2004 Dodge Durango Owners Manual

WARNING!

WARNING!

The limited use spare tires are for emergency use only. Installation of this limited use spare tire affects vehicle handling. With this tire, do not drive more than 60 mph (100 km/h). Keep inflated to the cold tire inflation pressure listed on either your tire placard or limited use spare tire and wheel assembly. Replace (or repair) the original tire at the first opportunity and reinstall it on your vehicle. Failure to do so could result in loss of vehicle control.

Tire Spinning When stuck in mud, sand, snow, or ice conditions, do not spin your vehicle’s wheels above 35 mph (55 km/h). See the paragraph on Freeing A Stuck Vehicle in Section 6 of this manual.

Fast spinning tires can be dangerous. Forces gener- ated by excessive wheel speeds may cause tire dam- age or failure. A tire could explode and injure someone. Do not spin your vehicle’s wheels faster than 35 mph (55 km/h) when you are stuck. And don’t let anyone near a spinning wheel, no matter what the speed.

Tread Wear Indicators Tread wear indicators are in the original equipment tires to help you in determining when your tires should be replaced.

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Replacement Tires The tires on your new vehicle provide a balance of many characteristics. They should be inspected regularly for wear and correct cold tire inflation pressure. The manu- facturer strongly recommends that you use tires equiva- lent to the originals in size, quality and performance when replacement is needed (see the paragraph on tread wear indicators). Refer to the Tire and Loading Informa- tion placard for the size designation of your tire. The service description and load identification will be found on the original equipment tire. Failure to use equivalent replacement tires may adversely affect the safety, han- dling, and ride of your vehicle. We recommend that you contact your original equipment or an authorized tire dealer with any questions you may have on tire specifi- cations or capability.

These indicators are molded into the bottom of the tread grooves and will appear as bands when the tread depth becomes 1/16 inch (2 mm). When the indicators appear in 2 or more adjacent grooves, the tire should be replaced. Many states have laws requiring tire replacement at this point.

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WARNING!

† Do not use a tire, wheel size or rating other than that specified for your vehicle. Some combinations of unapproved tires and wheels may change suspen- sion dimensions and performance characteristics, resulting in changes to steering, handling, and brak- ing of your vehicle. This can cause unpredictable handling and stress to steering and suspension com- ponents. You could lose control and have an accident resulting in serious injury or death. Use only the tire and wheel sizes with load ratings approved for your vehicle. † Never use a tire with a smaller load index or capacity, other than what was originally equipped on your vehicle. Using a tire with a smaller load index could result in tire overloading and failure. You could lose control and have an accident. † Failure to equip your vehicle with tires having adequate speed capability can result in sudden tire failure and loss of vehicle control.

CAUTION!

Replacing original tires with tires of a different size may result in false speedometer and odometer read- ings.

Alignment And Balance Poor suspension alignment may result in: † Fast tire wear. † Uneven tire wear, such as feathering and one-sided † Vehicle pull to right or left. Tires may also cause the vehicle to pull to the left or right. Alignment will not correct this condition. See your dealer for proper diagnosis.

wear.

Improper alignment will not cause vehicle vibration. Vibration may be a result of tire and wheel out-of- balance. Proper balancing will reduce vibration and avoid tire cupping and spotty wear.

SUPPLEMENTAL TIRE PRESSURE INFORMATION A light load vehicle condition is defined as two passen- gers {150 lbs (68 kg) each} plus 200 lbs (91kg) of cargo. Cold tire inflation pressures for a lightly loaded vehicle will be found on a “Supplemental Tire Pressure Inflation” label located on the face of the driver’s door or in the Tire Information Pressures pamphlet in the glove box.

TIRE CHAINS Use “Class S” chains on Durango, or other traction aids that meet SAE Type “S” specifications. NOTE: Chains must be the proper size for the vehicle, as recommended by the chain manufacturer.

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CAUTION!

To avoid damage to your vehicle, tires or chains, observe the following precautions:

† Because of limited chain clearance between tires and other

driving about 1/2 mile (0.8 km).

suspension components, it is important that only chains in good condition are used. Broken chains can cause serious vehicle damage. Stop the vehicle immediately if noise occurs that could suggest chain breakage. Remove the damaged parts of the chain before further use.

† Install chains as tightly as possible and then retighten after † Do not exceed 45 mph (72 km/h). † Drive cautiously and avoid severe turns and large bumps, † Do not install tire chains on front wheels of 4x2 vehicles. † Do not drive for a prolonged period on dry pavement. † Observe the tire chain manufacturer’s instructions on method

especially with a loaded vehicle.

of installation, operating speed, and conditions for usage. Always use the lower suggested operating speed of the chain manufacturer if different than the speed recommended by the manufacturer.

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These cautions apply to all chain traction devices, includ- ing link and cable (radial) chains. Tire chain use is permitted only on the rear tires of Durango trucks. NOTE: The use of class “S” chains is permitted on Durangos with P245/70R17 tires.

CAUTION!

Do not use tire chains on 4x4 Durango trucks equipped with P265/65R17 tires. There may not be adequate clearance for the chains and you are risking structural or body damage to your vehicle. Do not use tire chains on the 4X2 front wheels of Durango models. There may not be adequate clearance for the chains and you are risking structural or body dam- age to your vehicle.

SNOW TIRES Snow tires should be of the same size and type construc- tion as the front tires. Consult the manufacturer of the snow tire to determine any maximum vehicle speed requirement associated with the tire. These tires should always be operated at the vehicle maximum capacity inflation pressures under any load condition. While studded tires improve performance on ice, skid and traction capability on wet or dry surfaces may be poorer than that of non-studded tires. Some states pro- hibit studded tires; local laws should be checked before using these tire types.

therefore,

TIRE ROTATION RECOMMENDATIONS Tires on the front and rear axles of vehicles operate at different loads and perform different steering, driving, and braking functions. For these reasons, they wear at unequal rates and tend to develop irregular wear pat- terns. These effects can be reduced by timely rotation of tires. The benefits of rotation are especially worthwhile with aggressive tread designs such as those on all season type tires. Rotation will increase tread life, help to main- tain mud, snow and wet traction levels, and contribute to a smooth, quiet ride.

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Follow the recommended tire rotation frequency for your type of driving found in the “Maintenance Schedules” Section of this manual. More frequent rotation is permis- sible if desired. The reasons for any rapid or unusual wear should be corrected prior to rotation being per- formed.

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FUEL REQUIREMENTS

All engines (except 5.7L engines) are de- signed to meet all emissions regulations and provide excellent fuel economy and performance when using high quality un- leaded “regular” gasoline having an oc- tane rating of 87. The routine use of pre- All Engines Except 5.7L mium gasoline is not recommended. Under normal conditions the use of premium fuel will not provide a benefit over high quality regular gasolines and in some circumstances may result in poorer perfor- mance.

The 5.7L engine is designed to meet all emissions regulations and provide satisfac- tory fuel economy and performance when using high quality unleaded gasoline hav- ing an octane range of 87 to 89. The manu- facturer recommends the use of 89 octane for optimum performance.The routine use

5.7L Engines

of premium gasoline is not recommended. The use of premium gasoline will provide no benefit over high quality regular and mid-grade gasolines, and in some circumstances may result in poorer performance. Light spark knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and immediate service is required. Engine damage resulting from operation with a heavy spark knock may not be covered by the new vehicle warranty. Poor quality gasoline can cause problems such as hard starting, stalling and hesitations. If you experience these symptoms, try another brand of “regular” gasoline be- fore considering service for the vehicle. Over 40 auto manufacturers world-wide have issued and endorsed consistent gasoline specifications (the World- wide Fuel Charter, WWFC) to define fuel properties necessary to deliver enhanced emissions, performance

and durability for your vehicle. We recommend the use of gasolines that meet the WWFC specifications if they are available. Reformulated Gasoline Many areas of the country require the use of cleaner burning gasoline referred to as “Reformulated Gasoline.” Reformulated gasolines contain oxygenates, and are spe- cifically blended to reduce vehicle emissions and im- prove air quality. We strongly support the use of reformulated gasolines. Properly blended reformulated gasolines will provide excellent performance and durability for the engine and fuel system components.

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Gasoline/Oxygenate Blends Some fuel suppliers blend unleaded gasoline with oxy- genates such as 10% ethanol, MTBE and ETBE. Oxygen- ates are required in some areas of the country during the winter months to reduce carbon monoxide emissions. Fuels blended with these oxygenates may be used in your vehicle.

