2004 Dodge RAM Diesel Owners Manual

system. † To avoid burns, remember that the engine components † Do not use gasoline or other flammable materials to clean parts. Always use approved cleaning solvents. † Relieve all pressure in the fuel, oil and cooling systems before any lines, fittings or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes

will stay hot after the engine is shut off.

pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.

WARNING!

Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. † Important: All maintenance other than that listed in this manual, as well as some procedures listed here, MUST be performed by your local Dodge Truck Dealer. Your authorized Dodge Dealer has been trained and has the necessary parts to maintain your engine.

MAINTENANCE PROCEDURES The pages that follow contain the required maintenance services determined by the engineers who designed your vehicle. 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.

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Engine Oil

Checking Oil Level To assure proper lubrication of your vehicle’s engine, the engine oil must be maintained at the correct level. Check the oil level at regular intervals. The best time to check the oil level is before starting the engine after it has been parked overnight. When checking oil after operating the engine, first ensure the engine is at full operating tem- perature, then wait at least 15 minutes after engine shutdown to check the oil.

326 MAINTAINING YOUR VEHICLE

Checking the vehicle while it’s on level ground will also improve the accuracy of the oil level readings. Add oil only when the level on the dipstick is below the “ADD” mark. The total capacity from the low mark to the high mark is 2 quarts (1.9 liters).

Never operate the engine with oil level below the “ADD” mark or above the upper “SAFE” mark.

Change Engine Oil

CAUTION!

Overfilling or underfilling the crankcase will cause oil aeration or loss of oil pressure. This could dam- age your engine.

Road conditions as well as your kind of driving affect the interval at which your oil should be changed. Check the following to determine if any apply to you: † Frequent short trips where the engine does not achieve full operating temperature (operating temperature de- fined as 190° F (66° C ) coolant temperature). † Extensive engine idling (over 10 minutes per hour of operation) at ambient temperatures less than 32° F (0° C).

† Driving in dusty conditions. † Frequent trailer towing. † Taxi, police, or delivery service (commercial service). † Off-road or desert operation. † Extensive operation at high engine speeds (greater than 2900 rpm) and loads (greater than 70% throttle). If ANY of these apply to you, then change your engine oil at every interval shown in schedule 9B9 of the 9Mainte- nance Schedules9 section of this manual. If none of these apply to you, then change your engine oil at every interval shown on schedule 9A9 of the 9Mainte- nance Schedules9 section of this manual. NOTE: Most vehicles are operated under the conditions listed for Schedule 9B.9

Engine Oil Selection

1. Engine Oil Quality

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Use only oils conforming to API Service CI-4. A sulfated ash limit is specified for lubrication oil used in Cummins engines. Oils with a high ash content may produce de- posits on valves that can progress to guttering and valve burning. A maximum sulfated ash content of 1.85 mass % is recommended for all oil used in the engine.

2. Engine Oil Viscosity (SAE Grade) The proper SAE viscosity of engine oil for the expected ambient temperature range should be selected, as indi- cated in the following chart:

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NOTE: The same oil change interval is to be followed for synthetic oil as for petroleum based oil. Also, syn- thetic oil must meet the same performance specifications as petroleum oil.

Engine Oil Filter Refer to Recommended Fluids, Lubricants and Genuine Parts for the correct part number. The engine oil filter should be changed at every engine oil change. Engine Oil And Filter — Change

WARNING!

Hot oil can cause personal injury.

Operate the engine until the coolant temperature reaches 140°F (60°C). Shut the engine off. Remove the oil drain plug. Use a container that can hold at least 12 quarts (11.3
Liters) to hold the used oil.

Always check the condition of the used oil. This can give you an indication of some engine problems that might exist. † Thin, black oil indicates fuel dilution. † Milky discoloration indicates coolant dilution. Clean the area around the oil filter base. Remove the filter from the underside of the vehicle using a cap style oil filter wrench. Clean the gasket surface of the filter mount. The filter gasket can stick on the filter mount. Make sure it is removed. Change the engine oil filter with every engine oil change. Only a high quality MOPAR filter should be used to assure most efficient service.

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CAUTION!

The filtering medium of other aftermarket filters may disintegrate. Debris from failed filters may plug the piston oil cooling nozzles, resulting in scuffed pistons and engine failure.

CAUTION!

Fill the oil filter element with clean oil before installation. Use the same type oil that will be used in the engine. When filling the oil filter, prevent foreign material from falling into the filter. Severe engine damage may occur.

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Apply a light film of lubricating oil to the sealing surface of the filter gasket before installing the filter.

CAUTION!

Overtightening may distort the threads or damage the filter element seal.

Install the filter as specified by the filter manufacturer. Turn the filter 3/4 to one full turn after making contact with the gasket. Check the condition of the threads and sealing surface on the oil pan and drain plug. Install the drain plug and sealing washer and tighten to 37 ft-lbs. (50 N·m).

Use only high-quality multi-grade lubricating oil in your Cummins Diesel Engine. Choose the correct oil for your operating conditions as outlined in the Selection of Engine Oil. Cummins Turbo Diesel Fill the engine with the correct grade of new oil. The engine capacity is 11 quarts (10.4 liters) in the crankcase and 1 quart (.95 liter) in the lubricating oil filter. Start the engine and operate it at idle for several minutes. Check for leaks at the lubricating oil filter and oil pan drain plug. Stop the engine. Wait approximately 15 minutes to let the oil in the upper parts of the engine drain back to the pan. Check the oil level again. Add oil as necessary to bring the level to the “SAFE” mark on the dipstick.

Disposing Of Used Engine Oil And Filter Care should be taken in disposing of the used engine fluids from your vehicle. Used fluids, indiscriminately discarded, can present a problem to the environment. Contact your local dealer, service station, or governmen- tal agency for advice on recycling programs and where used fluids and filters can be safely discarded in your area. Drive Belt

Inspection Check the belt for intersecting cracks. † Transverse (across the belt width) cracks are accept- † Longitudinal (direction of belt length) cracks that intersect with transverse cracks are NOT acceptable.

able.

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Replace the belt if it has unacceptable cracks, is frayed or has pieces of material missing. The engine speed sensor, located near the damper, should be inspected for damage if a belt is frayed. Engine Air Cleaner Filter

CAUTION!

All air entering the engine intake must be filtered. The abrasive particles in unfiltered air will cause rapid wear to engine components.

The air filter housing on your Diesel Ram is equipped with a Filter Minder™. This is an air flow restriction gauge that will indicate when the filter element needs to be replaced.

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Do not remove the top of the air filter housing to inspect the filter element on your diesel engine under normal operating conditions.

