. The OBD II system may not be ready if your vehicle was recently
MAINTAINING YOUR VEHICLE 429
serviced, recently had a dead battery or a battery replace- ment. If the OBD II system should be determined not ready for the I/M test, your vehicle may fail the test. Your vehicle has a simple ignition key-actuated test, which you can use prior to going to the test station. To check if your vehicle’s OBD II system is ready, you must do the following: 1. Insert your ignition key into the ignition switch. 2. Turn the ignition to the ON position, but do not crank or start the engine. 3. If you crank or start the engine, you will have to start this test over. 4. As soon as you turn your key to the ON position, you will see the MIL symbol come on as part of a normal bulb check.
430 MAINTAINING YOUR VEHICLE
5. Approximately 15 seconds later, one of two things will happen:
a. The MIL will flash for about 10 seconds and then return to being fully illuminated until you turn OFF the ignition or start the engine. This means that your vehicle’s OBD II system is not ready and you should not proceed to the I/M station. b. The MIL will not flash at all and will remain fully illuminated until you turn OFF the ignition or start the engine. This means that your vehicle’s OBD II system is ready and you can proceed to the I/M station.
If your OBD II system is not ready, you should see your authorized dealer or repair facility. If your vehicle was recently serviced or had a battery failure or replacement, you may need to do nothing more than drive your vehicle as you normally would in order for your OBD II system to update. A recheck with the above test routine may then indicate that the system is now ready.
Regardless of whether your vehicle’s OBD II system is ready or not, if the MIL is illuminated during normal vehicle operation you should have your vehicle serviced before going to the I/M station. The I/M station can fail your vehicle because the MIL is on with the engine running.
REPLACEMENT PARTS Use of genuine MOPAR威 parts for normal/scheduled maintenance and repairs is highly recommended to en- sure the designed performance. Damage or failures caused by the use of non-MOPAR威 parts for maintenance and repairs will not be covered by the manufacturer’s warranty.
DEALER SERVICE Your authorized dealer has the qualified service person- nel, special tools and equipment to perform all service operations in an expert manner. Service Manuals are available which include detailed service information for
your vehicle. Refer to these manuals before attempting any procedure yourself. NOTE: systems can result against you.
Intentional tampering with emissions control in civil penalties being assessed
WARNING!
You can be badly injured working on or around a motor vehicle. Do only that service work for which you have the knowledge and the proper equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent mechanic.
MAINTENANCE PROCEDURES The pages that follow contain the required maintenance services determined by the engineers who designed your vehicle.
MAINTAINING YOUR VEHICLE 431
Besides the maintenance items for which there are fixed maintenance intervals, there are other items that should operate satisfactorily without periodic maintenance. However, if a malfunction of these items does occur, it could adversely affect the engine or vehicle performance. These items should be inspected if a malfunction is observed or suspected. Engine Oil
Checking Oil Level To assure proper lubrication of your vehicle’s engine, the engine oil must be maintained at the correct level. The best time to check the engine oil level is about five minutes after a fully warmed up engine is shut off or before starting the engine after it has sat overnight. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level readings. Always level within the SAFE zone on the maintain the oil
432 MAINTAINING YOUR VEHICLE
dipstick. Adding one quart of oil when the reading is at the bottom of the SAFE zone will result in a reading at the top of the safe zone on these engines.
CAUTION!
Overfilling or underfilling the crankcase will cause oil aeration or loss of oil pressure. This could damage your engine.
Change Engine Oil Refer to the “Maintenance Schedule” in Section 8 for the proper maintenance intervals. Engine Oil Selection For best performance and maximum protection under all types of operating conditions, the manufacturer only recommends engine oils that are API Certified and meet the requirements of Chrysler Material Standard MS-6395.
American Petroleum Institute (API) Engine Oil Identification Symbol
This symbol means that the oil has been certified by the American Petroleum Institute (API). The manufacturer only recommends API Certified engine oils.
Engine Oil Viscosity (SAE Grade) SAE 5W-20 engine oil is recommended for all operating temperatures. This engine oil improves low temperature starting and vehicle fuel economy. The engine oil filler cap also shows the recommended engine oil viscosity for your engine. For information on engine oil filler cap location, refer to “Engine Compartment” in this section.