CAUTION!

DO NOT use gasolines containing METHANOL. Gasoline containing methanol may damage critical fuel system components.

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MMT In Gasoline MMT is a manganese-containing metallic additive that is blended into some gasoline to increase octane. Gasolines blended with MMT provide no performance advantage beyond gasolines of the same octane number without MMT. Gasolines blended with MMT reduce spark plug life and reduce emission system performance. We recom- mend that gasolines free of MMT be used in your vehicle. The MMT content of gasoline may not be indicated on the gasoline pump; therefore, you should ask your gaso- line retailer whether or not his/her gasoline contains MMT. It is even more important to look for gasolines without MMT in Canada because MMT can be used at levels higher than allowed in the United States. MMT is pro- hibited in Federal and California reformulated gasolines.

Sulfur In Gasoline If you live in the northeast United States, your vehicle may have been designed to meet California low emission standards with Cleaner-Burning California reformulated gasoline with low sulfur. If such fuels are not available in states adopting California emission standards, your ve- hicles will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be adversely affected. Gasoline sold outside of California is permitted to have higher sulfur levels which may affect the performance of the vehicle’s catalytic converter. This may cause the Check Engine or Service Engine Soon light to illuminate. We recommend that you try a different brand of unleaded gasoline having lower sulfur to determine if the problem is fuel related prior to returning your vehicle to an authorized dealer for ser- vice.

CAUTION!

CAUTION!

If the Check Engine or Service Engine Soon light is flashing, immediate service is required; see onboard diagnostics system section.

To avoid fuel spillage and overfilling, do not “top off” the fuel tank after filling.

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Materials Added To Fuel All gasolines sold in the United States are required to contain effective detergent additives. Use of additional detergents or other additives is not needed under normal conditions and would result in unnecessary cost. There- fore, you should not have to add anything to the fuel. ADDING FUEL

If fuel is poured from a portable container, the NOTE: container should have a flexible nozzle long enough to extend into the fuel filler tube.

NOTE: When the fuel nozzle “clicks” or shuts off, the fuel tank is full. NOTE: Tighten the gas cap until you hear a “clicking” sound. This is an indication that the gas cap is properly tightened. Make sure that the gas cap is tightened each time the vehicle is refueled.

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WARNING!

CAUTION!

A fire may result if gasoline is pumped into a portable container that is inside of a vehicle or on a truck bed. You could be burned. Always place gas containers on the ground while filling.

Damage to the fuel system or emission control system could result from using an improper fuel tank filler tube cap (gas cap). A poorly fitting cap could let impurities into the fuel system.

Fuel Filler Cap (Gas Cap) The gas cap is behind the fuel filler door. If the gas cap is lost or damaged, be sure the replacement cap is for use with this vehicle.

WARNING!

† Remove the fuel tank filler tube cap (gas cap) slowly to prevent fuel spray from the filler neck which may cause injury. † The volatility of some gasolines may cause a buildup of pressure in the fuel tank that may increase while you drive. This pressure can result in a spray of gasoline and/or vapors when the cap is removed from a hot vehicle. Removing the cap slowly allows the pressure to vent and prevents fuel spray. † Never allow any lit smoking materials near the vehicles while removing the cap or filling the tank. † Never add fuel to the vehicle when the engine is

running.

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Fuel System Cautions

CAUTION!

Follow these guidelines to maintain your vehicle’s performance: † The use of leaded gas is prohibited by Federal law. Using leaded gasoline can impair engine performance, damage the emission control system, and could result in loss of warranty coverage. † An out-of-tune engine, or certain fuel or ignition malfunctions, can cause the catalytic converter to overheat. If you notice a pungent burning odor or some light smoke, your engine may be out of tune or malfunctioning and may require immediate service. Contact your dealer for service assistance.

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† When pulling a heavy load or driving a fully loaded vehicle when the humidity is low and the temperature is high, use a premium unleaded fuel to help prevent spark knock. If spark knock persists, lighten the load, or engine piston damage may result. † The use of fuel additives which are now being sold as octane enhancers is not recommended. Many of these products contain high concentrations of methanol. Fuel system damage or vehicle performance problems resulting from the use of such fuels or additives is not the responsibility of the manufacturer and may not be covered under the New Vehicle Warranty.

NOTE: systems can result against you.

Intentional tampering with emissions control in civil penalties being assessed

Carbon Monoxide Warnings

WARNING!

Carbon monoxide (CO) in exhaust gases is deadly. Follow the precautions below to prevent carbon monoxide poisoning: † Do not inhale exhaust gases. They contain carbon monoxide, a colorless and odorless gas which can kill. Never run the engine in a closed area, such as a garage, and never sit in a parked vehicle with the engine running for an extended period. If the vehicle is stopped in an open area with the engine running for more than a short period, adjust the ventilation system to force fresh, outside air into the vehicle. † Guard against carbon monoxide with proper mainte- nance. Have the exhaust system inspected every time

the vehicle is raised. Have any abnormal conditions repaired promptly. Until repaired, drive with all side windows fully open. † Keep the liftgate closed when driving your vehicle to prevent carbon monoxide and other poisonous ex- haust gases from entering the vehicle.

CATALYTIC CONVERTER The catalytic converter requires the use of unleaded fuel only. Leaded gasoline will destroy the effectiveness of the catalyst as an emission control device. Under normal operating conditions, the catalytic converter will not require maintenance. However, you must keep the en- gine maintained to assure proper operation and prevent possible damage. NOTE: systems can result against you.

Intentional tampering with emissions control in civil penalties being assessed

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CAUTION!

Damage to the catalytic converter can result if your vehicle is not kept in proper operating condition. In the event of engine malfunction, particularly involv- ing engine misfire or other apparent loss of perfor- mance, have your vehicle serviced promptly. Contin- ued operation of your vehicle with a severe malfunction could cause the converter to overheat, resulting in possible damage to the converter and vehicle.

As with any vehicle, do not park or operate this vehicle in areas where combustible materials such as grass or leaves can come in contact with a hot exhaust system. A scorching odor may be detected if you continue to run a malfunctioning engine. The odor may indicate severe and abnormal catalyst overheating. If this occurs, the

250 STARTING AND OPERATING

vehicle should be stopped, the engine shut off and the vehicle allowed to cool. Service, including a tune-up to manufacturer’s specifications should be obtained imme- diately. To minimize the possibility of catalyst damage: † Do not try to start the engine by pushing or towing the † Do not idle the engine with any spark plug wires † Do not idle the engine for prolonged periods during very rough idle or malfunctioning operating condi- tions.

disconnected or removed.

vehicle.

† Do not allow vehicle to run out of fuel.

VEHICLE LOADING

Certification Label As required by National Highway Traffic Safety Admin- istration Regulations, your vehicle has a certification label affixed to the driver’s side door.

This label contains the month and year of manufacture, Gross Vehicle Weight Rating (GVWR), Gross Axle Weight

Rating (GAWR) front and rear, and Vehicle Identification Number (VIN). A Month-Day-Hour (MDH) number is included on this label and shows the Month, Day, and Hour of manufacture. The bar code that appears on the bottom of the label is your Vehicle Identification Number (VIN). Gross Vehicle Weight Rating (GVWR) The GVWR is the total permissible weight of your vehicle including driver, passengers, vehicle, options, and cargo. The label also specifies maximum capacities of front and rear axle systems. Total load must be limited so that GVWR is not exceeded. Payload The payload of a vehicle is defined as the allowable load weight a truck can carry including the weight of the driver, all passengers, options, and cargo.

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Gross Axle Weight Rating (GAWR) The GAWR is the maximum permissible load on the front and rear axles. The load must be distributed in the cargo area so that the GAWR of each axle is not exceeded. Each axle GAWR is determined by the component in the system with the lowest load carrying capacity (axle, springs, tires, or wheels). Heavier axles or suspension components sometimes specified by purchasers for increased durability do not necessarily increase the vehicle’s GVWR. Tire Size This is the minimum allowable tire size for your vehicle. Replacement tires must be equal to the load capacity of this tire size. Rim Size This is the rim size that is appropriate for the tire size listed.

