2005 Dodge RAM Diesel Owners Manual

NOTE: reason, the fluid and filter should be changed, and the bands adjusted (if equipped). 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,

MAINTAINING YOUR VEHICLE 373

• 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.

374 MAINTAINING YOUR VEHICLE

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 375

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.

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,

376 MAINTAINING YOUR VEHICLE

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.

components including the muffler or tailpipe.

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

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,

MAINTAINING YOUR VEHICLE 377

emissions to exceed Federal standards, are covered by this warranty for the life of the vehicle.

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 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

30,000
48 000

37,500
60 000

45,000
72 000

60,000
96 000

7,500
12 000

22,500
36 000

15,000
24 000

52,500
84 000

378 MAINTAINING YOUR VEHICLE

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

90,000
144 000

97,500
126 000

67,500
108 000

82,500
132 000

75,000
120 000

84,000
156 000

105,00
168 000

112,500
181 000

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.

MAINTAINING YOUR VEHICLE 379

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.

NOTE: Fold the 7 x 10 inch trailer towing mirrors rearward prior to entering an automated car wash.

380 MAINTAINING YOUR VEHICLE

CAUTION!

CAUTION!

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

Do not attempt to fold the 7 x 10 inch trailer towing mirrors forward. The 7 x 10 inch trailer towing mirrors are not designed to be folded forward and doing so will damage the mirrors and/or vehicle. • 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. • Avoid using abrasive compounds and power buffing that may diminish the gloss or thin out the paint finish.

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. • 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. • If you carry special cargo such as chemicals, fertilizers, de-icer salt, etc., be sure that such materials are well packaged and sealed.

MAINTAINING YOUR VEHICLE 381

mud or stone shields behind each wheel.

• 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.

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

382 MAINTAINING YOUR VEHICLE

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. 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.

MAINTAINING YOUR VEHICLE 383

FUSE AND RELAY CENTER

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.

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.

384 MAINTAINING YOUR VEHICLE

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

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

BULB REPLACEMENT

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.

MAINTAINING YOUR VEHICLE 385

386 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 387

388 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.

Tail, Stop, Turn and Backup Lights

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

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.

MAINTAINING YOUR VEHICLE 389

3. Push the red lock slide in on the connector and remove the housing from the vehicle.

390 MAINTAINING YOUR VEHICLE

4. Remove the four (4) screws from the bulb strip in the housing.

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

• Top Bulb: Park/Turn/Hazard • Center Bulb: Stop/Park/Sidemarker • Bottom Bulb: Backup Lights

6. Reverse procedure for installation of bulbs and hous- ing. 7. While holding the taillight firmly in place, fasten the top screw first.

MAINTAINING YOUR VEHICLE 391

Center High-Mounted Stoplight With Cargo Light

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

392 MAINTAINING YOUR VEHICLE

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

4. Pull desired bulb straight from the socket.

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

• 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 393

394 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 395

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.

396 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 397

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

398 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 Mopar威 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 section ⬙Maintenance Procedures.⬙ Mopar威 Engine Oil Filter, P/N 05083285AA or equivalent. Mopar威 Fuel Filter, P/N 05015581AB or equivalent. Refer to the section ⬙Fuel Requirements⬙ for detailed information on fuel se- lection.

MAINTAINING YOUR VEHICLE 399

Chassis Component Automatic Transmission Transfer Case Manual Transmission Fluid NV 4500 Mopar威 75W-85 Synthetic, API grade GL4, Mopar P/N 4874459 or equiva-

Fluids, Lubricants and Genuine Parts. Mopar威 ATF+4, Automatic Transmission Fluid or equivalent. Mopar威 ATF+4, Automatic Transmission Fluid or equivalent.

lent

Manual Transmission Fluid NV 5600 Mopar威 manual transmission fluid P/N 4874464 or equivalent. Manual Transmission Fluid G-56
Clutch Linkage Front and Rear Axle Fluid 2500/3500
Models Brake Master Cylinder

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

Power Steering Reservoir

MAINTENANCE SCHEDULES

CONTENTS

䡵 Emission Control System Maintenance . . . . . . . . 402
䡵 Maintenance Schedules — 24–Valve Cummins

Turbo Diesel

. . . . . . . . . . . . . . . . . . . . . . . . . . 402

▫ Schedule “B” . . . . . . . . . . . . . . . . . . . . . . . . 405
▫ Schedule “A” . . . . . . . . . . . . . . . . . . . . . . . . 416

M

402 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 ⬙B⬙. If ANY of these apply to you then change your NOTE: coolant every 102,000 miles (163 000 km) or 60 months, whichever comes first and follow schedule “B” of the ⬙Maintenance Schedules⬙ section of this manual. Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Sched- ule ⬙B⬙. Use the schedule that best describes your driving condi- tions. Where time and mileage are listed, follow the interval that occurs first.