NOTE: For 2500/3500 trucks with a 5.7L engine oper- ating under a gross combined weight rating of 14,000 lbs (6 350 kg) or greater, SAE 5W-30 engine oil is recom- mended for all operating temperatures. Lubricants, which do not have both the engine oil certi- fication mark and the correct SAE viscosity grade num- ber, should not be used. Synthetic Engine Oils You may use synthetic engine oils if the recommended oil quality requirements are met, and the recommended maintenance intervals for oil and filter changes are followed. Materials Added to Engine Oil Do not add any supplemental materials, other than leak detection dyes, to the engine oil. Engine oil is an engi- neered product and its performance may be impaired by supplemental additives.
MAINTAINING YOUR VEHICLE 433
Disposing of Used Engine Oil and Oil Filters Care should be taken in disposing of used engine oil and oil filters from your vehicle. Used oil and oil filters, indiscriminately discarded, can present a problem to the environment. Contact your authorized dealer, service station, or governmental agency for advice on how and where used oil and oil filters can be safely discarded in your area. Engine Oil Filter The engine oil filter should be replaced at every engine oil change. Engine Oil Filter Selection The manufacturer’s engines have a full-flow type oil filter. Use a filter of this type for replacement. The quality of replacement filters varies considerably. Only high- quality filters should be used to assure most efficient service. MOPAR威 engine oil filters are a high-quality oil filter and are recommended.
434 MAINTAINING YOUR VEHICLE
Engine Air Cleaner Filter Refer to the “Maintenance Schedule” in Section 8 for the proper maintenance intervals.
WARNING!
The air induction system (air cleaner, hoses, etc.) can provide a measure of protection in the case of engine backfire. Do not remove the air induction system (air cleaner, hoses, etc.) unless such removal is necessary for repair or maintenance. Make sure that no one is near the engine compartment before starting the vehicle with the air induction system (air cleaner, hoses, etc.) removed. Failure to do so can result in serious personal injury.
Engine Air Cleaner Filter Selection The quality of replacement engine air cleaner filters varies considerably. Only high quality filters should be
used to assure most efficient service. MOPAR威 engine air cleaner filters are a high quality filter and are recommended. Maintenance-Free Battery The top of the maintenance-free battery is permanently sealed. You will never have to add water, nor is periodic maintenance required.
WARNING!
• Battery fluid is a corrosive acid solution and can burn or even blind you. Do not allow battery fluid to contact your eyes, skin or clothing. Do not lean over a battery when attaching clamps. If acid splashes in eyes or on skin, flush the area imme- diately with large amounts of water.
(Continued)
WARNING! (Continued)
• Battery gas is flammable and explosive. Keep flame or sparks away from the battery. Do not use a booster battery or any other booster source with an output greater than 12 Volts. Do not allow cable clamps to touch each other. • Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.
MAINTAINING YOUR VEHICLE 435
CAUTION!
• It is essential when replacing the cables on the battery that the positive cable is attached to the positive post and the negative cable is attached to the negative post. Battery posts are marked (+) positive and (-) negative and are identified on the battery case. • If a “fast charger” is used while the battery is in the vehicle, disconnect both vehicle battery cables before connecting the charger to the battery. Do not use a “fast charger” to provide starting voltage.
Air Conditioner Maintenance For best possible performance, your air conditioner should be checked and serviced by an authorized dealer at the start of each warm season. This service should
436 MAINTAINING YOUR VEHICLE
include cleaning of the condenser fins and a performance test. Drive belt tension should also be checked at this time.
WARNING!
• Use only refrigerants and compressor lubricants approved by the manufacturer for your air condi- tioning system. Some unapproved refrigerants are flammable and can explode, injuring you. Other unapproved refrigerants or lubricants can cause the system to fail, requiring costly repairs. Refer to Section 3 of the Warranty Information book for further warranty information. • The air conditioning system contains refrigerant under high pressure. To avoid risk of personal injury or damage to the system, adding refrigerant or any repair requiring lines to be disconnected should be done by an experienced repairman.