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Inflation Pressure (Cold) This is the cold tire inflation pressure for your vehicle for all loading conditions up to full GAWR. Curb Weight The curb weight of a vehicle is defined as the total weight of the vehicle with all fluids, including vehicle fuel, at full capacity conditions, and with no occupants or cargo loaded into the vehicle. The front and rear curb weight values are determined by weighing your vehicle on a commercial scale before any occupants or cargo are added. Loading The actual total weight and the weight of the front and rear of your vehicle at the ground can best be determined by weighing it when it is loaded and ready for operation. The entire vehicle should first be weighed on a commer- cial scale to insure that the GVWR has not been exceeded. The weight on the front and rear of the vehicle should

then be determined separately to be sure that the load is properly distributed over front and rear axle. Weighing the vehicle may show that the GAWR of either the front or rear axles has been exceeded but the total load is within the specified GVWR. If so, weight must be shifted from front to rear or rear to front as appropriate until the specified weight limitations are met. Store heavier items down low and be sure that the weight is distributed equally. Stow all loose items securely before driving. Improper weight distribution can have an adverse effect on the way your vehicle steers and handles and the way the brakes operate.

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after the vehicle has been weighed both in its (curb weight( condition, and in its (loaded and ready for operation( condition. Gross Vehicle Weight Rating (GVWR) 6500 LBS.

WARNING!

Do not load your vehicle any heavier than the GVWR or the maximum front and rear GAWR. If you do, parts on your vehicle can break, or it can change the way your vehicle handles. This could cause you to lose control. Also, overloading can shorten the life of your vehicle.

A loaded vehicle is shown in the following example. Note that neither GVWR nor GAWR capabilities are exceeded. Overloading can cause potential safety hazards and shorten service life. NOTE: The weights shown in this chart are not the weights for your vehicle. Also, the amount of load added to both the front and rear axles can be computed

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TRAILER TOWING To maintain warranty coverage, follow the requirements and recommendations in this manual concerning ve- hicles used for trailer towing. Definitions The following trailer towing related terminology defini- tions will assist in understanding the subsequent sec- tions: GROSS COMBINATION WEIGHT RATING (GCWR) is the total permissible weight of your vehicle and trailer when weighed in combination. (Note that GCWR ratings include a 68 kg (150 lb.) allowance for the presence of a driver.) Tongue Weight (of a trailer) is the weight placed on a vehicle’s trailer hitch by the trailer. GROSS TRAILER WEIGHT (GTW) is the weight of the trailer plus the weight of all cargo, consumables and equipment (permanent or temporary) loaded in or on the trailer in its 9loaded and ready for operation9 condition.

TRAILER SWAY CONTROL is a telescoping link that can be installed between the hitch receiver and the trailer tongue that typically provides adjustable friction associ- ated with the telescoping motion to dampen any un- wanted trailer swaying motions while traveling.

CAUTION!

† During the first 500 miles (805 km) your new vehicle is driven, do not tow a trailer. Doing so may damage your vehicle. † When first towing a trailer, limit your speed to 50
mph (80 km/h) during the first 500 miles (805 km) of towing.

Perform the maintenance listed in Section 8 of this manual. When towing a trailer, never exceed the GAWR, or GCWR, ratings.

Consider the following items when computing the weight on the rear axle: † The tongue weight of the trailer. † The weight of any other type of cargo or equipment

put in or on your vehicle.

NOTE: Remember that everything put into or on the trailer adds to the load on your vehicle. Also, additional factory-installed options, or dealer-installed options, must be considered as part of the total load on your vehicle. Refer to the Certification label located at the driver’s door for the Gross Vehicle Weight Rating.

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WARNING!

Improper towing can lead to an injury accident. Follow these guidelines to make your trailer towing as safe as possible: † Be sure the trailer is loaded heavier in front, with 60% to 65% of the weight in front of the axle(s). Loads balanced over the wheels or heavier in the rear can cause the trailer to sway severely side to side which will cause loss of control of vehicle and trailer. Failure to load trailers heavier in front is the cause of many trailer accidents. † Do not interconnect the hydraulic brake system of your vehicle with that of the trailer. This could cause inadequate braking and possible personal injury.

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† Trailer brakes are recommended for trailers over 1,000
lbs (454 kg) and required for trailers in excess of 2,000
lbs. (907 kg). † Use an approved trailer harness and connector. If a hitch is ordered, the proper wiring will be provided. † When hauling cargo or towing a trailer, do not over- load your vehicle or trailer. Overloading can cause a loss of control, poor performance or damage to brakes, axle, engine, transmission, steering, suspension, chas- sis structure or tires. † Make certain that the load is secured in the trailer and will not shift during travel. When trailering cargo that cannot be fully secured, dynamic load shifts can occur that may be difficult for the driver to control. † All trailer hitches should be professionally installed on

your vehicle.

vehicle and trailer.

† Safety chains must always be used between your † Connect trailer lighting and brakes using factory har- nesses only. Do not cut or splice any wiring to the brake circuits.

Trailer and Tongue Weight Gross Trailer Weight (GTW) means the maximum allow- able weight of the trailer plus the weight of all cargo and equipment loaded on the trailer when in actual under- way towing condition. The recommended way to mea- sure GTW is to put your fully loaded trailer on a vehicle scale. The entire weight of the trailer must be supported by the scale. Tongue Weight is the weight placed on the vehicle’s trailer hitch by the trailer. Always load a trailer with 60% to 65% of the weight in the front of the trailer. This places 10% to 15% of the GTW on the tow hitch of your vehicle.

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Gross Combined Vehicle Weight Rating (GCWR) The Gross Combined Vehicle Weight Rating (GCWR) is the MAXIMUM allowable weight of the towing vehicle, including passengers and cargo, and the weight of the loaded trailer. Calculate the maximum trailer weight (MTW) by subtracting the towing vehicle’s weight, in- cluding passengers, and cargo from GCWR. Trailer Towing—Hitches: With a Class IV Hitch, you can tow a trailer with a Gross Trailer Weight of up to 8, 900 lbs. (4037 kg.) depending on your vehicle equipment. The Trailer Tow Package in- cludes the platform hitch receiver, and a 7 lead wiring harness mounted on the hitch. Tongue weight must be equal to at least 10% of GTW, but no more that 15% of GTW. NOTE: When towing a trailer, the following require- ments must be adhered to: † GCWR must not be exceeded

Trailer sway control and equalizing hitch are required for tongue weights above 350 lbs. (159 kg). Also, there are maximum tongue weight ratings that are not to be exceeded, as follows: † Class IV (the receiver hitch type) 1200 lbs (544 kg)

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† Total weight must be distributed between the tow vehicle and the trailer such that the following four (4) ratings are not exceeded: 1. GVWR 2. GTW 3. Tongue weight rating for the trailer hitch utilized (This requirement may limit the ability to always achieve the 10% to 15% range of tongue weight as a percentage of total trailer weight.) 4. GAWR ratings

Trailer Towing Information (Maximum Trailer Weight Ratings) (Trailer Towing Guide( NOTE: For trailer towing information (maximum trailer weight ratings) refer to the following website address: http:// www.dodge.com/towing.

In Canada, refer to the following website address: http:// www.dodge.ca. Trailer Towing Requirements All Dodge Durango trucks are intended to tow trailers up to 2,000 lbs. (907 kg) without added equipment or alterations to standard equipment. Your vehicle may be factory equipped for safe towing of trailers over 2,000 lbs. (907 kg) with the trailer tow package.The electrical part of this package includes an instruction sheet and wiring pigtail for an aftermarket electric trailer brake controller. These items are stored in the glove box. If you regularly pull a trailer, regardless of the trailer size, stop and turn signals on the trailer are recommended for motoring safety. When the additional trailer lighting is connected to the vehicle, the flasher does not provide an indication of

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Heavy trailer towing also may require breakaway electric trailer brakes, anti-sway devices or equalizing hitches for safe operation. Such devices are commonly required by state law. Trailer Tow Wiring The Trailer Tow Package includes a 4 and 7 pin wiring harness located at the rear underbody of the vehicle. NOTE: Connect trailer lighting and brakes using factory harnesses only. Do not cut or splice wiring to the brake circuits.

outside lamp/bulb failure. Therefore, an occasional vi- sual check around the vehicle is recommended. Once the trailer is removed the above indication will return to the vehicle.

WARNING!

The direct connection of hydraulic brake lines from vehicle brake system to trailer system is not accept- able. The extra load may cause brake failure and you may be injured.

All Durango models are equipped with an Anti-Lock Brake System and require an electrically actuated electric brake controller. A blue colored connector for electric brake hookup is located under the instrument panel above the brake pedal.