The clear plastic housing on the Filter Minder™ allows you to view the amount of air pressure drop across the filter element. It consists of a diaphragm and a calibrated spring sealed inside the plastic housing. As the air

cleaner filter becomes clogged and air pressure drop across the filter element increases, a yellow disc travels along a graduated scale on the side of the Filter Minder™. The yellow disc will always show the greatest restriction experienced by the filter element. When the disc reaches the red zone, the filter element may need to be replaced. There is no other time or mileage interval for changing the air cleaner filter element. If the vehicle experiences a sudden loss of engine power when being driven in heavy snow or rain or when plowing snow, check the Filter Minder™ † If the Filter Minder™ is showing a plugged filter, the filter should be visually inspected for snow/ice build up or extreme water saturation. † If any of these conditions exist, the filter element

should be replaced.

A visual inspection of the air cleaner filter element is never recommended under normal circumstances. A badly restricted element may appear clean while a soiled element may be quite effective in filtering particles without restricting air flow. Rely on the Filter Minder™ to determine when a filter change is necessary. After a new filter element is inserted, press the rubber button on the top of the Filter Minder™. This action will reset the yellow disc to the clean position.

MAINTAINING YOUR VEHICLE 333

CAUTION!

When using an engine cleaner or a degreaser, be sure to wrap and tape the Filter Minder™ to protect the plastic housing from damage and discoloration.

NOTE: Many aftermarket performance air filter ele- ments do not adequately filter the air entering the engine. Use of such filters can severely damage your engine and such damage is not covered by the manufacturer’s war- ranty.

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Draining Fuel/Water Separator Filter

CAUTION!

Do not drain the fuel/water separator filter when the engine is running.

Drain a small amount from the fuel/water separator filter periodically or when the WATER IN FUEL indicator lamp is on. Pull outward on the drain valve lever, located on the side of the filter, and allow any accumulated water to drain. Hold the drain valve open until all water and contaminants have been removed. Close the drain release valve, by returning it to the inward position, when clean fuel is visible. NOTE: The Fuel / Water separator drain valve is identified by its yellow handle and is located on the inboard side of the fuel filter housing. If more than a couple ounces of fuel has been drained, follow the directions below for “Priming if the engine has run out of fuel.”

WARNING!

4. Repeat the procedure if the engine does not start.

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Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death.

Priming if the engine has run out of fuel 1. Add a substantial quantity of fuel to the tank 5 to 10
gallons (19L to 38L). 2. Crank the engine for 1 to 2 seconds. If the engine does not start, then release the key or starter button back to the RUN position (do not turn the key back to the OFF position). The electric fuel transfer pump will continue to run and purge air from the system for about 25 seconds. After 25 seconds, attempt to start the engine again. 3. Start the engine using the Normal Starting Procedure.

CAUTION!

Do not engage the starter motor for more than 15
seconds at a time. Allow two minutes between the cranking intervals.

NOTE: The engine may run rough until the air is forced from all the fuel lines.

CAUTION!

Diesel fuel will damage black top paving surfaces. Drain the filter into an appropriate container.

In addition, commercially available fuel addi- NOTE: tives are not necessary for the proper operation of your Cummins Diesel equipped Dodge Ram Truck. Maintenance Free Batteries The top of the maintenance free batteries are perma- nently sealed. You will never have to add water, nor is periodic maintenance required.

336 MAINTAINING YOUR VEHICLE

WARNING!

Do not use alcohol or gasoline as a fuel blending agent. They can be unstable under certain conditions and be hazardous or explosive when mixed with diesel fuel.

NOTE: Due to lack of lubricants in alcohol or gasoline, the use of these fuels can cause damage to the fuel system. Hence, use of these fuels will void the warranty on the engine. NOTE: As sufficient testing as not been completed, organically blended diesel fuels (e.g. biodiesel, ethanol, and methanol blends) are not recommended or approved for use with your Cummins Diesel equipped Dodge Ram Truck.

To determine the battery charge, check the battery test indicator (if equipped) on top of each battery. If the test indicator (if equipped) appears light or yellow, replace the battery. NOTE: Replacement batteries should both be of equal capacity to prevent damage to the vehicle’s charging system.

MAINTAINING YOUR VEHICLE 337

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 identified on the battery case. Also, if a “fast charger” is used while battery is in vehicle, disconnect both vehicle battery cables be- fore connecting the charger to battery. Do not use a “fast charger” to provide starting voltage.

WARNING!

Battery posts, terminals, and related accessories con- tain lead and lead compounds. Always wash hands after handling the battery.

338 MAINTAINING YOUR VEHICLE

Battery Blanket Usage A battery loses 60% of its cranking power as the battery temperature decreases to 0°F (-18°). For the same de- crease in temperature, the engine requires twice as much power to crank at the same RPM. The use of 120 VAC powered battery blankets will greatly increase starting capability at low temperatures. Suitable battery blankets are available from your authorized Mopart dealer. 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 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. † 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.

Refrigerant Recovery and Recycling R-134a Air Conditioning Refrigerant is a hydrofluorocar- bon (HFC) that is endorsed by the Environmental Pro- tection Agency and is an ozone-saving product. How- ever, the manufacturer recommends that air conditioning service be performed by dealers or other service facilities using recovery and recycling equipment. NOTE: Air Conditioning systems found to be contami- nated with A/C System Sealers, Stop Leak Products, Seal Conditioners, Compressor Oil, or Refrigerants not ap- proved by the manufacturer, voids the warranty for the Air Conditioning system. Power Steering — Fluid Check Checking the power steering fluid level at a defined service interval is not required. The fluid should only be checked if a leak is suspected, abnormal noises are

MAINTAINING YOUR VEHICLE 339

apparent, and/or the system is not functioning as antici- pated. Coordinate inspection efforts through a certified DaimlerChrysler Dealership.9

WARNING!

Fluid level should be checked on a level surface and with the engine off to prevent injury from moving parts and to insure accurate fluid level reading. Do not overfill. Use only manufacturers recommended power steering fluid.

If necessary, add fluid to restore to the proper indicated level. With a clean cloth, wipe any spilled fluid from all surfaces. Refer to Recommended Fluids, Lubricants, and Genuine Parts for correct fluid type.

340 MAINTAINING YOUR VEHICLE

Front Suspension Ball Joints The ball joints originally supplied with the vehicle are permanently lubricated at the factory and do not require service. The ball joints and seals should be inspected whenever the vehicle is serviced for other reasons. Steering Linkage — Inspection Whenever the vehicle is hoisted, all steering linkage joints should be inspected for evidence of damage. If seals are damaged, parts should be replaced to prevent leakage or contamination of the grease. Front Axle Universal Drive Joints And Pivot Bearings The front axle universal joint and pivot bearings are permanently lubricated and do not require servicing.

