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Side window demisters direct air flow specifically to the window glass to help prevent interior fogging of the glass. They are located in the extreme outside upper edges of the instrument panel. The demisters also pro- vide extra air ducts for circulation. They are in operation whenever the Floor, Mix or Defrost modes are in use. To remove frost from the side windows, it is best to use the full defrost mode. NOTE: When you turn off the engine you may hear a hissing sound from under the hood for a short period of time. This is a normal condition that occurs if the air conditioning system has been on. It is not an indication of a problem with the air conditioning system.
UNDERSTANDING YOUR INSTRUMENT PANEL 233
Air Conditioning with Dual Zone Temperature Control — If Equipped With the Dual Zone Temperature Control System, each front seat occupant can independently control the tem- perature of air coming from the outlets on their side of the vehicle.
Dual Zone Control Head
234 UNDERSTANDING YOUR INSTRUMENT PANEL
Air Conditioning and Heating Operation To turn on the Air Conditioning, set the fan control at any speed and press the snowflake button located on the control panel. Conditioned air will be directed through the outlets selected by the mode control. A light in the snowflake button shows that the air conditioning is on. Press the button a second time to turn the air condition- ing off. A/C Pushbutton
With the fan control in the ON posi- tion, pushing the A/C button turns on the air conditioning compressor. An indicator light on the button shows that the Air Conditioning compressor is on. Conditioned air is now directed through the mode outlets selected. Pushing the button a second time turns the compressor OFF.
Recirculation Pushbutton
Pushing the Recirculation button al- lows interior air to recirculate continu- ously in any position except defrost and defrost/floor mode for rapid cool down of interior. See “Fast Cooldown” later in this section.
the
Mode Control
The mode control allows you to choose from several patterns of air distribution.
NOTE: To improve your selection choices, the system allows you to operate at intermediate positions between
UNDERSTANDING YOUR INSTRUMENT PANEL 235
Mix
Outside air flows in equal proportions through the floor and defroster outlets.
Defrost
Outside air is primarily directed to the windshield through the defroster outlets located at the base of
the windshield and side window demist outlets. NOTE: The air conditioning compressor operates in both Mix and Defrost or a blend of these modes, even if the A/C button has not been pressed. This dehumidifies the air to help dry the windshield.
the major modes. These intermediate positions are iden- tified by the small dots and give an even blend of both modes. Panel
Outside air flows through the outlets located in the instrument panel. These outlets can be adjusted to
direct the airflow. Bi-Level
Air flows through the outlets located in the instru- ment panel and those located on the floor.
NOTE: There is a difference in temperature between the upper and lower outlets for added comfort. The warmer air goes to the floor outlets. This feature gives improved comfort during sunny but cool conditions. Heat
Outside air flows primarily through the floor out- lets located under the instrument panel.
236 UNDERSTANDING YOUR INSTRUMENT PANEL
Blower Control
The rotary knob on the left of the control panel is the blower control. Turn the knob clockwise to one of the four positions to obtain the blower speed you desire. To turn the blower off, turn the knob to the far left posi- tion.
Dual Zone Temperature Control
Dual Zone Temperature Control
Use this control to regulate the temperature of the air inside the passenger compartment. This is accomplished by having separate temperature control slides for both
the driver and front passenger. The blue area of the scale indicates cooler temperatures while the red area indicates warmer temperatures. Circulation The cab is designed with features to promote outside air circulation. There are grilles in the cab back panel. These are air exhausters that provide the means for regular exchange of cab air. Side window demisters direct air flow specifically to the window glass to help prevent interior fogging of the glass. They are located in the extreme outside upper edges of the instrument panel. The demisters also pro- vide extra air ducts for circulation. They are in operation whenever the Floor, Mix or Defrost modes are in use. NOTE: When you turn off the engine you may hear a hissing sound from under the hood for a short period of time. This is a normal condition that occurs if the air
UNDERSTANDING YOUR INSTRUMENT PANEL 237
conditioning system has been on. It is not an indication of a problem with the air conditioning system. Operating Tips
Fast Cooldown For a fast cooldown, turn the blower fan rotary knob to the extreme right position, turn the mode control to the panel fresh position, press the snowflake button to turn on the air conditioning, and drive with the windows open for the first few minutes. Once the hot air has been expelled, close the windows and press the Recirculation push-button. When a comfortable condition has been reached, choose a mode position and adjust the tempera- ture control slide and blower speed as necessary to maintain comfort. For high humidity conditions it may be necessary to remain in the Recirculation mode to maintain comfort.