260 STARTING AND OPERATING

The electrical connections are all complete to the vehicle but you must mate the harness to a trailer connector. Refer to the following illustrations.

4 - Pin Connector

7 - Pin Connector

Cooling System Tips—Trailer Towing To reduce potential for engine and transmission over- heating, take the following actions: † City Driving When stopped for short periods of time, put transmission in neutral and increase engine idle speed.

† Highway Driving Reduce speed. † Air Conditioning Turn off temporarily. † See Cooling System Operating information in the Maintenance section of this manual for more informa- tion.

To reduce potential for automatic transmission overheat- ing, turn the “TOW/HAUL” feature on when driving in hilly areas or shift the transmission to Drive position 2 on more severe grades. Move the shift lever to the next lower position to eliminate excessive transmission shift- ing. This action will also reduce the possibility of trans- mission overheating and provide better engine braking.

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SNOWPLOW

Dodge Durango Models

NOTE: Do not use Dodge Durango Models for snow- plow applications.

WARNING!

Snowplows, winches, and other aftermarket equip- ment should not be added to the front end or your vehicle. The airbag crash sensors may be affected by the change in the front end structure. The airbags could deploy unexpectedly or could fail to deploy during a collision resulting in serious injury or death.

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CAUTION!

RECREATIONAL TOWING (BEHIND MOTORHOME, ETC.) OF 4X4 VEHICLES

Using this vehicle for snowplow applications can cause damage to the vehicle.

WARNING!

WARNING!

Attaching a snowplow to this vehicle could ad- versely affect performance of the airbag system in an accident. Do not expect that the airbag will perform as described earlier in this manual

You or others could be injured if you leave the vehicle unattended with the transfer case in the Neutral (N) position without first fully engaging the parking brake. The transfer case Neutral (N) position disengages both the front and rear driveshafts from the powertrain and will allow the vehicle to move despite the transmission position. The parking brake should always be applied when the driver is not in the vehicle.

STARTING AND OPERATING 263

CAUTION!

CAUTION!

Internal damage to the transfer case will occur if a front or rear wheel lift is used when recreational towing.

It is necessary to follow these steps to be certain that the transfer case is fully in Neutral (N) before recreational towing to prevent damage to internal parts.

NOTE: The NV 244 Generation II transfer case must be shifted into Neutral (N) for recreational towing. The Neutral (N) selection button is located on the lower left hand corner of the 4WD Control Switch. Shifts into and out of transfer case Neutral (N) can take place with the selector switch in any mode position. Shifting into Neutral (N)

Use the following procedure to prepare your vehicle for recreational towing.

1. Bring vehicle to a complete stop. 2. Shut engine OFF. 3. Place ignition key in the ON position. 4. Depress brake pedal. 5. Shift automatic transmission to Neutral (N). 6. Using the point of a ballpoint pen or similar object, depress the recessed transfer case Neutral (N) button for 4 seconds.

264 STARTING AND OPERATING

7. After shift is completed and the Neutral (N) light comes on release Neutral (N) button. 8. Start engine. 9. Shift automatic transmission into Reverse (R). 10. Release brake pedal for five seconds and ensure that there is no vehicle movement. 11. Repeat steps 9 and 10 with the transmission in Drive (D). 12. Shut engine OFF and place ignition key to the unlocked OFF position. 13. Shift automatic transmission into Park (P). 14. Attach vehicle to tow vehicle with tow bar.

Items 1 through 5 are requirements that must be NOTE: met prior to depressing the Neutral (N) selection button, and must continue to be met until the 4 seconds elaspes and the shift has been completed. If any of these requirements (with the exception of 3 - Key ON) are not met prior to depressing the Neutral (N) button or are no longer met during the 4 second timer, then the Neutral (N) indicator light will flash continu- ously until all requirements are met or until the Neutral (N) button is released. NOTE: The ignition key must be ON for a shift to take place and for the position indicator lights to be operable. If the key is not ON, the shift will not take place and no position indicator lights will be on or flashing.

CAUTION!

Damage to the transmission may occur if the trans- mission is shifted into Park (P) with the transfer case in Neutral (N) and the engine RUNNING. With the transfer case in Neutral (N) ensure that the engine is OFF prior to shifting the transmission into Park (P)

Shifting OUT of Neutral (N)

Use the following procedure to prepare your vehicle for normal usage. 1. Bring vehicle to a complete stop. 2. Shut engine OFF. 3. Place ignition key in the ON position. 4. Depress brake pedal. 5. Shift automatic transmission to Neutral (N).

STARTING AND OPERATING 265

6. Using the point of a ballpoint pen or similar object, depress the recessed transfer case Neutral (N) button for 1 second. 7. After the Neutral (N) indicator light turns off release the Neutral (N) button. 8. After the Neutral (N) button has been released the transfer case will shift to the position identified by the selector switch. 9. Shift automatic transmission into Drive (D). Items 1 through 5 are requirements that must be NOTE: met prior to depressing the Neutral (N) selection button, and must continue to be met until 1 second elapses and the shift has been completed. If any of these requirements are not met prior to depress- ing the Neutral (N) button or are no longer met during

266 STARTING AND OPERATING

the 1 second time, then all of the position indicator lights will flash continuously until all requirements are met or until the Neutral (N) button is released. NOTE: The ignition key must be ON for a shift to take place and for the position indicator lights to be operable. If the key is not On, the shift will not take place and no position indicator lights will be on or flashing. NOTE: Flashing neutral (N) position indicator light indicates that shift requirements have not been met.

CAUTION!

† Do not use a bumper mounted clamp-on tow bar on your vehicle. The bumper face bar will be damaged. † Do not disconnect the rear driveshaft because fluid will leak from the transfer case and damage internal parts.

STARTING AND OPERATING 267

EQUIPMENT IDENTIFICATION PLATE The equipment Identification Plate is located on the hood inner surface. The following information about your vehicle is dis- played on this plate: Model, Wheelbase, Vehicle Identifi- cation Number, Truck Order Number, and code numbers with descriptions of all production and special equip- ment on the truck as shipped from the factory. NOTE: Always refer to the Equipment Identification Plate When Ordering Parts.

TRACTION When driving on wet or slushy roads, it is possible for a wedge of water to build up between the tire and road surface. This is known as hydroplaning and may cause partial or complete loss of vehicle control and stopping ability. To reduce this possibility, the following precau- tions should be observed: 1. Slow down during rainstorms or when roads are slushy. 2. Slow down if road has standing water or puddles. 3. Replace tires when tread wear indicators first become visible. 4. Keep tires properly inflated. 5. Maintain sufficient distance between your vehicle and the car in front to avoid a collision in a sudden stop.

WHAT TO DO IN EMERGENCIES

CONTENTS

m Hazard Warning Flasher . . . . . . . . . . . . . . . . . . 270
m Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 270
m Changing A Flat Tire . . . . . . . . . . . . . . . . . . . . 272
N Jack Location . . . . . . . . . . . . . . . . . . . . . . . . 272
N Removing The Spare Tire . . . . . . . . . . . . . . . . 273

N Tire Changing Procedure . . . . . . . . . . . . . . . . 275
m Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . 280
m Towing A Disabled Vehicle . . . . . . . . . . . . . . . . 282
N Four-Wheel Drive Vehicles . . . . . . . . . . . . . . . 282
N Two-Wheel Drive Vehicles . . . . . . . . . . . . . . . 282

270 WHAT TO DO IN EMERGENCIES

HAZARD WARNING FLASHER The flasher switch is on the top of the steering column, just behind the steering wheel. Press the flasher switch and all front and rear directional signals will flash intermittently. Press the switch a second time to turn off the emergency flashers.

This is an emergency warning system and should not be used when the vehicle is in motion. Use it when your vehicle is disabled and is creating a safety hazard for other motorists. If it is necessary to leave the vehicle to go for service, the flasher system will continue to operate with the ignition key removed and the vehicle locked.

ADDING FUEL If using a portable fuel container, it should have a flexible nozzle long enough to reach past the restriction in the fuel filler tube.

WARNING!

WARNING!

WHAT TO DO IN EMERGENCIES 271

A fire may result if gasoline is pumped into a portable container that is in a vehicle or on a truck bed. You could be burned. Always place gas contain- ers on the ground while filling.