Body Lubrication Locks and all body pivot points, including such items as seat tracks, doors,liftgate and hood hinges, should be lubricated periodically to assure quiet, easy operation and to protect against rust and wear. Prior to the appli- cation 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 insure 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 Mopart Lock Cylinder Lubricant directly into the lock cylinder.

Windshield Wiper Blades The rubber edges of the wiper blades and the windshield should be cleaned periodically with a sponge or soft cloth and a mild nonabrasive cleaner. This will remove accu- mulations 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. Windshield Washers 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).

MAINTAINING YOUR VEHICLE 341

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.

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 All Weather Windshield Washer Solution, used with water as

342 MAINTAINING YOUR VEHICLE

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, fol- low the preceding safety tips.

Exhaust System Rubber Isolator and Loop-Type Hanger — If Equipped Inspect surfaces whenever the vehicle is hoisted for rubber to metal separation or deep cracks. If, however, excessively deep localized cracks are present, or any part of the exhaust system abnormally contacts the under- body hardware, the isolator and/or hanger should be replaced.

Cooling System

Cooling System Maintenance At the intervals shown in the Maintenance Schedules Section of the manual, the system should be drained, flushed and filled. Inspection Coolant protection checks should be made every 12
months (prior to the onset of freezing weather, where applicable). If coolant is dirty or rusty in appearance, the system should be drained, flushed and refilled with fresh coolant as specified. Inspect the entire cooling system for leaks. Check the face of the radiator for any accumulation of bugs, leaves, or other foreign matter. If dirty, clean the radiator core with a garden hose. With the engine OFF, gently spray water from the back of the radiator core. Check coolant bottle tube for condition and tightness of connections at coolant bottle and radiator.

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Check the coolant pressure cap and coolant bottle for proper vacuum sealing. With the engine at normal oper- ating temperature, note the level of the coolant in the coolant bottle. Without removing the pressure cap (with the engine off), drain a small amount of coolant from the radiator drain cock. If the coolant level in the coolant bottle drops, the system is sealing properly. Extremely cold ambient temperature may require the addition of a “winter front” for effective operation of the cab heating/cooling system. Make certain that a percent- age of the radiator is exposed for adequate air flow through the charge air cooler and automatic transmission oil cooler. The percentage of opening must be increased with the increasing ambient air temperature and/or engine load. If the cooling fan can be heard cycling frequently, increase the size of the opening in the winter front.

344 MAINTAINING YOUR VEHICLE

Coolant bottle level check The coolant reserve system provides a quick visual method of determining that the coolant level is adequate. With the engine idling, and warmed to the normal operating temperature, the level of the coolant on the coolant bottle should be between the fluid level marks. Check the coolant level whenever the hood is raised. The radiator normally remains completely full, so there is no longer a need to remove the coolant pressure cap except for checking coolant freeze point or replacement with new antifreeze coolant.

WARNING!

Never add coolant to the radiator when the engine is overheated. Do not loosen or remove pressure cap to cool overheated engine! The coolant is under pres- sure and severe scalding could result.

Drain, Flush And Refill At intervals shown on the Maintenance Schedules, the system should be drained, flushed and refilled. Refer to your dealer or consult a service manual for proper procedures. Adding Coolant When adding coolant or refilling system, a 50% solution of ethylene glycol antifreeze coolant in water should be used. Higher concentrations (not to exceed 65%) are required if temperatures below -34 °F (-37 °C) are antici- pated. Use only high purity water such as distilled or deionized water when mixing the water/antifreeze solu- tion. 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 maintain the proper level of protection against freezing according to the temperatures occurring in the area where the vehicle is operated.

NOTE: Mixing coolant types will decrease the life of the engine coolant and will require more frequent coolant changes. When additional coolant is needed to maintain the proper level, add the recommended concentration of antifreeze and water to the overflow bottle. Do not overfill. NOTE: Failure to follow the antifreeze concentration and replacement recommendations, or failure to use antifreeze formulated to prevent corrosion of all cooling system metals, may result in radiator plugging, overheat- ing, or cooling system leaks such as in core hole plugs.

MAINTAINING YOUR VEHICLE 345

WARNING!

Never add coolant to the radiator when the engine is overheated. Do not loosen or remove pressure cap to cool an overheated engine. The coolant is under pressure and severe scalding could result.

Recommended Engine Coolant Refer to Recommended Fluids, Lubricants and Genuine Parts for the correct Fluid type.

346 MAINTAINING YOUR VEHICLE

CAUTION!

Mixing of coolants other than specified (HOAT), may result in engine damage that may not be cov- ered under the new vehicle warranty, and decreased corrosion protection. If a non-HOAT coolant is intro- duced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible. Do not use plain water alone or alcohol base anti- freeze products. Do not use additional rust inhibi- tors or antirust products, as they may not be compat- ible with the radiator coolant and may plug the radiator. This vehicle has not been designed for use with Propylene Glycol based coolants. Use of Propylene Glycol based coolants is not recommended.

Disposal Of Used Engine Coolant Used ethylene glycol based engine coolant is a regulated substance requiring proper disposal. Check with your local authorities to determine the disposal rules for your community. Do not store ethylene glycol-based engine coolant in open containers or allow it to remain in puddles on the ground. Prevent ingestion by animals and children. If ingested by a child, contact a physician immediately. Clean up any ground spills immediately. Coolant Pressure Cap The coolant pressure cap must be fully tightened to prevent loss of coolant and to insure that coolant will return to the radiator from the coolant reserve tank.

WARNING!

Fan

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Never add coolant when the engine is overheated. Do not loosen or remove the pressure cap to cool an overheated engine. Heat causes pressure 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.

CAUTION!

Recheck the cooling system to insure total system is full of coolant.

Inspection Check the fan for cracks and bent or broken blades. If any of these conditions exist, you must replace the fan. Make sure it is securely mounted. NOTE: This service procedure must be performed by a trained service technician. Make arrangements with your authorized Dodge Truck Dealer for this inspection. Charge Air Cooler (Inter-Cooler) The charge air cooler is positioned between the radiator and the air conditioner condenser. Air enters the engine through the air cleaner and passes through the turbo- charger where it is pressurized. This pressurized air rapidly reaches high temperature. The air is then directed through a hose to the charge air cooler and through another hose to the intake manifold of the engine. The air entering the engine has been cooled by about 50 to 100

348 MAINTAINING YOUR VEHICLE

degrees Fahrenheit. This cooling process enables more efficient burning of fuel resulting in fewer emissions. To guarantee optimum performance of the system, keep the surfaces of the charge air cooler, condenser and radiator clean and free of debris. Periodically check the hoses leading to and from the charge air cooler for cracks or loose clamps resulting in loss of pressure and reduced engine performance. Hoses And Vacuum/Vapor Harnesses Inspect surfaces of hoses and nylon tubing for evidence of heat and mechanical damage. Hard or soft spots, brittle rubber, cracking, tears, cuts, abrasions, and exces- sive swelling indicate deterioration of the rubber. Pay particular attention to those hoses nearest to high heat sources such as the exhaust manifold. Inspect hose routing to be sure hoses do not come in contact with any heat source or moving component which may cause heat damage or mechanical wear.