238 UNDERSTANDING YOUR INSTRUMENT PANEL
Window Fogging Windows will fog on the inside when the humidity inside the vehicle is high. This often occurs in mild or cool temperatures when it’s rainy or humid. In most cases turning on the Air-conditioning (pressing the snowflake button) will clear the fog. Adjust the temperature control, air direction and blower speed to maintain comfort. As the temperature gets colder it may be necessary to direct air onto the windshield by using MIX Mode position on the control. Adjust the temperature control and blower speed to maintain comfort. Higher blower speeds will reduce fogging. Interior fogging on the windshield can be quickly removed by selecting the defrost mode. Regular cleaning of the inside of the windows with a non-filming cleaning solution (vinegar and water works very well) will help prevent contaminates (cigarette
smoke, perfumes, etc.) from sticking to the windows. Contaminates increase the rate of window fogging. Summer Operation Air conditioned vehicles must be protected with a high quality antifreeze coolant during summer to provide proper corrosion protection and to raise the boiling point of the coolant for protection against overheating. A 50 % concentration is recommended. Refer to Recommended Fluids and Genuine Parts for the proper coolant type. When using the air conditioner in extremely heavy traffic in hot weather especially when towing a trailer, addi- tional engine cooling may be required. If this situation is encountered, operate the transmission in a lower gear to increase engine RPM, coolant flow and fan speed. When stopped in heavy traffic, it may be necessary to shift into NEUTRAL and depress the accelerator slightly for fast idle operation to increase coolant flow and fan speed.
NOTE: On models equipped with Diesel engines, the idle speed will automatically increase to 1000 rpm at elevated coolant temperatures to improve engine cooling. Your air conditioning system is also equipped with an automatic recirculation system. When the system senses a heavy load or high heat conditions, it may use partial Recirculation A/C mode to provide additional comfort.
UNDERSTANDING YOUR INSTRUMENT PANEL 239
Winter Operation When operating the system during the winter months, make sure the air intake, located directly in front of the windshield, is free of ice, slush, snow, or other obstruc- tions.
240 UNDERSTANDING YOUR INSTRUMENT PANEL
Operating Tips Chart
STARTING AND OPERATING
CONTENTS
m Starting Procedures – Gas Engines . . . . . . . . . . . 245
N Manual Transmission . . . . . . . . . . . . . . . . . . 245
N Automatic Transmission . . . . . . . . . . . . . . . . 245
N Normal Starting . . . . . . . . . . . . . . . . . . . . . . 246
N If Engine Fails To Start . . . . . . . . . . . . . . . . . 246
N After Starting . . . . . . . . . . . . . . . . . . . . . . . . 248
m Engine Block Heater — If Equipped . . . . . . . . . 249
m Automatic Transmission . . . . . . . . . . . . . . . . . . 249
N Automatic Transmission With Overdrive . . . . . 250m Manual Transmission . . . . . . . . . . . . . . . . . . . . 255
N Manual Transmission — 6 Speed (G56) . . . . . . 256
N Recommended Vehicle Shift Speeds . . . . . . . . 257
N Downshifting – All Manual Transmissions . . . . 257
m Four-Wheel- Drive Operation . . . . . . . . . . . . . . 258N Manually Shifted Transfer Case Operating
Information/Precautions . . . . . . . . . . . . . . . . 258
N Shifting Procedure - Manually Shifted Transfer
Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
. . . . . . . . . . . . 262N Transfer Case Reminder Light
242 STARTING AND OPERATING
m Limited-Slip Differential — If Equipped . . . . . . . 262
m Driving On Slippery Surfaces . . . . . . . . . . . . . . 263
m Axle Locker System . . . . . . . . . . . . . . . . . . . . . 264
m Stabilizer/Sway Bar System . . . . . . . . . . . . . . . 267
m Power Wagon – Safe Off-Road Driving . . . . . . . 268N Off-Road Driving Tips And Vehicle
Characteristics
. . . . . . . . . . . . . . . . . . . . . . . 268
N Driving In Snow, Mud And Sand . . . . . . . . . . 273
N Crossing Obstacles (Rocks And Other HighPoints) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
N Hill Climbing . . . . . . . . . . . . . . . . . . . . . . . . 278
N Driving Through Water . . . . . . . . . . . . . . . . . 281