MAINTENANCE SCHEDULES 403

CAUTION!

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

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.

required.

404 MAINTENANCE SCHEDULES

damage.

nals as required.

Once a Month • Check tire pressure and look for unusual wear or • Inspect the batteries and clean and tighten the termi- • 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.

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

sion components.

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).

• Driving in dusty conditions.

SCHEDULE “B” 405

• 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 NOTE: coolant every 102,000 miles (163 000 km) or 60 months, whichever comes first and follow schedule “B” of the ⬙Maintenance Schedules⬙ section of this manual.

M

406 SCHEDULE “B”

Miles (Kilometers) Change engine oil and engine oil filter. Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). 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. Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). 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. Change rear axle fluid. Change front axle fluid (4X4). Check transfer case fluid level (4X4). Drain and refill automatic transmission fluid. Replace filter and adjust bands (48RE only).

SCHEDULE “B” 407

22,500
(36 000)

26,250
(42 000)

30,000
(48 000)

33,750
(54 000)

37,500
(60 000)

M

408 SCHEDULE “B”

Miles (Kilometers) Change engine oil and engine oil filter. Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). 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. Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). Flush and replace engine coolant at 60 months, if not replaced at 102,000 miles (163 000 km). 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. Inspect front wheel bearings. Change rear axle fluid.

SCHEDULE “B” 409

60,000
(96 000)

63,750
(102 000)

67,500
(108 000)

71,250
(114 000)

75,000
(120 000)

410 SCHEDULE “B”

Miles (Kilometers) Change front axle fluid (4X4). Change 6-spd manual transmission (G-56) fluid 2500/3500 models only. Inspect brake linings. Inspect and adjust parking brake if necessary. Drain and refill transfer case fluid (4X4). Drain and refill automatic transmission fluid and change main sump filter (545 RFE only). Drain and refill automatic transmission fluid. Re- place filter and adjust bands (48RE only).

60,000
(96 000)

63,750
(102 000)

67,500
(108 000)

71,250
(114 000)

75,000
(120 000)

Miles (Kilometers) Change engine oil and engine oil filter. Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). Rotate tires. Lubricate outer tie rod ends 2500/3500 (4X4) mod- els 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.

78,750
(126 000)

82,500
(132 000)

86,250
(138 000)

90,000
(144 000)

93,750
(150 000)

SCHEDULE “B” 411

412 SCHEDULE “B”

Miles (Kilometers) Inspect front wheel bearings. Inspect brake linings. Inspect and adjust parking brake if necessary. Drain and refill automatic transmission fluid. Re- place filter and adjust bands (48RE only).

78,750
(126 000)

82,500
(132 000)

86,250
(138 000)

90,000
(144 000)

93,750
(150 000)

Miles (Kilometers) Change engine oil and engine oil filter. Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). Flush and replace engine coolant, if not replaced at 60 months. 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)

112,500
101,250
(162 000) (168 000) (174 000) (180 000)

108,750

105,000

SCHEDULE “B” 413

M

414 SCHEDULE “B”

Miles (Kilometers) Change engine oil and engine oil filter. Lubricate Front Drive Shaft Fitting (2500/ 3500, 4X4). Rotate tires. Flush and replace engine coolant at 120
months, if not replaced at 102,000 miles (163
000 km). Lubricate outer tie rod ends 2500/3500 (4X4) models only. Clean engine air filter canister. Adjust valve lash clearance. Inspect drive belts, replace as required. Drain and refill transfer case fluid (4X4). Inspect fan hub. Inspect damper. Inspect water pump weep hole for blockage.