Remove the gas cap slowly to prevent fuel spray from the filler neck which may cause injury. The volatility of present gasolines may cause a build up of pressure in the fuel tank that may increase while you drive. This pressure can result in a spray of gasoline and/or vapors when you remove the cap from a hot vehicle. Removing the cap slowly allows the pressure to vent and prevents fuel spray. Never allow any lit smoking materials near the vehicles while removing the cap or filling the tank. Never add fuel to the vehicle when the engine is running.

272 WHAT TO DO IN EMERGENCIES

CHANGING A FLAT TIRE

Jack Location In the Durango, the scissor jack and tire changing tools are stowed under the second row seat. The jack is secured in place with a winged stud and a fixed stud. It is very important to secure the jack tightly in place by engaging the slot in the base to the fixed stud under the middle seat. The winged stud inserts through the eyelet in the end of the jack’s worm screw.

WARNING!

The jack is designed as a tool for changing tires only. The jack should not be used to lift the vehicle for service purposes, unless suitable supports are placed under the vehicle as a safety measure. The vehicle should be jacked on a firm level surface only. Avoid ice or slippery areas.

WHAT TO DO IN EMERGENCIES 273

Removing The Spare Tire The spare tire on the Dodge Durango is located under- neath the vehicle in the rear.

274 WHAT TO DO IN EMERGENCIES

Remove the spare tire before attempting to jack the truck. 1. Remove the rubber plug from the floor in the cargo area.

3. Turn the wrench counterclockwise to lower the spare tire. Continue to turn the wrench until the spare tire can be pulled out from under the vehicle. It is recommended that you stow the flat or spare to avoid tangling the loose cable.

CAUTION!

The winch mechanism is designed for use with the jack extension tube only. Use of an air wrench or other power tools is not recommended and can damage the winch.

2. Engage the jack wrench extension to the spare tire winch through the hole in the floor.

Tire Changing Procedure

WARNING!

Getting under a jacked-up vehicle is dangerous. The vehicle could slip off the jack and fall on you. You could be crushed. Never get any part of your body under a vehicle that is on a jack. Never start or run the engine while the vehicle is on a jack. If you need to get under a raised vehicle, take it to a service center where it can be raised on a lift.

Do not raise this vehicle using a bumper jack. The scissor jack is designed as a tool for changing tires on this vehicle only. It is not recommended that the jack be used for service purposes or to lift more than one wheel at a time.

WHAT TO DO IN EMERGENCIES 275

Preparations Park the vehicle on a firm level surface, avoiding ice or slippery areas. Set the parking brake and place the gear selector in PARK (automatic transmission). On Four Wheel Drive vehicles, shift the transfer case to the “4L” position.

WARNING!

Do not attempt to change a tire on the side of the vehicle close to moving traffic. Pull far enough off the road to avoid the danger of being hit when operating the jack or changing the wheel. † Turn on the Hazard Warning Flasher.

276 WHAT TO DO IN EMERGENCIES

† Block both the front and rear of the wheel diagonally oppo- site the jacking position. For example, front wheel is being changed, block the left rear wheel. † Passengers should not remain in the vehicle when the

the right

if

vehicle is being jacked.

4. When changing a front wheel, place the jack under the frame rail behind the wheel. Locate the jack as far forward as possible on the straight part of the frame (prior to inboard transition. Operate the jack using the jack drive tube and the wheel wrench - the tube exten- sion, may be used but is not required.

Instructions 1. Remove the spare wheel, jack, and tools from storage. 2. Remove wheel center cap using the spade end of the wheel wrench. 3. Using the wheel wrench, loosen, but do not remove, the wheel nuts by turning them counterclockwise one turn while the wheel is still on the ground.

Front Jacking Location

When changing a rear wheel, assemble the jack drive tube to the jack and connect the drive tube to the extension tube. Place the jack under the axle as close to the tire as posssible with the drive tubes extending to the rear. Connect the jack tube extension and wheel wrench.

WHAT TO DO IN EMERGENCIES 277

Rear Right Jacking Location

Before raising the wheel off the ground, make sure that the jack will not damage surrounding truck parts and adjust the jack position as required. 5. By rotating the wheel wrench clockwise, raise the vehicle until the wheel just clears the surface.

Rear Left Jacking Location

278 WHAT TO DO IN EMERGENCIES

WARNING!

WARNING!

Raising the vehicle higher than necessary can make the vehicle unstable and cause an accident. It could slip off the jack and hurt someone near it. Raise the vehicle only enough to remove the tire.

A loose tire or jack thrown forward in a collision or hard stop could injure someone in the vehicle. Always stow the jack, tools and the extra tire and wheel in the places provided.

6. Remove the wheel nuts and pull the wheel off. Install the spare wheel and wheel nuts with the cone shaped end of the nuts toward the wheel. Lightly tighten the nuts. To avoid risk of forcing the vehicle off the jack, do not fully tighten the nuts until the vehicle has been lowered. NOTE: Do not oil wheel studs. For chrome wheels, do not substitute with chrome plated wheel nuts. 7. Using the wheel wrench, finish tightening the nuts in a crisscross pattern. Correct nut tightness is 85-115 ft. lbs. (115-155 N·m) torque. If in doubt about the correct tightness, have them checked with a torque wrench by your dealer or at a service station.

8. Install wheel center cap and remove wheel blocks. Do not install chrome or aluminum wheel center caps on the spare wheel. This may result in cap damage. 9. Lower the jack to its fully closed position. Stow the replaced tire, jack, and tools as previously described. 10. Adjust the tire pressure when possible. NOTE: Do not oil wheel studs. For chrome wheels, do not substitute with chrome plated wheel nuts.

WHAT TO DO IN EMERGENCIES 279

To Stow The Flat Or Spare Turn the wheel so that the valve stem is down. Slide the wheel retainer through the center of the wheel and position it properly across the wheel opening. For convenience in checking the spare tire inflation, stow with the valve stem toward the rear of the vehicle. Rotate the winch mechanism until the wheel is drawn into place against the underside of the vehicle. Continue to rotate until you feel the winch mechanism slip or click 2 times. It cannot be overtightened. Push against the tire several times to be sure it is firmly in place.

WARNING!

raised.

Carefully follow these tire changing warnings to help prevent personal injury or damage to your vehicle: † Always park on a firm, level surface as far from the edge of the roadway as possible before raising the vehicle. † Block the wheel diagonally opposite the wheel to be † Apply the parking brake firmly before jacking. † Never start the engine with the vehicle on a jack. † Do not let anyone sit in the vehicle when it is on a † Do not get under the vehicle when it is on a jack. † Only use the jack in the positions indicated. † If working on or near a roadway, be extremely † To assure that spare tires, flat or inflated are securely stowed, spares must be stowed with the value stem facing the ground.

careful of motor traffic.

jack.

280 WHAT TO DO IN EMERGENCIES

JUMP STARTING

WARNING!

† Battery fluid is a corrosive acid solution; do not allow battery fluid to contact eyes, skin or cloth- ing. Don’t lean over battery when attaching clamps or allow the clamps to touch each other. If acid splashes in eyes or on skin, flush the con- taminated area immediately with large quantities of water. † A battery generates hydrogen gas which is flam- mable and explosive. Keep flame or spark away from the vent holes. Do not use a booster battery or any other booster source with an output that exceeds 12 volts.

Check the Battery Test Indicator (if equipped). If a light or bright colored dot is visible in the indicator (if equipped), DO NOT jump-start the battery. If the indicator (if equipped) is dark or shows a green dot, proceed as follows: 1. Wear eye protection and remove all metal jewelry such as watch bands or bracelets which might make an unintended electrical contact. 2. Park the booster vehicle within cable reach but with- out letting the vehicles touch. Set the parking brake, place the automatic transmission in PARK and turn the ignition OFF on both vehicles. 3. Turn OFF heater, radio and all unnecessary electrical loads.

4. Connect one end of a jumper cable to the positive terminal of the booster battery. Connect the other end of the same cable to the positive terminal of the discharged battery.

WARNING!

Do not permit vehicles to touch each other as this could establish a ground connection and personal injury could result.

5. Connect the other cable, first to the negative terminal of the booster battery and then to the engine of the vehicle with the discharged battery. Make sure you have a good contact on the engine.

WHAT TO DO IN EMERGENCIES 281

WARNING!

Do not connect the cable to the negative post of the discharge battery. The resulting electrical spark could cause the battery to explode. During cold weather when temperatures are below freezing point, electrolyte in a discharged battery may freeze. Do not attempt jump starting because the battery could rupture or explode. The battery temperature must be brought up above freezing point before attempting jump start.

6. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery. 7. When removing the jumper cables, reverse the above sequence exactly. Be careful of the moving belts and fan.

282 WHAT TO DO IN EMERGENCIES

WARNING!

Any procedure other than above could result in: 1. Personal injury caused by electrolyte squirting out the battery vent; 2. Personal injury or property damage due to battery explosion; 3. Damage to charging system of booster vehicle or of immobilized vehicle.

TOWING A DISABLED VEHICLE Proper towing or lifting equipment is required to prevent damage to your vehicle. Use of safety chains is recom- mended. Attach towing device to main structural mem- bers of the vehicle — not to bumpers or associated brackets. State and local laws applying to vehicles under tow must be observed.

Four-Wheel Drive Vehicles The manufacturer recommends towing with all wheels off the ground. Acceptable methods are to tow the vehicle on a flatbed or with one end of the vehicle raised and the opposite end on a towing dolly. Two-Wheel Drive Vehicles

Provided that the transmission is operable, tow with the transmission in Neutral and the ignition key in the OFF position along with the front wheels raised and the rear wheels on the ground. The speed must not exceed 30
mph (50 km/h) and the distance must not exceed 15
miles (25 km). If the vehicle is to be towed more than 15 miles (25 km ), it must be towed on a flatbed, or with the rear wheels raised and the front wheels on the ground, or with the front end raised and the rear wheels on a towing dolly.

MAINTAINING YOUR VEHICLE

CONTENTS

m Engine Compartment 3.7L V6 . . . . . . . . . . . . . . 286
m Engine Compartment 4.7L V-8 . . . . . . . . . . . . . . 287
m Engine Compartment 5.7L HEMI V-8 . . . . . . . . . 288
m Onboard Diagnostic System — OBD II . . . . . . . . 289
m Emissions Inspection And Maintenance

Programs

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
m Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 291
m Dealer Service . . . . . . . . . . . . . . . . . . . . . . . . . 291
m Maintenance Procedures . . . . . . . . . . . . . . . . . . 292

N Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 292
N Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . 297
N Drive Belts — Check Condition And Tension . . 297
N Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . 297
N Ignition Cables . . . . . . . . . . . . . . . . . . . . . . . 298
N Engine Air Cleaner Filter . . . . . . . . . . . . . . . . 298
N Engine Fuel Filter . . . . . . . . . . . . . . . . . . . . . 299
N Catalytic Converter . . . . . . . . . . . . . . . . . . . . 299
N Maintenance-Free Battery . . . . . . . . . . . . . . . . 300

284 MAINTAINING YOUR VEHICLE

N Air Conditioner Maintenance . . . . . . . . . . . . . 302
N Power Steering — Fluid Check . . . . . . . . . . . . 303
N Front Suspension Ball Joints . . . . . . . . . . . . . . 304
N Drive Shaft Constant Velocity Joints . . . . . . . . 304
N Body Lubrication . . . . . . . . . . . . . . . . . . . . . 304
N Windshield Wiper Blades . . . . . . . . . . . . . . . . 305
N Windshield Washers . . . . . . . . . . . . . . . . . . . 305
N Exhaust System . . . . . . . . . . . . . . . . . . . . . . 306
N Cooling System . . . . . . . . . . . . . . . . . . . . . . . 306
N Emission Related Components . . . . . . . . . . . . 311
N Brake System . . . . . . . . . . . . . . . . . . . . . . . . 313
N Automatic Transmission . . . . . . . . . . . . . . . . 315
N Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . 319

N Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
N Selection Of Lubricating Grease . . . . . . . . . . . 320
N Appearance Care And Protection From

Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
m Power Distribution Center (Fuse/Relay) . . . . . . . 325
m Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
m Vehicle Storage . . . . . . . . . . . . . . . . . . . . . . . . 326
m Replacement Light Bulbs . . . . . . . . . . . . . . . . . 327
m Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . 327
. . . . . . . . . . 327

N Headlights/Parking/Turn Signal N Rear Side Marker, Tail Lights, Turn Signals And

Backup Lights — Replacement . . . . . . . . . . . . 329
N License Lights . . . . . . . . . . . . . . . . . . . . . . . . 333
N Center High-Mounted Stoplight . . . . . . . . . . . 334

N Fog Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 335
. . . . . . . . . . . . . . . . . . . 335

m Fluids And Capacities m Recommended Fluids, Lubricants And Genuine

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

MAINTAINING YOUR VEHICLE 285

N Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
N Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

286 MAINTAINING YOUR VEHICLE

ENGINE COMPARTMENT 3.7L V6

ENGINE COMPARTMENT 4.7L V-8

MAINTAINING YOUR VEHICLE 287

288 MAINTAINING YOUR VEHICLE

ENGINE COMPARTMENT 5.7L HEMI V-8

ONBOARD DIAGNOSTIC SYSTEM — OBD II Your vehicle is equipped with a sophisticated onboard diagnostic system called OBD II. This system monitors the performance of the emissions, engine, and automatic transmission control systems. When these systems are operating properly, your vehicle will provide excellent performance and fuel economy, as well as engine emis- sions well within current government regulations. If any of these systems require service, the OBD II system will turn on the “Malfunction Indicator Light.” It will also store diagnostic codes and other information to assist your service technician in making repairs. Al- though your vehicle will usually be drivable and not need towing, see your dealer for service as soon as possible.

MAINTAINING YOUR VEHICLE 289

CAUTION!

† Prolonged driving with the “Malfunction Indica- tor Light” on could cause further damage to the emission control system. It could also affect fuel economy and driveability. The vehicle must be serviced before any emissions tests can be per- formed. † If the “Malfunction Indicator Light” is flashing while the engine is running, severe catalytic con- verter damage and power loss will soon occur. Immediate service is required.

290 MAINTAINING YOUR VEHICLE

EMISSIONS INSPECTION AND MAINTENANCE PROGRAMS In some localities, it may be a legal requirement to pass an inspection of your vehicle’s emissions control system. Failure to pass could prevent vehicle registration.

For states which have an I/M (Inspection and Maintenance) requirement, this check verifies the following: the MIL (Malfunction Indicator Lamp) is functioning and is not on when the engine is running, and that the OBD (On Board Diagnostic) system is ready for testing. Normally, the OBD system will be ready. The OBD system may not be ready if your vehicle was recently serviced, if you recently had a dead battery, or a battery replacement. If the OBD system should be determined not ready for the I/M test, your vehicle may fail the test.

Your vehicle has a simple ignition key actuated test which you can use prior to going to the test station. To check if your vehicle’s OBD system is ready, you must do the following: 1. Insert your ignition key into the ignition switch. 2. Turn the ignition to the ON position, but do not crank or start the engine. 3. If you crank or start the engine, you will have to start this test over. 4. As soon as you turn your key to the ON position, you will see your MIL symbol come on as part of a normal bulb check. 5. Approximately 15 seconds later, one of two things will happen:

a. The MIL light will blink for approximately 5 sec- onds and then remain on until the first engine crank or

the key is turned off. This means that your vehicle’s OBD system is not ready and you should not proceed to the I/M station. b. The MIL light will remain fully illuminated until the first engine crank or the key is turned off. This means that your vehicle’s OBD system is ready and you can proceed to the I/M station.

If your OBD system is not ready, you should see your dealer or repair facility. If your vehicle was recently serviced or had a battery failure or replacement, you may need to do nothing more than drive your vehicle as you normally would in order for your OBD system to update. A recheck with the above test routine may then indicate that the system is now ready. Regardless of whether your vehicle’s OBD system is ready or not ready, if the MIL symbol is illuminated during normal vehicle operation, you should have your

MAINTAINING YOUR VEHICLE 291

vehicle serviced before going to the I/M station. The I/M station can fail your vehicle because the MIL symbol is on with the engine running.

REPLACEMENT PARTS Use of genuine Mopart parts for normal/scheduled maintenance and repairs is highly recommended to in- sure the designed performance. Damage or failures caused by the use of non-Mopart parts for maintenance and repairs will not be covered by the manufacturer’s warranty.

DEALER SERVICE Your dealer has the qualified service personnel, special tools and equipment to perform all service operations in an expert manner. Service manuals are available which include detailed service information for your vehicle. Refer to these manuals before attempting any procedure yourself.

292 MAINTAINING YOUR VEHICLE

NOTE: systems can result against you.

Intentional tampering with emissions control in civil penalties being assessed

WARNING!

You can be badly injured working on or around a motor vehicle. Do only that service work for which you have the knowledge and the proper equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent mechanic.