Insure nylon tubing in these areas has not melted or collapsed. Inspect all hose connections such as clamps and cou- plings to make sure they are secure and no leaks are present. Components should be replaced immediately if there is any evidence of wear or damage that could cause failure. Brake System

Power Disc Brakes (Front and Rear) Disc brakes do not require adjustment; however, several hard stops during the break-in period are recommended to seat the linings and wear off any foreign material. Brake Master Cylinder 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.

MAINTAINING YOUR VEHICLE 349

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 Recommended Fluids, Lubricants and Genuine Parts for the correct Fluid type.

WARNING!

Use of a brake fluid that may have a lower initial boiling point, or unidentified as to specification, may result in sudden brake failure during hard prolonged braking. You could have an accident.

The brake master cylinder has a translucent plastic reservoir. On the outboard side of the reservoir, there is a “FULL” dot and an “ADD” dot. The fluid level must be kept within these two dots. Do not add fluid above the full mark because leakage may occur at the cap.

350 MAINTAINING YOUR VEHICLE

WARNING!

Overfilling the brake fluid reservoir can result in spilling brake fluid on hot engine parts and the brake fluid catching fire.

Use only brake fluid that has been in a tightly closed container to avoid contamination from foreign matter or moisture.

CAUTION!

Do not allow a petroleum-base fluid to contaminate the brake fluid. Seal damage and loss of brake performance may result.

Brake Hoses Inspection should be performed whenever the brake system is serviced or at intervals specified. Inspect hy- draulic brake hoses for surface cracking, scuffing or worn spots. If there is any evidence of cracking, scuffing, or worn spots, the hose should be replaced immediately! Eventual deterioration of the hose can take place with possible burst failure. Clutch Linkage If the clutch pedal linkage begins to squeak or grunt, the clutch pedal pivot bushings should be lubricated. Refer to Recommended Fluids, Lubricants and Genuine Parts for the correct type. Multipurpose Grease, NLGI Grade 2 E.P.

lubricant

Clutch Hydraulic System The clutch hydraulic system is a sealed maintenance-free system. In the event of leakage or other malfunction, the system must be replaced. Propeller Shaft Universal Joints Cross Type (No fittings) — Relubrication of this type of universal joint is not required. The seals should be inspected for external leaks or damage. If external leaks or damage is evident, the universal joint should be replaced. Rear Axle And 4x4 Front Driving Axle Fluid Level For Model 9.25 Front Axles and 10.5”/11.5” Rear Axles refer to Recommended Fluids, Lubricants and Genuine Parts for the correct lubricant type. 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.

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When checking the fluid level, the vehicle should be in a level position. The fluid level should be 1/4” ± 1/4” (6.4
mm ± 6.4 mm) below the fill hole on the 9.25” Front Axle. The fluid level should be 3/4” ± 1/4” (19 mm ± 6.4 mm) below the fill hole on all 10.5” and 1/4” ± 1/4” (6.4 mm ± 6.4 mm) on 11.5” Rear Axles. Drain And Refill Vehicles operated in normal service do not have regularly scheduled oil changes. If fluid has become contaminated with water or subjected to severe service, follow the recommended change intervals in Maintenance Schedule “B” in Section 8 of this manual. Lubricant Selection Refer to Recommended Fluids, Lubricants and Genuine Parts for the correct lubricant type. 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

352 MAINTAINING YOUR VEHICLE

encountered in some off-highway types of service, will require draining and refilling the axle to avoid damage. Limited-Slip Differentials in vehicles equipped with 10.5”/11.5” Axles DO NOT REQUIRE any limited slip oil additive (friction modifiers). Transfer Case — If Equipped

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. Lubricant Selection Refer to Recommended Fluids, Lubricants and Genuine Parts for the correct lubricant type.

Manual Transmission — If Equipped

Fluid Level Check This fluid level can be checked by removing the filler plug. If the level of the lubricant is more than 1/4” below the bottom of the filler hole while the vehicle is on level ground, enough lubricant should be added to bring the level to the bottom of the filler hole. Lubricant Selection for NV-4500 (5-Speed Manual Transmission) — If Equipped This transmission does not require periodic changing. If it becomes necessary to add fluid or change the fluid, be sure to use the same lubricant or equivalent. Refer to Recommended Fluids, Lubricants and Genuine Parts for the correct lubricant type.

Lubricant Selection for NV-5600 (6-Speed Manual Transmission) — If Equipped This transmission does not require periodic changing. If it becomes necessary to add fluid or change the fluid, be sure to use the same lubricant or equivalent. Refer to Recommended Fluids, Lubricants and Genuine Parts for the correct lubricant type. Automatic Transmission

Fluid Level Check The fluid level should be checked when the engine is fully warmed up and the fluid in the transmission is at normal operating temperature. Operation of the trans- mission 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.

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Procedure For Checking Fluid Level To properly check the automatic transmission fluid level, the following procedure must be used: 1. The vehicle must be on level ground. 2. The engine should be running at curb idle speed for a minimum of 60 seconds. 3. Fully apply parking brake. 4. Place the gear selector briefly in each gear position ending with the lever in N (Neutral). 5. Remove the dipstick and determine if the fluid is hot or warm. Hot fluid is approximately 180°F (82°C) which is the normal operating temperature after the vehicle has been driven at least 15 miles. The fluid can not be comfortably held between the finger tips. Warm is when fluid is between 85° - 125°F (29° - 52°C).

354 MAINTAINING YOUR VEHICLE

6. Wipe the dipstick clean and reinsert until seated. Remove dipstick and note reading.

a. If the fluid is hot, the reading should be in the crosshatched area marked “OK”. b. If the fluid is warm, the reading should be between the two holes. If the fluid level indicates low, add sufficient fluid to bring to the proper level.

Fluid is added through the dipstick tube. NOTE: To prevent dirt and water from entering the transmission after checking or replenishing fluid, make certain that the dipstick cap is properly seated. Selection Of Lubricant Refer to Recommended Fluids, Lubricants and Genuine Parts for the correct lubricant type. It is important that the transmission fluid be maintained at the prescribed level using the recommended fluid.