116,250
(186 000)

120,000
(192 000)

123,750
(198 000)

127,500
(204 000)

131,250
(210 000)

135,000
(216 000)

116,250
(186 000)

Miles (Kilometers) Replace fuel filter element. Clean the water in fuel sensor. Inspect front wheel bearings. Change rear axle fluid. Change front axle fluid (4X4). Change 6-spd manual transmission (G-56) fluid 2500/3500 models only. Inspect brake linings. Inspect and adjust parking brake if necessary. Drain and refill automatic transmission fluid and change main sump and spin-on cooler return filter (if equipped) (545 RFE only). Drain and refill automatic transmission fluid. Replace filter and adjust bands (48RE only). Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.

SCHEDULE “B” 415

120,000
(192 000)

123,750
(198 000)

127,500
(204 000)

131,250
(210 000)

135,000
(216 000)

M

416 SCHEDULE “A”

Schedule “A” Miles (Kilometers) [Months] Change engine oil and engine oil filter. Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). Rotate tires. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Check transfer case fluid level (4X4). Inspect water pump weep hole for blockage Replace fuel filter element. Clean the water in fuel sensor. Inspect drive belts, replace as necessary. Inspect brake linings. Inspect and adjust parking brake if necessary. Inspect fan hub. Inspect damper. Inspect front wheel bearings.

7,500
(12 000)

[6]

15,000
(24 000)

[12]

37,500
(60 000)

[30]

22,500
(36 000)

[18]

30,000
(48 000)

[24]

Miles (Kilometers) [Months] Change engine oil and engine oil filter. Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). Rotate tires. Lubricate outer tie rod ends 2500/3500 (4X4) mod- els only. Check transfer case fluid level. Flush and replace engine coolant at 60 months, if not replaced at 102,000 miles (163 000 km). Inspect drive belts, replace as necessary. 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.

SCHEDULE “A” 417

45,000
(72 000)

[36]

52,500
(84 000)

[42]

60,000
(96 000)

[48]

67,500
(108 000)

[54]

75,000
(120 000)

[60]

418 SCHEDULE “A”

Miles (Kilometers) [Months] Inspect fan hub. Inspect damper. Inspect front wheel bearings. Replace fuel filter element. Clean the water in fuel sensor

45,000
(72 000)

[36]

52,500
(84 000)

[42]

67,500
(108 000)

[54]

75,000
(120 000)

[60]

60,000
(96 000)

[48]

Miles (Kilometers) [Months] Change engine oil and engine oil filter. Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). Rotate tires. Lubricate outer tie rod ends 2500/3500 (4X4) mod- els only. Flush and replace engine coolant, if not replaced at 60 mos. Check transfer case fluid level (4X4). 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.

82,500
(132 000)

[66]

90,000
(144 000)

[72]

97,500
(156 000)

[78]

SCHEDULE “A” 419

100,000
(160 000)

105,000
(168 000)

[84]

420 SCHEDULE “A”

Miles (Kilometers) [Months] Inspect front wheel bearings. Inspect brake linings. Inspect and adjust parking brake if necessary. Drain and refill automatic transmission fluid. Re- place filter and adjust bands (48 RE only).

82,500
(132 000)

[66]

90,000
(144 000)

[72]

97,500
(156 000)

[78]

100,000
(160 000)

105,000
(168 000)

[84]

Miles (Kilometers) [Months] Change engine oil and engine oil filter. Lubricate Front Drive Shaft Fitting (2500/ 3500, 4X4). Rotate tires. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Flush and replace engine coolant at 120
months, if not replaced at 100,000 miles (160
000 km). Inspect drive belt, replace as required. Drain and refill transfer case fluid (4X4). Check tranfer case fluid level (4X4). Inspect fan hub. Inspect damper. Inspect water pump weep hole for blockage.

112,500
(181 000)

[90]

SCHEDULE “A” 421

120,000
(193 000)

127,500
(205 000)

135,000
(217 000)

142,500
(229 000)

150,000
(241 000)

[96]

[102]

[108]

[114]

[120]

422 SCHEDULE “A”

112,500
(181 000)

[90]

Miles (Kilometers) [Months] Replace fuel filter element. Clean the water in fuel sensor. Inspect front wheel bearings. Inspect brake linings. Inspect and adjust parking brake if necessary. Adjust valve lash clearance. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all re- ceipts.

120,000
(193 000)

127,500
(205 000)

135,000
(217 000)