N Airing Down For Off-Road Driving . . . . . . . . 283
N Vehicle Recovery . . . . . . . . . . . . . . . . . . . . . . 284N After Driving Off-Road . . . . . . . . . . . . . . . . . 288
m Winch Usage – If Equipped . . . . . . . . . . . . . . . 289
N Things To Know Before Using Your Winch . . . 289
N Understanding The Features Of Your Winch . . 291
N Winch Accessories . . . . . . . . . . . . . . . . . . . . . 293
N Operating Your Winch . . . . . . . . . . . . . . . . . . 294
N Rigging Techniques . . . . . . . . . . . . . . . . . . . . 305
m Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . 308
m Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . 309
N Brake Noise . . . . . . . . . . . . . . . . . . . . . . . . . 310
N Four-Wheel Anti-Lock Brake System (ABS)—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . 310
m Power Steering . . . . . . . . . . . . . . . . . . . . . . . . 312m Multi Displacement System (MDS) - 5.7L Engine
Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
m Tire Safety Information . . . . . . . . . . . . . . . . . . . 313
N Tire Markings . . . . . . . . . . . . . . . . . . . . . . . . 313
N Tire Identification Number (TIN) . . . . . . . . . . 317
N Tire Loading And Tire Pressure . . . . . . . . . . . 318
m Tires — General Information . . . . . . . . . . . . . . . 322
N Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 322
N Tire Inflation Pressures . . . . . . . . . . . . . . . . . 323
N Radial-Ply Tires . . . . . . . . . . . . . . . . . . . . . . 326
N Compact Spare Tire — If Equipped . . . . . . . . . 327
N Limited Use Spare — If Equipped . . . . . . . . . 328
N Tire Spinning . . . . . . . . . . . . . . . . . . . . . . . . 328STARTING AND OPERATING 243
N Tread Wear Indicators . . . . . . . . . . . . . . . . . . 329
N Life Of Tire . . . . . . . . . . . . . . . . . . . . . . . . . 330
N Replacement Tires . . . . . . . . . . . . . . . . . . . . . 330
N Alignment And Balance . . . . . . . . . . . . . . . . . 331m Supplemental Tire Pressure Information – If
Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
m Tire Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
m Snow Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
m Tire Rotation Recommendations . . . . . . . . . . . . 334
m Fuel Requirements . . . . . . . . . . . . . . . . . . . . . . 335
N Reformulated Gasoline . . . . . . . . . . . . . . . . . 335
N Gasoline/Oxygenate Blends . . . . . . . . . . . . . . 336
N MMT In Gasoline . . . . . . . . . . . . . . . . . . . . . 336244 STARTING AND OPERATING
m Adding Fuel
N Adding Fuel (Gas Engines)
N Sulfur In Gasoline . . . . . . . . . . . . . . . . . . . . . 337
N Materials Added To Fuel . . . . . . . . . . . . . . . . 337
N Fuel System Cautions . . . . . . . . . . . . . . . . . . 338
N Carbon Monoxide Warnings . . . . . . . . . . . . . . 339
. . . . . . . . . . . . . . . . . . . . . . . . . . 339
. . . . . . . . . . . . . . 339
m Vehicle Loading . . . . . . . . . . . . . . . . . . . . . . . . 341
N Certification Label . . . . . . . . . . . . . . . . . . . . . 341
m Trailer Towing . . . . . . . . . . . . . . . . . . . . . . . . . 345
N Common Towing Definitions . . . . . . . . . . . . . 345
N Trailer Hitch Classification . . . . . . . . . . . . . . . 349
N Trailer Towing Weights (Maximum TrailerWeight Ratings)
. . . . . . . . . . . . . . . . . . . . . . 350
N Trailer And Tongue Weight . . . . . . . . . . . . . . 350
N Towing Requirements . . . . . . . . . . . . . . . . . . 351
N Towing Tips . . . . . . . . . . . . . . . . . . . . . . . . . 356
N Trailer Towing Mirrors — If Equipped . . . . . . 358
m Snowplow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
N Dodge Power Wagon Models . . . . . . . . . . . . . 359m Recreational Towing — 4–Wheel Drive Vehicles
(Behind Motorhome, Etc.) . . . . . . . . . . . . . . . . . 360
N Recreational Towing Procedure — ManualShift Transfer Case — If Equipped . . . . . . . . . 361
N Returning To Normal Operation — Manual
Shift Transfer Case . . . . . . . . . . . . . . . . . . . . 362
m Equipment Identification Plate . . . . . . . . . . . . . 363STARTING PROCEDURES – GAS ENGINES The starter should not be operated for more than 15- second intervals. Waiting a few seconds between such intervals will protect the starter from overheating.