NOTE: Use only manufacturer approved A/C System Sealers, Stop Leak Products, Seal Conditioners, Compres- sor Oil, or Refrigerants. Refrigerant Recovery and Recycling R-134a air conditioning refrigerant is a hydrofluoro- carbon (HFC) that is endorsed by the Environmental Protection Agency (EPA) and is an ozone-saving product. However, the manufacturer recommends that air condi- tioning service be performed by authorized dealers or other service facilities using recovery and recycling equipment. Front Prop Shaft Lubrication — 2500/3500 (4X4) Models Lubricate the front driveshaft grease fitting at each oil change. Refer to the “Maintenance Schedule” in Section 8
for the proper maintenance intervals. Use MOPAR威 Type MS-6560 (lithium-based grease), or equivalent.Body Lubrication Locks and all body pivot points, including such items as seat tracks, door hinge pivot points and rollers, liftgate, tailgate, sliding doors and hood hinges, should be lubri- cated periodically with a lithium based grease such as MOPAR威 Spray White Lube to assure quiet, easy opera- tion and to protect against rust and wear. Prior to the application of any lubricant, the parts concerned should be wiped clean to remove dust and grit; after lubricating excess oil and grease should be removed. Particular attention should also be given to hood latching compo- nents to ensure proper function. When performing other underhood services, the hood latch, release mechanism and safety catch should be cleaned and lubricated. The external lock cylinders should be lubricated twice a year, preferably in the Fall and Spring. Apply a small amount of a high quality lubricant such as MOPAR威 Lock Cylinder Lubricant directly into the lock cylinder.
MAINTAINING YOUR VEHICLE 437
Windshield Wiper Blades Clean the rubber edges of the wiper blades and the windshield periodically with a sponge or soft cloth and a mild nonabrasive cleaner. This will remove accumula- tions of salt or road film. Operation of the wipers on dry glass for long periods may cause deterioration of the wiper blades. Always use washer fluid when using the wipers to remove salt or dirt from a dry windshield. Avoid using the wiper blades to remove frost or ice from the windshield. Keep the blade rubber out of contact with petroleum products such as engine oil, gasoline, etc.
438 MAINTAINING YOUR VEHICLE
Adding Washer Fluid The fluid reservoir is located under the hood and should be checked for fluid level at regular intervals. Fill the reservoir with windshield washer solvent only (not ra- diator antifreeze). When refilling the washer fluid reser- voir, take some washer fluid and apply it to a cloth or towel and wipe clean the wiper blades, this will help blade performance. To prevent freeze-up of your windshield washer system in cold weather, select a solution or mixture that meets or exceeds the temperature range of your climate. This rating information can be found on most washer fluid containers. The washer fluid reservoir will hold a full gallon of fluid when the “Low Washer Fluid Light” illuminates.
WARNING!
Commercially available windshield washer solvents are flammable. They could ignite and burn you. Care must be exercised when filling or working around the washer solution.
After the engine has warmed, operate the defroster for a few minutes to reduce the possibility of smearing or freezing the fluid on the cold windshield. MOPAR威 All Weather Windshield Washer Solution, used with water as directed on the container, aids cleaning action, reduces the freezing point to avoid line clogging, and is not harmful to paint or trim. Exhaust System The best protection against carbon monoxide entry into the vehicle body is a properly maintained engine exhaust system.
Whenever a change is noticed in the sound of the exhaust system, when exhaust fumes can be detected inside the vehicle, or when the underside or rear of the vehicle is damaged, have a competent mechanic inspect the com- plete exhaust system and adjacent body areas for broken, damaged, deteriorated, or mispositioned parts. Open seams or loose connections could permit exhaust fumes to seep into the passenger compartment. In addition, inspect the exhaust system each time the vehicle is raised for lubrication or oil change. Replace as required.
WARNING!
Exhaust gases can injure or kill. They contain carbon monoxide (CO) which is colorless and odorless. Breathing it can make you unconscious and can eventually poison you. To avoid breathing CO, refer to “Exhaust Gas” in the “Safety Tips” section of this manual.
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The catalytic converter requires the use of unleaded fuel only. Leaded gasoline will destroy the effectiveness of the catalyst as an emission control device. Under normal operating conditions, the catalytic con- verter will not require maintenance. However, it is im- portant to keep the engine properly tuned to assure proper catalyst operation and prevent possible catalyst damage.
440 MAINTAINING YOUR VEHICLE
CAUTION!
WARNING!
Damage to the catalytic converter can result if your vehicle is not kept in proper operating condition. In the event of engine malfunction, particularly involv- ing engine misfire or other apparent loss of perfor- mance, have your vehicle serviced promptly. Contin- ued operation of your vehicle with a severe malfunction could cause the converter to overheat, resulting in possible damage to the converter and the vehicle.