CAUTION!

Using a transmission fluid other than the manufac- turers recommended fluid may cause deterioration in transmission shift quality and/or torque converter shudder. Using a transmission fluid other than the manufacturers recommended fluid will result in more frequent fluid and filter changes. Refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type.

Automatic Transmission Fluid and Filter Change To obtain best performance and long life for automatic transmissions, the manufacturer recommends that they be given regular maintenance service by an Authorized Dodge Dealer or Service Center. It is important that the transmission be adjusted periodically, the fluid main- tained at the correct level, and that it be drained and refilled as specified.

It is important that proper lubricant is used in the transmission. Refer to Recommended Fluids, Lubricants and Genuine Parts for the correct lubricant type. A band adjustment and filter change should be made at the time of the oil change. The fluid and filter should be changed and the bands adjusted as specified in the Maintenance Schedule (Sec- tion 8). Vehicles having severe usage should follow Maintenance Schedule “B” of the Maintenance Schedule (Section 8). Severe usage consists of: † Off-the-highway operation; † Trailer towing; † Snow plow operation; † Prolonged operation with heavy loading, especially in

hot weather.

MAINTAINING YOUR VEHICLE 355

If the transmission is disassembled for any NOTE: reason, the fluid and filter should be changed, and the bands adjusted. Special Additives The manufacturer recommends against the addition of any additives to the transmission. Exception to this policy is the use of special dyes to aid in detecting fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals. Front Wheel Bearings Front wheel bearings for all Dodge Ram Trucks are sealed-for-life. They do not require greasing or seal replacement. these bearings will “purge” excess grease and the bearing housing will look slightly wet. This is normal. † Periodic inspection for excess play is recommended.

In some instances,

356 MAINTAINING YOUR VEHICLE

† If a bearing assembly is accidentally separated when

servicing the brake rotors, it should be replaced.

Rear Wheel Bearings Clean and repack when brake linings are replaced or rotors resurfaced. Selection Of Lubricating Grease The National Lubricating Grease Institute (NLGI) has developed a symbol (Certification Mark) to aid the vehicle owner in the proper selection of grease for the lubrication of wheel bearings and chassis components. This symbol (an example shown below) is located on the grease container and identifies the application and qual- ity of the grease.

are

There two groups identified: those for wheel bearings (Letter “G”) and those for chassis (Letter “L”) lubrication. Perfor- mance categories within these groups result in dual letter for each group. The letter des- ignations shown in the ex- ample the highest quality level available and when combined as shown can be used for both wheel bearing and chassis lubrication. Use only those greases that have the NLGI symbol on the container along with the proper quality level for your application.

designations

are

Noise Control System Required Maintenance & Warranty For 3500 Two-Wheel Drive and Four-Wheel Drive mod- els over 10,000 lbs. (4 535 kg) Gross Vehicle Weight Rating. All vehicles built over 10,000 lbs. (4 535 kg) Gross Vehicle Weight Rating and manufactured for sale and use in the United States are required to comply with the Federal Government’s Exterior Noise Regulations. These vehicles can be identified by the Noise Emission Control Label located in the operator’s compartment.

MAINTAINING YOUR VEHICLE 357

Required Maintenance For Noise Control Systems The following maintenance services must be performed every 6 months or 6,000 miles (9 600 km), whichever comes first, to assure proper operation of the noise control systems. inspection and service should be performed anytime a malfunction is observed

In addition,

358 MAINTAINING YOUR VEHICLE

or suspected. Proper maintenance of the entire vehicle will help the effectiveness of the noise control systems. Exhaust System Inspect the entire exhaust system for leaks and damaged parts. Devices such as hangers, clamps, and U-bolts should be tight and in good condition. Damaged compo- nents, burned or blown out mufflers, burned or rusted out exhaust pipes should be replaced according to the procedures and specifications outlined in the appropriate service manual. Air Cleaner Assembly Inspect air cleaner housing for proper assembly and fit. Make certain that the air cleaner is properly positioned and that the cover is tight. Check all hoses leading to the cleaner for tightness. The air filter element must also be clean and serviced according to the instructions outlined in the Maintenance Schedule Section of this manual.

Tampering With Noise Control System Prohibited Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorpo- rated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below.

† AIR CLEANER − Removal of the air cleaner. − Removal of the air cleaner filter element from the air

cleaner housing.

− Removal of the air ducting. † EXHAUST SYSTEM − Removal or rendering inoperative exhaust system † ENGINE COOLING SYSTEM − Removal or rendering inoperative the fan clutch. − Removal of the fan shroud.

components including the muffler or tailpipe.

MAINTAINING YOUR VEHICLE 359

Noise Emission Warranty The manufacturer warrants that this vehicle as manufac- tured by the manufacturer, was designed, built and equipped to conform at the time it left the manufacturer’s control with all applicable U.S. EPA Noise Control Regu- lations. This warranty covers this vehicle as designed, built and equipped by the manufacturer, and is not limited to any particular part, component or system of the vehicle manufactured by the manufacturer. Defects in design, assembly or in any part, component or system of the vehicle as manufactured by the manufacturer, which, at the time it left the manufacturer’s control, caused noise emissions to exceed Federal standards, are covered by this warranty for the life of the vehicle.

360 MAINTAINING YOUR VEHICLE

7,500
12 000

15,000
24 000

22,500
36 000

30,000
48 000

Maintenance Log and Service Chart — 24 Valve Cummins Turbo Diesel Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest to the mileage at which service was performed. MILES KILOMETERS Exhaust system- inspect Air cleaner assembly-inspect ODOMETER READING PERFORMED BY PERFORMED AT

60,000
96 000

52,500
84 000

45,000
72 000

37,500
60 000

Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest to the mileage at which service was performed.

MAINTAINING YOUR VEHICLE 361

MILES KILOMETERS Exhaust system- inspect Air cleaner assembly-inspect ODOMETER READING PERFORMED BY PERFORMED AT

67,500
108 000

75,000
120 000

82,500
132 000

90,000
144 000

97,500
126 000

84,000
156 000

105,00
168 000

112,500
181 000

362 MAINTAINING YOUR VEHICLE

Appearance Care and Protection from Corrosion

Protection of Body and Paint from Corrosion Vehicle body care requirements vary according to geo- graphic locations and usage. Chemicals that make roads passable in snow and ice, and those that are sprayed on trees and road surfaces during other seasons, are highly corrosive to the metal in your vehicle. Outside parking, which exposes your vehicle to airborne contaminants, road surfaces on which the vehicle is operated, extreme hot or cold weather and other extreme conditions will have an adverse effect on paint, metal trim, and under- body protection. The following maintenance recommendations will enable you to obtain maximum benefit from the corrosion resistance built into your vehicle. What Causes Corrosion? Corrosion is the result of deterioration or removal of paint and protective coatings from your vehicle.