WARNING!
Be sure to turn off the engine if you want to rest or sleep in your car. Accidents can be caused by inad- vertently moving the gear selection lever or by pressing the accelerator pedal. This may cause exces- sive heat in the exhaust system, resulting in over- heating and vehicle fire which may cause serious or fatal injuries.
STARTING AND OPERATING 245
WARNING!
Do not leave children or animals inside parked vehicles in hot weather. Interior heat build up may cause serious injury or death.
Manual Transmission Apply the parking brake, place the gearshift control lever in NEUTRAL and depress the clutch pedal to the floor before starting the vehicle. This vehicle is equipped with a clutch interlocking ignition system. It will not start unless the clutch is fully depressed. Automatic Transmission Start the engine with the selector lever in NEUTRAL or PARK position. Apply the brake before shifting to any driving range.
246 STARTING AND OPERATING
Normal Starting Normal starting of either a warm or cold engine is obtained without pumping or depressing the accelerator pedal. Turn the key to the START position and release when the engine starts. If the engine fails to start within 10 seconds, turn the key to the OFF position, wait 5
seconds, then repeat the starting procedure. NOTE: This vehicle is equipped with a transmission shift interlocking system. The brake pedal must be depressed to shift out of Park (P).Tip Start Feature — Automatic Transmission Only Do not press the accelerator. Turn the ignition key briefly to START position, and release it. The starter motor will continue to run, but will automatically disengage itself when the engine is running.
Ignition Key Positions
If Engine Fails To Start If the engine fails to start after you have followed the normal starting procedure, it may be flooded. Push the accelerator pedal all the way to the floor and hold it there while cranking the engine. This should clear any excess fuel in case the engine is flooded.
CAUTION!
To prevent damage to the starter, do not crank the engine for more than 15 seconds at a time. Wait 10 to 15 seconds before trying again.
WARNING!
Never pour fuel or other flammable liquids into the throttle body air inlet opening in an attempt to start the vehicle. This could result in a flash fire causing serious personal injury.
STARTING AND OPERATING 247
WARNING!
Do not attempt to push or tow your vehicle to get it started. Vehicles equipped with an automatic trans- mission cannot be started this way. Unburned fuel could enter the catalytic converter and once the engine has started, ignite and damage the converter and vehicle. If the vehicle has a discharged battery, booster cables may be used to obtain a start from a booster battery or the battery in another vehicle. This type of start can be dangerous if done improperly. See section 6 of this manual for the proper jump starting procedures and follow them carefully.
If the engine has been flooded, it may start to run, but not have enough power to continue running when the key is
248 STARTING AND OPERATING
released. If this occurs, continue cranking with the accel- erator pedal pushed all the way to the floor. Release the accelerator pedal and the key once the engine is running smoothly. If the engine shows no sign of starting after two 15
second periods of cranking with the accelerator pedal held to the floor, the normal starting procedure should be repeated. After Starting The idle speed is automatically controlled and will de- crease as the engine warms up.WARNING!
Be sure to turn off the engine if you want to rest or sleep in your car. Accidents can be caused by inad- vertently moving the gear selection lever or by pressing the accelerator pedal. This may cause exces- sive heat in the exhaust system, resulting in over- heating and vehicle fire which may cause serious or fatal injuries.
WARNING!
Do not leave children or animals inside parked vehicles in hot weather. Interior heat build up may cause serious injury or death.
ENGINE BLOCK HEATER — IF EQUIPPED The engine block heater warms engine coolant and permits quicker starts in cold weather. Connect the cord to a standard 110-115 volt AC electrical outlet with a grounded, three-wire extension cord. The engine block heater cord is routed under the hood on the driver side of the vehicle. It has a removable cap that is located on the driver side of the Integrated Power Module.
WARNING!
Remember to disconnect the cord before driving. Damage to the 110-115 volt electrical cord could cause electrocution.
STARTING AND OPERATING 249
AUTOMATIC TRANSMISSION
CAUTION!
a complete stop.