NOTE: systems can result against you.
Intentional tampering with emissions control in civil penalties being assessed
A hot exhaust system can start a fire if you park over materials that can burn. Such materials might be grass or leaves coming into contact with your exhaust system. Do not park or operate your vehicle in areas where your exhaust system can contact anything that can burn.
In unusual situations involving grossly malfunctioning engine operation, a scorching odor may indicate severe and abnormal catalyst overheating. If this occurs, the vehicle should be stopped, the engine shut off and the vehicle allowed to cool. Thereafter, service, including a tune-up to manufacturer’s specifications, should be ob- tained immediately.
To minimize the possibility of catalyst damage: • Do not shut off the engine or interrupt the ignition when the transmission is in gear and the vehicle is in motion. • Do not try to start the engine by pushing or towing the • Do not idle the engine with any spark plug wires disconnected or removed, such as when diagnostic testing, or for prolonged periods during very rough idling or malfunctioning operating conditions.
vehicle.
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Cooling System
WARNING!
You or others can be badly burned by hot engine coolant (antifreeze) or steam from your radiator. If you see or hear steam coming from under the hood, do not open the hood until the radiator has had time to cool. Never try to open a cooling system pressure cap when the radiator is hot.
Engine Coolant Checks Check the engine coolant (antifreeze) protection every 12 months (before the onset of freezing weather, where applicable). If the engine coolant (antifreeze) is dirty or rusty in appearance, the system should be drained, flushed and refilled with fresh engine coolant (anti- freeze). Check the front of the A/C condenser for any
442 MAINTAINING YOUR VEHICLE
accumulation of bugs, leaves, etc. If dirty, clean by gently spraying water from a garden hose vertically down the face of the condenser. Check the coolant recovery bottle tubing for brittle rub- ber, cracking, tears, cuts and tightness of the connection at the bottle and radiator. Inspect the entire system for leaks. With the engine at normal operating temperature (but not running), check the cooling system pressure cap for proper vacuum sealing by draining a small amount of engine coolant (antifreeze) from the radiator drain cock. If the cap is sealing properly, the engine coolant (anti- freeze) will begin to drain from the coolant recovery bottle. DO NOT REMOVE THE COOLANT PRESSURE CAP WHEN THE COOLING SYSTEM IS HOT.
Cooling System — Drain, Flush and Refill If the engine coolant (antifreeze) is dirty or contains a considerable amount of sediment, clean and flush with a reliable cooling system cleaner. Follow with a thorough rinsing to remove all deposits and chemicals. Properly dispose of the old engine coolant (antifreeze) solution. Refer to the “Maintenance Schedule” in Section 8 for the proper maintenance intervals. Selection Of Coolant Use only the manufacturer’s recommended engine cool- ant (antifreeze). Refer to “Fluids, Lubricants, and Genu- ine Parts” in this section for the correct fluid type.
CAUTION!
• Mixing of engine coolant (antifreeze) other than specified HOAT engine coolant (antifreeze), may result in engine damage and may decrease corro- sion protection. If a non-HOAT engine coolant (antifreeze) is introduced into the cooling system in an emergency, it should be replaced with the specified engine coolant (antifreeze) as soon as possible. • Do not use water alone or alcohol-based engine coolant (antifreeze) products. Do not use addi- tional rust inhibitors or antirust products, as they may not be compatible with the radiator engine coolant (antifreeze) and may plug the radiator.
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MAINTAINING YOUR VEHICLE 443
CAUTION! (Continued)
• This vehicle has not been designed for use with Propylene Glycol based engine coolant (anti- freeze). Use of Propylene Glycol based engine coolant (antifreeze) is not recommended.
Adding Coolant Your vehicle has been built with an improved engine coolant (antifreeze) that allows extended maintenance intervals. This engine coolant (antifreeze) can be used up to 5 Years or 102,000 miles (170 000 km) before replace- ment. To prevent reducing this extended maintenance period, it is important that you use the same engine coolant (antifreeze) throughout the life of your vehicle. Please review these recommendations for using Hybrid Organic Additive Technology (HOAT) engine coolant (antifreeze).