The most common causes are: † Road salt, dirt and moisture accumulation. † Stone and gravel impact. † Insects, tree sap and tar. † Salt in the air near seacoast localities. † Atmospheric fallout/industrial pollutants. Washing † Wash your vehicle regularly. Always wash your ve- hicle in the shade using a mild car wash soap, and rinse the panels completely with clear water. † If insects, tar or other similar deposits have accumu- † Use Mopar auto polish to remove road film and stains and to polish your vehicle. Take care never to scratch the paint.

lated on your vehicle, wash it as soon as possible.

† Avoid using abrasive compounds and power buffing that may diminish the gloss or thin out the paint finish.

CAUTION!

Do not use abrasive or strong cleaning materials such as steel wool or scouring powder, which will scratch metal and painted surfaces.

Special Care † If you drive on salted or dusty roads or if you drive near the ocean, hose off the undercarriage at least once a month. † It is important that the drain holes in the lower edges of the doors, rocker panels and tailgate be kept clear and open.

MAINTAINING YOUR VEHICLE 363

† If you detect any stone chips or scratches in the paint, touch them up immediately. The cost of such repairs is considered the responsibility of the owner. † If your vehicle is damaged due to an accident or similar cause which destroys the paint and protective coating have your vehicle repaired as soon as possible. The cost of such repairs is considered the responsibil- ity of the owner. † All wheels and wheel trim, especially aluminum and chrome plated wheels should be cleaned regularly with mild soap and water to prevent corrosion. To remove heavy soil, select a nonabrasive, non-acidic cleaner. Do not use scouring pads, steel wool, a bristle brush or metal polishes. Only Mopar cleaners are recommended. Do not use oven cleaner. Avoid auto- matic car washes that use acidic solutions or harsh brushes that may damage the wheels’ protective fin- ish.

364 MAINTAINING YOUR VEHICLE

† If you carry special cargo such as chemicals, fertilizers, de-icer salt, etc., be sure that such materials are well packaged and sealed. † If a lot of driving is done on gravel roads, consider † Use Mopar touch up paint on scratches as soon as possible. Your dealer has touch up paint to match the color of your vehicle.

mud or stone shields behind each wheel.

Interior Care Use Mopar Fabric Cleaner to clean fabric upholstery and carpeting. Use Mopar Vinyl Cleaner to clean vinyl upholstery and trim. Mopar Total Clean is specifically recommended for leather upholstery.

Your leather upholstery can be best preserved by regular cleaning with a damp soft cloth. Small particles of dirt can act as an abrasive and damage the leather upholstery and should be removed promptly with a damp cloth. Stubborn soils can be removed easily with a soft cloth and Mopar Total Clean. Care should be taken to avoid soaking your leather upholstery with any liquid. Please do not use polishes, oils, cleaning fluids, solvents, deter- gents, or ammonia based cleaners to clean your leather upholstery. Application of a leather conditioner is not required to maintain the original condition.

WARNING!

Do not use volatile solvents for cleaning purposes. Many are potentially flammable, and if used in closed areas they may cause respiratory harm.

Glass Surfaces All glass surfaces should be cleaned on a regular basis with any commercial household-type glass cleaner. Never use an abrasive type cleaner. Use caution when cleaning inside rear windows equipped with electric defrosters or windshields equipped with a windshield wiper de-icer. Do not use scrapers or other sharp instru- ments which may scratch the elements. When cleaning the rear view mirror, spray cleaner on the towel or rag that you are using. Do not spray cleaner directly on the mirror. Cleaning Plastic Instrument Cluster Lenses The lenses in front of the instruments in this vehicle are molded in clear plastic. When cleaning the lenses, care must be taken to avoid scratching the plastic.

MAINTAINING YOUR VEHICLE 365

1. Clean with a wet soft rag. A mild soap solution may be used, but do not use high alcohol content or abrasive cleaners. If soap is used, wipe clean with a clean damp rag. 2. Dry with a soft tissue. Seat Belt Maintenance Do not bleach, dye or clean the belts with chemical solvents or abrasive cleaners. This will weaken the fabric. Sun damage will also weaken the fabric. If the belts need cleaning, use a mild soap solution or lukewarm water. Do not remove the belts from the car to wash them. Replace the belts if they appear frayed or worn or if the buckles do not work properly.

366 MAINTAINING YOUR VEHICLE

FUSE AND RELAY CENTER

Your vehicle is equipped with a fuse and relay center located in the engine compartment near the battery. Located on the underside of the cover is a label that identifies each component. 1. Disconnect the battery negative (-) cables from the right and left batteries before removing the cover.

2. Use specified fuses only. 3. Always properly reinstall the cover.

VEHICLE STORAGE If you are storing your vehicle for more than 21 days, we recommend that you take the following steps to mini- mize the drain on your vehicle’s battery: † Disconnect the Ignition-Off Draw fuse (I.O.D.) fuse located in the Fuse and Relay Center, located in the engine compartment. The I.O.D. cavity includes a snap-in retainer that allows the fuse to be discon- nected, without removing it from the fuse block. † The electronic shift transfer case should be placed in the 4HI mode and kept in this position to minimize the battery drain. † As an alternative to the above steps you may, discon-

nect the negative cables from both batteries.

REPLACEMENT LIGHT BULBS

BULB REPLACEMENT

MAINTAINING YOUR VEHICLE 367

LIGHT BULBS — Inside Bulb No. Overhead Console Lights . . . . . . . . . . . . . . . TS 212-2
Dome Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7679
All of the inside bulbs are brass or glass wedge base. Aluminum base bulbs are not approved.

LIGHT BULBS — Outside Bulb No. Back-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057
Center High Mounted Stop Lamp . . . . . . . . . . . . . 912
Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 9006LL Headlamp (Halogen) . . . . . . . . . . . . . . . . . . . 9007QL Park & Turn Signal . . . . . . . . . . . . . . . . . . . 3157NAK Rear License Plate Lamp . . . . . . . . . . . . . . . . . . . 168
Rear Cargo Light. . . . . . . . . . . . . . . . . . . . . . . . . 912
Tail & Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057
Cab Clearance Lights . . . . . . . . . . . . . . . . . . . . . . 168
Dual Rear Wheel Sidemarker Light . . . . . . . . . . . . 168
Dual Rear Wheel Tailgate ID Lights (3) . . . . . . . . . 168

Headlight (Halogen)/Front Park and Turn Lights

CAUTION!