Damage to the transmission may occur if the follow- ing precautions are not observed: † Shift into PARK only after the vehicle has come to † Shift into or out of REVERSE only after the vehicle has come to a complete stop and the engine is at idle speed. † Do not shift from REVERSE, PARK, or NEUTRAL into any forward gear when the engine is above idle speed. † Before shifting into any gear, make sure your foot
is firmly on the brake pedal.
250 STARTING AND OPERATING
WARNING!
It is dangerous to shift the selector lever out of “P” or “N” if the engine speed is higher than idle speed. If your foot is not firmly on the brake pedal, the vehicle could accelerate quickly forward or in re- verse. You could lose control of the vehicle and hit someone or something. Only shift into gear when the engine is idling normally and when your right foot is firmly on the brake pedal.
Automatic Transmission with Overdrive The gear shift selector display, located in the instrument panel cluster, indicates the transmission gear range (the selector is illuminated for night driving). The selector lever is mounted on the right side of the steering column. You must depress the brake pedal, to pull the selector lever out of park (P) position (Brake Interlock System). To drive, move the selector lever from Park or Neutral to the
desired drive position. Pull the selector lever toward you when shifting into Reverse, Second, First or Park, or when shifting out of Park. Gear Ranges DO NOT race the engine when shifting from Park or Neutral position into another gear range. “P” Park This gear position supplements the parking brake by locking the transmission. The engine can be started in this range. Never use Park while the vehicle is in motion. Apply the parking brake when leaving the vehicle in this range. Always apply parking brake first, then place the selector in Park position. On 4-wheel-drive vehicles be sure that the transfer case is in a drive position!
WARNING!
WARNING!
STARTING AND OPERATING 251
Never use Park position on an automatic transmis- sion as a substitute for the parking brake. Always apply parking brake fully when parked to guard against vehicle movement and possible injury or damage.
WARNING!
Your vehicle could move and injure you and others if it is not completely in P (Park). Check by trying to move the gearshift lever back and forth without first pulling it toward you after you have set it in P. Make sure it is in Park before leaving the vehicle.
It is dangerous to shift the selector lever out of “P” or “N” if the engine speed is higher than idle speed. If your foot is not firmly on the brake pedal, the vehicle could accelerate quickly forward or in re- verse. You could lose control of the vehicle and hit someone or something. Only shift into gear when the engine is idling normally and when your right foot is firmly on the brake pedal.
“R” Reverse Use this range only after the vehicle has come to a complete stop.
252 STARTING AND OPERATING
“N” Neutral Shift to Neutral when the vehicle is standing for pro- longed periods with the engine running. The engine may be started in this range. Set the parking brake if you must leave the vehicle. NOTE: Towing the vehicle, coasting, or driving, with the transmission in neutral (N) position, can cause severe damage to the transmission. “D” Drive This position provides all forward gears, including 3rd gear direct and 4th and 5th (if equipped) gear overdrive (see Overdrive Operation). Use this range for most city and highway driving. “2” Second Use this position for driving slowly in heavy city traffic or on mountain roads where more precise speed control
is desirable. Use it also when climbing long grades, and for engine braking when descending moderately steep grades. NOTE: Do not exceed maximum engine speed. “1” First Use this position for driving up very steep hills and for engine braking at low speeds (20 mph [32 km/h] or less) when going downhill. NOTE: Do not exceed maximum engine speed. Overdrive Operation The overdrive automatic transmission contains an elec- tronically controlled fourth and fifth (if equipped) speed (Overdrive). The transmission will automatically shift from Drive to Overdrive if the following conditions are present: † the transmission selector is in Drive;
perature;
† the engine coolant has reached normal operating tem- † vehicle speed is above approximately 30 mph (48
† the “TOW HAUL O/D OFF” switch has not been † transmission has reached normal operating tempera-activated;
km/h);
ture. If the vehicle is started in extremely cold tem- NOTE: peratures, the transmission may not shift into Overdrive and will automatically select the most desirable gear for operation at this temperature. Normal operation will resume when the transmission fluid temperature has risen to a suitable level. Refer also to the Note under torque converter clutch, later in this section.
STARTING AND OPERATING 253
If the transmission temperature gets extremely hot, the transmission will automatically select the most desirable gear for operation at this temperature. If the transmission temperature becomes hot enough the TRANS TEMP light may illuminate and the transmission may downshift out of Overdrive until the transmission cools down. After cooldown, the transmission will resume normal opera- tion. The transmission will downshift from Overdrive to Drive if the accelerator pedal is fully depressed at vehicle speeds above approximately 35 mph (56 km/h).