444 MAINTAINING YOUR VEHICLE
When adding engine coolant (antifreeze): • The manufacturer
recommends using MOPAR威 Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology). • Mix a minimum solution of 50% HOAT engine coolant (antifreeze) and distilled water. Use higher concentra- tions (not to exceed 70%) if temperatures below -34°F (-37°C) are anticipated. • Use only high purity water such as distilled or deion- ized water when mixing the water/engine coolant (antifreeze) solution. The use of lower quality water will reduce the amount of corrosion protection in the engine cooling system.
Please note that it is the owner’s responsibility to main- tain the proper level of protection against freezing ac- cording to the temperatures occurring in the area where the vehicle is operated.
NOTE: Mixing engine coolant (antifreeze) types will decrease the life of the engine coolant (antifreeze) and will require more frequent engine coolant (antifreeze) changes. Cooling System Pressure Cap The cap must be fully tightened to prevent loss of engine coolant (antifreeze), and to ensure that engine coolant (antifreeze) will return to the radiator from the coolant recovery bottle. The cap should be inspected and cleaned if there is any accumulation of foreign material on the sealing surfaces.
WARNING!
• The warning words “DO NOT OPEN HOT” on the cooling system pressure cap are a safety pre- caution. Never add engine coolant (antifreeze) when the engine is overheated. Do not loosen or remove the cap to cool an overheated engine. Heat causes pressure to build up in the cooling system. To prevent scalding or injury, do not remove the pressure cap while the system is hot or under pressure. • Do not use a pressure cap other than the one specified for your vehicle. Personal injury or en- gine damage may result.
Disposal of Used Engine Coolant Used ethylene glycol-based engine coolant (antifreeze) is a regulated substance requiring proper disposal. Check with your local authorities to determine the disposal
MAINTAINING YOUR VEHICLE 445
rules for your community. To prevent ingestion by ani- mals or children do not store ethylene glycol-based engine coolant (antifreeze) in open containers or allow it to remain in puddles on the ground. If ingested by a child, contact a physician immediately. Clean up any ground spills immediately. Coolant Level The coolant bottle provides a quick visual method for determining that the engine coolant (antifreeze) level is adequate. With the engine cold, the level of the engine coolant (antifreeze) in the coolant recovery bottle should be between the ranges indicated on the bottle. The radiator normally remains completely full, so there is no need to remove the radiator cap unless checking for engine coolant (antifreeze) freeze point or replacing en- gine coolant (antifreeze). Advise your service attendant of this. As long as the engine operating temperature is satisfactory, the coolant bottle only needs to be checked once a month.
446 MAINTAINING YOUR VEHICLE
When additional engine coolant (antifreeze) is needed to maintain the proper level, it should be added to the coolant bottle. Do not overfill. Points To Remember NOTE: When the vehicle is stopped after a few miles (a few kilometers) of operation, you may observe vapor coming from the front of the engine compartment. This is normally a result of moisture from rain, snow, or high humidity accumulating on the radiator and being vapor- ized when the thermostat opens, allowing hot engine coolant (antifreeze) to enter the radiator. If an examination of your engine compartment shows no evidence of radiator or hose leaks, the vehicle may be safely driven. The vapor will soon dissipate. • Do not overfill the coolant recovery bottle. • Check the engine coolant (antifreeze) freeze point in the radiator and in the coolant recovery bottle. If
engine coolant (antifreeze) needs to be added, the contents of the coolant recovery bottle must also be protected against freezing. • If frequent engine coolant (antifreeze) additions are required, or if the level in the coolant recovery bottle does not drop when the engine cools, the cooling system should be pressure tested for leaks. • Maintain engine coolant (antifreeze) concentration at 50% HOAT engine coolant (antifreeze) (minimum) and distilled water for proper corrosion protection of your engine, which contains aluminum components. • Make sure that the radiator and coolant recovery bottle overflow hoses are not kinked or obstructed. • Keep the front of the radiator clean. If your vehicle is equipped with air conditioning, keep the front of the condenser clean.
• Do not change the thermostat for Summer or Winter operation. If replacement is ever necessary, install ONLY the correct type thermostat. Other designs may result in unsatisfactory coolant performance, poor gas mileage, and increased emissions.