This is a halogen bulb. Avoid touching the glass with your fingers. Reduced bulb life will result.

1. Remove the expanding fastener from the headlight welt.

368 MAINTAINING YOUR VEHICLE

2. Remove the three (3) bolts from the headlight housing. NOTE: The lower bolt on the driver side headlight also retains the ambient temperature sensor between the headlight assembly and the frame.

MAINTAINING YOUR VEHICLE 369

370 MAINTAINING YOUR VEHICLE

3. Pull the housing out from the fender to allow room to disconnect the electrical connectors.

4. Unlock and pull connector straight from the base of the headlight halogen bulb.

5. Twist connector on turn signal/park light bulb 1⁄4 turn and remove connector and bulb from housing. 6. Remove housing from vehicle with headlight halogen bulb in housing. 7. Twist collar on headlight halogen bulb 1⁄4 turn and remove headlight bulb from the housing. 8. Replace headlight or turn signal bulb. Do not touch the headlight halogen bulb. 9. Reverse procedure for installation of bulbs and hous- ing. 10. Tighten the outboard fastener first.

MAINTAINING YOUR VEHICLE 371

Tail, Stop, Turn and Backup Lights

1. Remove the two (2) screws that pass through the bed sheetmetal.

372 MAINTAINING YOUR VEHICLE

2. Pull the housing straight out from the body, with a quick motion, to separate the housing from the body. If not pulled straight, locators may be damaged.

3. Push the red lock slide in on the connector and remove the housing from the vehicle. 4. Remove the four (4) screws from the bulb strip in the housing.

5. Pull the appropriate bulb straight from the bulb strip.

MAINTAINING YOUR VEHICLE 373

7. While holding the taillight firmly in place, fasten the top screw first. Center High-Mounted Stoplight With Cargo Light

1. Remove the two (2) screws holding the housing/lens to the body as shown.

† Top Bulb: Park/Turn/Hazard † Center Bulb: Stop/Park/Sidemarker † Bottom Bulb: Backup Lights 6. Reverse procedure for installation of bulbs and hous- ing.

374 MAINTAINING YOUR VEHICLE

2. Separate the connector holding the housing and wir- ing harness to the body.

3. Turn desired bulb socket 1⁄4 turn and remove socket and bulb from housing. 4. Pull desired bulb straight from the socket.

† Outside Bulbs: Cargo Lamps † Inside Bulb: Center High Mount Stop Lamp 5. Reverse procedure for installation of bulbs and hous- ing.

Cab Top Clearance Lights — If Equipped

1. Remove the two screws from the top of the light.

2. Rotate the socket 1⁄4 turn and pull it from the light assembly.

MAINTAINING YOUR VEHICLE 375

376 MAINTAINING YOUR VEHICLE

3. Pull the bulb straight from it’s socket and replace.

Tailgate ID Lights (Dual Rear Wheels)

1. Remove the two screws and housing and access the bulb sockets from the rear.

MAINTAINING YOUR VEHICLE 377

2. Turn socket 1⁄4 turn counterclockwise to access the bulb.

3. Pull bulb straight out from socket. 4. Reverse procedure for installation of bulbs and hous- ing.

378 MAINTAINING YOUR VEHICLE

Side Marker Lights (Dual Rear Wheels)

5. Reverse procedure for installation of bulbs and hous- ing. Fog Lights

1. Reach under the vehicle, unlock and twist connector counterclockwise 1⁄4 turn and remove connector and bulb from housing.

1. Push rearward on the side marker light assembly. 2. Pull the entire assembly from the fender. 3. Turn socket 1⁄4 turn counterclockwise and remove from assembly to access the bulb. 4. Pull bulb straight out from socket.

2. Pull bulb straight from the connector.

3. Reverse procedure for installation of bulbs and hous- ing.

MAINTAINING YOUR VEHICLE 379

FLUID CAPACITIES FLUID CAPACITIES Fuel

2500 Shortbed Models 2500 Longbed Models 3500 Shortbed Models 3500 Longbed Models

Engine Oil

U.S.

Metric

34 gal. 35 gal. 34 gal. 35 gal.

128L 132L 128L 132L

5.9L Diesel Engine I-6

12.0 qts.

11.4L

Cooling System

5.9L Diesel Engine I-6

7 gal.

26.5L

380 MAINTAINING YOUR VEHICLE

RECOMMENDED FLUIDS, LUBRICANTS AND GENUINE PARTS Engine Component Engine Coolant

Engine Oil

Engine Oil Filter Engine Fuel Filter Fuel Selection

Fluids, Lubricants and Genuine Parts Mopart Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Or- ganic Additive Technology) P/N 5011764AB or equivalent. For the proper quality and SAE Grade oil for your engine, refer to the sec- tion 9Maintenance Procedures.9
Mopart Engine Oil Filter, P/N 05083285AA or equivalent. Mopart Fuel Filter, P/N 05015581AB or equivalent. Refer to the section 9Fuel Requirements9 for detailed information on fuel se- lection.

MAINTAINING YOUR VEHICLE 381

Fluids, Lubricants and Genuine Parts. Mopart ATF+4, Automatic Transmission Fluid Mopart ATF+4, Automatic Transmission Fluid

Chassis Component Automatic Transmission Transfer Case Manual Transmission Fluid NV 4500 Mopart 75W-85 Synthetic, API grade GL4, Mopar P/N 4874459, Manual Transmission Fluid NV 5600 Mopart manual transmission fluid P/N 4874464. Clutch Linkage Front and Rear Axle Fluid 2500/3500
Models Brake Master Cylinder

Multipurpose Grease, NLGI Grade 2 E.P. GL-5 SAE 75W-90 Synthetic Limited-Slip AAM Rear Axles DO NOT RE- QUIRE a limited slip additive. Mopart DOT 3 and SAE J1703 should be used. If DOT 3 brake fluid is not available, then DOT 4 is acceptable. Use only recommended brake fluids. Mopart ATF+4, Automatic Transmission Fluid

Power Steering Reservoir

MAINTENANCE SCHEDULES

CONTENTS

m Emission Control System Maintenance . . . . . . . . 384
m Maintenance Schedules — 24–Valve Cummins

Turbo Diesel

. . . . . . . . . . . . . . . . . . . . . . . . . . 384

N Schedule “B” . . . . . . . . . . . . . . . . . . . . . . . . 387
N Schedule “A” . . . . . . . . . . . . . . . . . . . . . . . . 396

M

384 MAINTENANCE SCHEDULES

EMISSION CONTROL SYSTEM MAINTENANCE The “Scheduled” maintenance services, listed in bold type in this section (Section 8) must be done at the times or mileages specified to assure the continued proper functioning of the emission control system. These, and all other maintenance services included in this manual, should be done to provide best vehicle performance and reliability. More frequent maintenance may be needed for vehicles in severe operating conditions such as dusty areas and very short trip driving. Inspection and service also should be done any time a malfunction is suspected. NOTE: Maintenance, replacement, or repair of the emis- sion control devices and systems on your vehicle may be performed by any automotive repair establishment or individual using any automotive part which has been certified pursuant to U.S. EPA or, in the State of Califor- nia, California Air Resources Board regulations.