MAINTENANCE PROCEDURES The pages that follow contain the required maintenance services determined by the engineers who designed your vehicle. Besides the maintenance items for which there are fixed maintenance intervals, there are other items that should operate satisfactorily without periodic maintenance. However, if a malfunction of these items does occur, it could adversely affect the engine or vehicle performance. These items should be inspected if a malfunction is observed or suspected. Engine Oil

Checking Engine Oil Level To assure proper lubrication of your vehicle’s engine, the engine oil must be maintained at the correct level. The best time to check the engine oil level is about 5 minutes after a fully warmed up engine is shut off or before starting the engine after it has sat overnight.

1. Position the vehicle on a level surface. 2. Turn Off the engine and allow approximately 5 min- utes for the oil to settle to the bottom of the crankcase. 3. Remove the engine oil level indicator (dipstick). 4. Wipe the engine oil level indicator (dipstick) clean. 5. Install the engine oil level indicator (dipstick) and make sure it is seated in the tube. 6. Remove the engine oil level indicator (dipstick), keep- ing the handle above the tip, and read the oil level on the engine oil level indicator (dipstick). 7. Add oil only if the level is below the “SAFE” range (at or below the “ADD” mark) on the engine oil level indicator (dipstick). Adding one quart of oil when the reading is at the ADD mark will result in a SAFE reading on these engines.

MAINTAINING YOUR VEHICLE 293

CAUTION!

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

294 MAINTAINING YOUR VEHICLE

Frequency Of Oil Change Road conditions and your style of driving affect the interval at which your oil should be changed. Check the following to determine if ANY apply to you: † Day or night temperatures are below 32°F (0°C). † Stop and Go driving. † Extensive engine idling. † Driving in dusty conditions. † Short trips of less than 10 miles (16.2 km). † More than 50% of your driving is at sustained high † Trailer towing, Taxi, Police or delivery service (com- † Off-Road or desert operation.

speeds during hot weather, above 90°F (32°C).

mercial service).

† If equipped for and operating with E-85 (ethanol)

fuel.

If ANY of these apply to you then change your NOTE: engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first and follow schedule “B” of the 9Maintenance 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. 4x4 Models, If Used Primarily For Off-Road Operation Every 50 hours of use. Dusty Conditions Driving through dust-laden air increases the problems of keeping abrasive materials out of the engine. Under these conditions, special attention should be given to the engine air cleaner and the crankcase inlet air cleaner. The crankcase ventilation system should also be checked

periodically. Make sure that these units are always clean. This will tend to reduce to a minimum the amount of abrasive material that may enter the engine. Engine Oil Selection For best performance and maximum protection under all types of operating conditions, the manufacture only recommends engine oils that are API certified and meet the requirements of DaimlerChrysler Material Standard MS-6395. Use Mopar or an equivalent oil meeting the specification MS-6395. Engine Oil Identification (API) Symbol There is a symbol to aid you in selecting the proper engine oil.

MAINTAINING YOUR VEHICLE 295

This symbol means that the oil has been certified by the American Petroleum Institute (API). The manufacture only recommends API Certified engine oils that meet of DaimlerChrysler Material Stan- dard MS-6395. Use Mopar or an equivalent oil meeting the specifi-

requirements

the

cation MS-6395. Engine Oil Viscosity Chart The proper SAE viscosity grade of engine oil should be selected based on the following recommendation and be within the operating temperature shown in the recom- mended SAE viscosity chart. † SAE 5W-30 is the preferred oil for Dodge Trucks with 3.7L/4.7L/5.7L engines. Synthetic engine oils may be

296 MAINTAINING YOUR VEHICLE

used provided that the oil quality requirements de- scribed above are met and the recommended mainte- nance intervals for oil and filter changes are followed. † Lubricants which do not have both the engine oil certification mark or current service symbol and the correct viscosity grade number should not be used.

Preferred Viscosity for 3.7L/4.7L/5.7L Engines

Synthetic Engine Oils There are a number of engine oils being promoted as either synthetic or semi-synthetic. If you chose to use such a product, use only those oils that meet the Ameri- can Petroleum Institute (API) and SAE viscosity stan- dard. Follow the service schedule that describes your driving type. Materials Added to Engine Oils The manufacture strongly recommends against the addi- tion of any additives (other than leak detection dyes) to the engine oil. Engine oil is an engineered product and it’s performance may be impaired by supplemental ad- ditives. Disposing of Used Engine Oil And Oil Filters Care should be taken in disposing of used engine oil and oil filters from your vehicle. Used oil and oil filters, indiscriminately discarded, can present a problem to the environment. Contact your dealer, service station, or

governmental agency for advice on how and where used oil and oil filters can be safely discarded in your area. Engine Oil Filter The engine oil filter should be replaced at every engine oil change. Engine Oil Filter Selection The manufacturer’s engines have a full-flow type oil filter. Use a filter of this type for replacement. The quality of replacement filters varies considerably. Only high quality filters should be used to assure most efficient service. Mopart Engine Oil Filters are a high quality oil filter and are recommended. Drive Belts — Check Condition and Tension At the mileage indicated in the maintenance schedule, all belts should be checked for condition and proper tension. Improper belt tension can cause belt slippage and failure.

MAINTAINING YOUR VEHICLE 297

Belts should be inspected for evidence of cuts, cracks, or glazing, and replaced if there is indication of damage which could result in belt failure. If adjustment is re- quired, see your authorized dealer for service. Low generator belt tension can cause battery failure. A special tool is required to properly measure tension and to restore belt tension to factory specifications. Also check belt routing to make sure there is no interfer- ence between the belts and other engine components. Spark Plugs Spark plugs must fire properly to assure proper engine performance and emission control. The plugs installed in your vehicle should operate satisfactorily in normal service for the mileage indicated in the Maintenance Chart. New plugs should be installed at this mileage. The entire set should be replaced if there is any malfunction

298 MAINTAINING YOUR VEHICLE

due to a faulty spark plug. Check the Vehicle Emissions Control Information label for the proper type of spark plug for your vehicle.

CAUTION!

When replacing plugs, do not overtighten. You could damage them and cause them to leak.

Ignition Cables Replace the ignition cables (5.7L engines only) at the mileage interval shown in the maintenance charts. Engine Air Cleaner Filter Under normal driving conditions, replace the air filter at the intervals shown on Schedule “A”. If, however, you

drive the vehicle frequently under dusty or severe con- ditions, the filter element should be inspected periodi- cally and replaced if necessary at the intervals shown on Schedule “B”.

WARNING!

The air cleaner can provide a measure of protection in the case of engine backfire. Do not remove the air cleaner unless such removal is necessary for repair or maintenance. Make sure that no one is near the engine compartment before starting the vehicle with the air cleaner removed. Failure to do so can result in serious personal injury.

Engine Fuel Filter A plugged fuel filter can cause stalling, limit the speed at which a vehicle can be driven or cause hard starting. Should an excessive amount of dirt accumulate in the fuel tank, frequent filter replacement may be necessary. Catalytic Converter The catalytic converter requires the use of unleaded fuel only. Leaded gasoline will destroy the effectiveness of the catalyst as an emission control device. Under normal operating conditions, the catalytic con- verter will not require maintenance. However, it is im- portant to keep the engine properly tuned to assure proper catalyst operation and prevent possible catalyst damage.

MAINTAINING YOUR VEHICLE 299

CAUTION!

Damage to the catalytic converter can result if your vehicle is not kept in proper operating condition. In the event of engine malfunction, particularly involv- ing engine misfire or other apparent loss of perfor- mance, have your vehicle serviced promptly. Contin- ued operation of your vehicle with a severe malfunction could cause the converter to overheat, resulting in possible damage to the converter and the vehicle.

NOTE: systems can result against you.

Intentional tampering with emissions control in civil penalties being assessed

300 MAINTAINING YOUR VEHICLE

WARNING!

A hot exhaust system can start a fire if you park over materials that can burn. Such materials might be grass or leaves coming into contact with your ex- haust system. Do not park or operate your vehicle in areas where your exhaust system can contact any- thing that can burn.

In unusual situations involving grossly malfunctioning engine operation, a scorching odor may indicate severe and abnormal catalyst overheating. If this occurs, the vehicle should be stopped, the engine shut off and the vehicle allowed to cool. Thereafter, service, including a tune-up to manufacturer’s specifications, should be ob- tained immediately.