Brake System
Master Cylinder — Brake Fluid Level Check The fluid level of the master cylinder should be checked when performing under the hood service, or immedi- ately if the brake system warning lamp indicates system failure. The brake master cylinder has a translucent plastic reservoir. On the outboard side of the reservoir, there is a “FULL” mark and an “ADD” mark. The fluid level must be kept within these two marks. Do not add fluid above the “FULL” mark, because leakage may occur at the cap.
MAINTAINING YOUR VEHICLE 447
With disc brakes the fluid level can be expected to fall as the brake linings wear. However, an unexpected drop in fluid level may be caused by a leak and a system check should be conducted. Refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct fluid type.
WARNING!
• Use of a brake fluid that may have a lower initial boiling point, or is unidentified as to specification, may result in sudden brake failure during hard prolonged braking. You could have an accident. • Overfilling the brake fluid reservoir can result in spilling brake fluid on hot engine parts and the brake fluid catching fire.
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448 MAINTAINING YOUR VEHICLE
WARNING! (Continued)
• Use only brake fluid that has been in a tightly- closed container to avoid contamination from for- eign matter or moisture.
CAUTION!
Do not allow a petroleum-base fluid to contaminate the brake fluid. Seal damage may result.
Rear Axle And 4x4 Front Driving Axle Fluid Level For normal service, periodic fluid level checks are not required. When the vehicle is serviced for other reasons the exterior surfaces of the axle assembly should be inspected. If gear oil leakage is suspected inspect the fluid level. Refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct fluid type.
This inspection should be made with the vehicle in a level position. The fluid level should be even with the bottom of the fill hole for the manufacturer’s C205F HD front axles. The fluid level should be 5/8 in (16 mm) below the fill hole on 9 1/4 in manufacturer’s rear axles. For all 2500/3500 Model axles, the fluid level should be 1/4” ± 1/4 in (6.4 mm ± 6.4 mm) below the fill hole on the 9.25 in front and 3/4 in ± 1/4 in (19 mm ± 6.4 mm) on 10.5 in rear axles. The 11.5 in rear axle level should be 1/4 in ± 1/4 in (6.4 mm ± 6.4 mm) below the fill hole. Drain and Refill Refer to the “Maintenance Schedule” in Section 8 for the proper maintenance intervals. Lubricant Selection Refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct fluid type.
MAINTAINING YOUR VEHICLE 449
NOTE: The presence of water in the gear lubricant will result in corrosion and possible failure of differential components. Operation of the vehicle in water, as may be encountered in some off-highway types of service, will require draining and refilling the axle to avoid damage. 2500/3500 Model Axles DO NOT REQUIRE any limited slip oil additive (friction modifiers). Transfer Case
Drain And Refill Refer to the “Maintenance Schedule” in Section 8 for the proper maintenance intervals. Lubricant Selection Refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct fluid type.
Fluid Level Check This fluid level can be checked by removing the filler plug. The fluid level should be to the bottom edge of the filler plug hole with the vehicle in a level position. Automatic Transmission
Selection Of Lubricant It is important that the proper lubricant is used in the transmission to assure optimum transmission perfor- mance. Use only the manufacturer’s recommended trans- mission fluid. Refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct fluid type. It is important that the transmission fluid be maintained at the prescribed level using the recommended fluid. No chemical flushes should be used in any transmission; only the approved lubricant may be used.
450 MAINTAINING YOUR VEHICLE
CAUTION!
Using a transmission fluid other than the manufac- turer’s recommended fluid may cause deterioration in transmission shift quality and/or torque converter shudder. Using a transmission fluid other than the manufacturer’s recommended fluid will result in more frequent fluid and filter changes. Refer to “Fluids, Lubricants, and Genuine Parts” in this sec- tion for correct fluid type.
Fluid Level Check If your vehicle is equipped with a dipstick, use the following procedure. If your vehicle has a capped dip- stick tube, it is sealed and should not be tampered with. Your authorized dealer has the proper tools to ensure that the fluid level is set properly. The fluid level should be checked when the engine is fully warmed up and the
fluid in the transmission is at normal operating tempera- ture. Operation of the transmission with an improper fluid level will greatly reduce the life of the transmission and of the fluid. Check the fluid level whenever the vehicle is serviced. Fluid Level Check – 545RFE Check the fluid level while the transmission is at normal operating temperature 82°C (180°F). This occurs after at least 15 miles (25 km) of driving. At normal operating temperature the fluid cannot be held comfortably be- tween the fingertips.