MAINTENANCE SCHEDULES — 24–VALVE CUMMINS TURBO DIESEL There are two maintenance schedules that show the required service for your vehicle. First is Schedule “B”. It is for vehicles that are operated under the conditions that are listed below and at the beginning of the schedule. † Frequent short trips where the engine does not achieve full operating temperature (operating temperature de- fined as 190° F (66° C ) coolant temperature). † Extensive engine idling (over 10 minutes per hour of operation) at ambient temperatures less than 32° F (0° C).

† Driving in dusty conditions. † Frequent trailer towing. † Taxi, police, or delivery service (commercial service).

† Off-road or desert operation. † Extensive operation at high engine speeds (greater than 2900 rpm) and loads (greater than 70% throttle). NOTE: Most vehicles are operated under the conditions listed for Schedule 9B9. Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Sched- ule 9B9. Use the schedule that best describes your driving condi- tions. Where time and mileage are listed, follow the interval that occurs first.

CAUTION!

Failure to perform the required maintenance items may result in damage to the vehicle.

MAINTENANCE SCHEDULES 385

At Each Stop for Fuel † Check the engine oil level about 15 minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark. † Check the windshield washer solvent and add if † Drain water from the fuel filter. Once a Month † Check tire pressure and look for unusual wear or † Inspect the batteries and clean and tighten the termi-

required.

damage.

nals as required.

386 MAINTENANCE SCHEDULES

† Check the fluid levels of coolant reservoir, brake master cylinder, and transmission and transfer case (if equipped), add as needed. † Check Filter Minder™. Replace air cleaner filter † Check all lights and all other electrical items for correct

element if necessary.

operation.

sion components.

† Inspect the brake hoses. † Inspect the CV joints (if equipped) and front suspen- † Check the automatic transmission fluid level. † Check the manual transmission fluid level. † Check the coolant level, hoses, and clamps.

At Each Oil Change † Change the engine oil filter. † Inspect the exhaust system.

Schedule “B” Follow schedule “B” if you usually operate your vehicle under one or more of the following conditions. † Frequent short trips where the engine does not achieve full operating temperature (operating temperature de- fined as 190° F (66° C ) coolant temperature). † Extensive engine idling (over 10 minutes per hour of operation) at ambient temperatures less than 32° F (0° C).

SCHEDULE “B” 387

† Driving in dusty conditions. † Frequent trailer towing. † Taxi, police, or delivery service (commercial service). † Off-road or desert operation. † Extensive operation at high engine speeds (greater than 2900 rpm) and loads (greater than 70% throttle).

388 SCHEDULE “B”

Miles (Kilometers) Change engine oil and engine oil filter. Rotate tires. Lubricate outer tie rod ends 2500/3500 (4X4) mod- els only. Inspect water pump weep hole for blockage. Replace fuel filter element. Clean the water in fuel sensor. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect and adjust parking brake if necessary.

3,750
(6 000)

7,500
(12 000)

11,250
(18 000)

15,000
(24 000)

18,750
(30 000)

Miles (Kilometers) Change engine oil and engine oil filter. Rotate tires. Lubricate outer tie rod ends 2500/3500 (4X4) mod- els only. Inspect drive belt, replace as required. Inspect fan hub. Inspect damper. Inspect water pump weep hole for blockage. Replace fuel filter element. Clean the water in fuel sensor. Change rear axle fluid. Change front axle fluid (4X4). Check transfer case fluid level (4X4). Drain and refill automatic transmission fluid. Re- place filter and adjust bands.

SCHEDULE “B” 389

22,500
(36 000)

26,250
(42 000)

30,000
(48 000)

33,750
(54 000)

37,500
(60 000)

M

390 SCHEDULE “B”

Miles (Kilometers) Change engine oil and engine oil filter. Rotate tires. Lubricate outer tie rod ends 2500/3500 (4X4) mod- els only. Inspect drive belt, replace as required. Inspect water pump weep hole for blockage. Replace fuel filter element. Clean the water in fuel sensor. Inspect brake linings. Inspect and adjust parking brake if necessary. Change rear axle fluid. Change front axle fluid (4X4).

41,250
(66 000)

45,000
(72 000)

48,750
(78 000)

52,500
(84 000)

56,250
(90 000)

Miles (Kilometers) Change engine oil and engine oil filter. Rotate tires. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Inspect drive belt, replace as required. Inspect fan hub. Inspect damper. Inspect water pump weep hole for blockage. Replace fuel filter element. Clean the water in fuel sensor. Inspect front wheel bearings. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect and adjust parking brake if necessary. Drain and refill transfer case fluid (4X4). Drain and refill automatic transmission fluid. Replace fil- ter and adjust bands.

SCHEDULE “B” 391

60,000
(96 000)

63,750

67,500

71,250

75,000

(102 000)

(108 000)

(114 000)

(120 000)

M

392 SCHEDULE “B”

Miles (Kilometers) Change engine oil and engine oil filter. Rotate tires. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Inspect drive belt, replace as required. Change rear axle fluid. Change front axle fluid (4X4). Check transfer case fluid level (4X4). Inspect fan hub. Inspect damper. Inspect water pump weep hole for blockage. Replace fuel filter element. Clean the water in fuel sensor. Inspect front wheel bearings. Inspect brake linings. Inspect and adjust parking brake if necessary. Drain and refill automatic transmission fluid. Replace fil- ter and adjust bands.

78,750

82,500

86,250

90,000

93,750

(126 000)

(132 000)

(138 000)

(144 000)

(150 000)

Miles (Kilometers) Change engine oil and engine oil filter. Rotate tires. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Flush and replace engine coolant. Inspect drive belt, replace as required. Inspect water pump weep hole for blockage. Replace fuel filter element. Clean the water in fuel sensor. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect and adjust parking brake if necessary.

97,500
(156 000)

100,000
(160 000)

101,250
(162 000)

105,000
(168 000)

108,750
(174 000)

112,500
(180 000)

SCHEDULE “B” 393