To minimize the possibility of catalyst damage: † Do not shut off the engine or interrupt the ignition when the transmission is in gear and the vehicle is in motion. † Do not try to start engine by pushing or towing the † Do not idle the engine with any spark plug wires disconnected or removed, such as when diagnostic testing, or for prolonged periods during very rough idling or malfunctioning operating conditions.

vehicle.

Maintenance-Free Battery All Dodge trucks are equipped with maintenance-free batteries. You will never have to add water, nor is periodic maintenance required.

WARNING!

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

MAINTAINING YOUR VEHICLE 301

To determine the battery charge, check the battery test indicator (if equipped) on top of the battery. Refer to the illustration.

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 the vehicle, disconnect both vehicle battery cables be- fore connecting the charger to battery. Do not use a “fast charger” to provide starting voltage.

302 MAINTAINING YOUR VEHICLE

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 303

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.

304 MAINTAINING YOUR VEHICLE

Front Suspension Ball Joints The ball joints and seals should be inspected whenever the vehicle is serviced for other reasons. Damaged seals should be replaced to prevent leakage or contamination of the grease. Drive Shaft Constant Velocity Joints All four wheel drive models are equipped with four constant velocity joints. Periodic lubrication of these joints is not required. However, the joint boot should be inspected for external leakage or damage periodically. If external leakage or damage is evident, the joint boot and grease should be replaced immediately. Continued op- eration could result in failure of the joint due to water and dirt contamination of the grease. This would require complete replacement of the joint assembly. Refer to the Service Manual for the detailed replacement procedure.

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 should be checked for fluid level at regular intervals. When freezing weather is anticipated, flush out the water in the reservoir by operating the

MAINTAINING YOUR VEHICLE 305

system. Fill the reservoir with windshield washer anti- freeze (not radiator antifreeze), and operate the system for a few seconds to flush out the residual water. 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

306 MAINTAINING YOUR VEHICLE

freezing the fluid on the cold windshield. Mopart All Weather Windshield Washer Solution used with water as directed on the container, aids cleaning action, reduces 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.

Cooling System

Inspection Coolant protection checks should be made at every 12
months (before 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. Check face of radiator for any accumulation of

bugs, leaves, etc. If dirty, clean the radiator core by gently spraying water from a garden hose at the back of the core. Check the coolant bottle tubing for condition and tight- ness of connection at coolant bottle and radiator. Inspect the entire system for leaks. With the engine at normal operating temperature (but not running), check the coolant pressure cap for proper vacuum sealing by draining a small amount of coolant from the radiator drain cock. If the cap is sealing prop- erly, the coolant will begin to drain from the coolant bottle. Do not remove the pressure cap when the cooling system is hot.

MAINTAINING YOUR VEHICLE 307

WARNING!

You or others can be badly burned by hot coolant or steam from your radiator. If you see or hear steam coming from under the hood don’t open the hood until the radiator has had time to cool. If you open the hood and see steam or hot coolant escaping from the radiator, don’t touch anything. Get away quickly. Never try to open a pressure cap when the radiator is hot.

Cooling System Maintenance At the intervals shown in the Maintenance Schedules section of this manual, the system should be drained, flushed and refilled. See your authorized dealer for proper cooling system maintenance.

308 MAINTAINING YOUR VEHICLE

Cooling System — Drain, Flush And Refill If the solution is dirty and contains a considerable amount of sediment, it should be cleaned and flushed. See your authorized dealer for proper draining, flushing and refilling of your vehicle’s cooling system. 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.

Recommended Engine Coolant This vehicle has been factory filled with an Ethylene Glycol based engine coolant with long life corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology). Follow the “Maintenance Schedule” for the recommended coolant change intervals. Refer to Recom- mended Fluids, Lubricants and Genuine Parts for correct fluid type.

CAUTION!

Mixing of coolants other than specified (non- HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. If a non-HOAT cool- ant is introduced 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.

MAINTAINING YOUR VEHICLE 309

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 -37°F (-38°C) are antici- pated. Use only high purity water such as distilled or deionized water when mixing the water/antifreeze solution. The use of lower quality water will reduce the amount of corrosion protection in the engine cooling system. It is the owner’s responsibility to maintain the NOTE: proper level of protection against freezing according to the temperatures occurring in the area where the vehicle is operated.

310 MAINTAINING YOUR VEHICLE

WARNING!

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.

The warning words “DO NOT OPEN HOT” on the coolant pressure cap are a safety precaution. Heat causes pressure to build up in the cooling system. To prevent scalding or injury, do not remove the pres- sure cap when the system is hot or under pressure.

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 coolant bottle. The pressure cap should be inspected and cleaned if there is any accumulation of foreign material on the sealing surfaces.

Coolant Level The coolant bottle system provides a quick visual method for determining that the coolant level is adequate. With the engine idling, and warmed to normal operating temperature, remove the cap from the bottle, remove the dipstick and wipe the excess coolant from it. Reinsert the dipstick and remove. Observe the dipstick checking the holes along the stem for coolant. Check the coolant level whenever the hood is raised.

The radiator normally remains completely full, so there is no need to remove the pressure cap except checking coolant freeze point or replacement with new antifreeze coolant. Your service attendant should be advised of this. When additional coolant is needed to maintain the proper level, it should be added to the coolant bottle. Do not overfill. Points To Remember A. Do not overfill the coolant bottle. B. Check coolant freeze point in the radiator and in the coolant bottle. If antifreeze needs to be added, contents of coolant bottle also must be protected against freezing. C. If frequent coolant additions are required, or if the level in the coolant bottle does not drop when the engine cools, the cooling system should be pressure tested for leaks.

MAINTAINING YOUR VEHICLE 311

D. Maintain a minimum coolant concentration of 50% ethylene glycol. E. Make sure that the radiator and coolant bottle over- flow hoses are not kinked or obstructed. F. Keep the front of the radiator clean. If your vehicle is equipped with air conditioning, keep the front of the condenser clean also. G. The thermostat should not be changed for summer or winter operation. If replacement is ever necessary, install ONLY the correct type thermostat. Other designs may result in unsatisfactory cooling performance. Emission Related Components

Fuel System Hoses And Vapor/Vacuum Harnesses When the vehicle is serviced for scheduled maintenance, inspect surface of hoses and nylon tubing for evidence of heat and mechanical damage. Hard and brittle rubber, cracking, checking, tears, cuts, abrasions, and excessive

312 MAINTAINING YOUR VEHICLE

swelling suggest deterioration of the rubber. Particular attention should be given to examining hose surfaces nearest to high heat sources, such as the exhaust mani- fold. Insure nylon tubing in these areas has not melted or collapsed. Inspect all hose clamps and couplings to make sure they are secure and no leaks are present. NOTE: Fluids such as oil, power steering fluid, and brake fluid are used during assembly plant operations to ease the assembly of hoses to couplings. Therefore, oil wetness at the hose-coupling area is not necessarily an indication of leakage. Actual dripping of hot fluid when systems are under pressure (during vehicle operation), should be noted before hose is replaced based on leakage. You are urged to use only the manufacturer’s specified hoses and clamps, or their equivalent in material and

specification, in any fuel system servicing. It is manda- tory to replace all clamps that have been loosened or removed during service. Care should be taken in install- ing new clamps to insure they are properly torqued. Positive Crankcase Ventilation (PCV) Valve Proper operation of the crankcase ventilation system requires that the PCV valve be free of sticking or plug- ging because of deposits. Deposits can accumulate in the PCV valve and passage with increasing mileage. Have the PCV valve, hoses, and passages checked for proper operation at the valve is plugged or sticking, replace with a new valve – Do not attempt to clean the oil PCV valve! Check ventilating hose for indication of damage or plugging with deposits. Replace if necessary.

the intervals specified.

If

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Brake Master Cylinders The fluid level in the master cylinders should be checked whenever the vehicle is serviced, or immediately if the brake system warning light is on. If necessary, add fluid to bring level to the full mark on the side of the reservoir of the brake master cylinder. Be sure to clean the top of the master cylinder area before removing the cap. With disc brakes, fluid level can be expected to fall as the brake pads wear. Brake fluid level should be checked when pads are replaced. If the brake fluid level is abnormally low, check system for leaks. Refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type.

Brake System

Power Disc Brakes (Front) 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.

314 MAINTAINING YOUR VEHICLE

WARNING!

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

WARNING!

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

Brake Hoses Inspection should be performed whenever the brake