254 STARTING AND OPERATING
When To Use “TOW HAUL” and “O/D OFF” Modes
Tow Haul O/D Off Switch
When driving in hilly areas, towing a trailer, carrying a heavy load, etc., and frequent transmission shifting oc- curs, press the “TOW HAUL O/D OFF” button once to select TOW HAUL. This will improve performance and
reduce the potential for transmission overheating or failure due to excessive shifting. When operating in “TOW HAUL” mode, 5th gear (if equipped) is disabled and 2-3 and 3-4 shift patterns are modified. Shifts into Overdrive (4th gear) are allowed during steady cruise (for improved fuel economy) and automatic closed- throttle downshifts to 3rd gear are performed (for im- proved braking) when driving conditions warrant. Press- ing the “TOW HAUL O/D OFF” button a second time to select O/D OFF will disable 4th and 5th gear completely, which should eliminate any excessive transmission shift- ing. The “TOW HAUL” or “O/D OFF” light will illuminate in the instrument cluster to indicate when the switch has been activated. Pressing the switch a third time restores normal operation. If the “TOW HAUL” or “O/D OFF” modes are desired, the button must be pressed each time the engine is started.
Torque Converter Clutch A feature, designed to improve fuel economy, has been included in the automatic transmission on your vehicle. A clutch within the torque converter engages automati- cally at calibrated speeds. This may result in a slightly different feeling or response during normal operation in the upper gears. When the vehicle speed drops or during acceleration when the transmission downshifts to second gear, the clutch automatically disengages. NOTE: The torque converter clutch will not engage until the transmission fluid and engine coolant are warm [usually after 1-3 miles (1.6 - 4.8 km) of driving]. Because the engine speed is higher when the torque converter clutch is not engaged, it may seem as if the transmission is not shifting into Overdrive when cold. This is normal. Pressing the “TOW HAUL O/D OFF” button, when the transmission is sufficiently warm, will demonstrate that the transmission is able to shift into and out of overdrive.
STARTING AND OPERATING 255
If the vehicle has not been driven in several NOTE: days, the first few seconds of operation after shifting the transmission into gear may seem sluggish. This is due to the fluid partially draining from the torque converter into the transmission. This condition is normal and will not cause damage to the transmission. The torque converter will refill within five seconds of shifting from Park into any other gear position.
MANUAL TRANSMISSION
WARNING!
You or others could be injured if you leave the vehicle unattended without having the parking brake fully applied. The parking brake should al- ways be applied when the driver is not in the vehicle, especially on an incline.
256 STARTING AND OPERATING
Truck models with manual transmission are equipped with a clutch interlocking ignition system. The clutch pedal must be fully depressed to start the vehicle. Fully depress the clutch pedal before shifting gears. As you release the clutch pedal, lightly depress the accelera- tor pedal. To shift into Reverse, come to a complete stop. Depress the clutch and pause briefly to allow the gear train to stop. Move the shift lever from the Neutral position straight across and back into Reverse. Never drive with your foot resting on the clutch pedal, or attempt to hold the vehicle on a hill with the clutch pedal partially engaged, as this will cause abnormal wear on the clutch.
Manual Transmission — 6 Speed (G56) The Power Wagon may be equipped with the G56
manual transmission. This transmission has a “creeper” 1st gear which should be used to start from a standing position when carrying a payload or towing a trailer. Damage to the clutch can result from starting in 2nd or 3rd gear with a loaded vehicle. An unloaded vehicle may be launched in 2nd gear. Use each gear in numerical order – do not skip a gear. For most city driving you may find it easier to use only 1st through 5th gear ranges. For steady highway driving with light accelerations, 6th gear is recommended. To shift into 5th gear, move the shift lever to the right beyond the spring pressure point and push it forward. When shifting from 5th to 4th gear, pull the lever down toward you in one motion. Do not pull the lever sharply left as you may shift accidentally into 2nd gear and damage the transmission.To shift into Reverse, come to a complete stop. Depress the clutch and pause briefly to allow the gear train to stop. Reverse has a “crash-through” lockout feature. Move the shift lever from the Neutral position straight across, in one swift motion, and down into Reverse. Recommended Vehicle Shift Speeds To utilize your manual transmission efficiently for both fuel economy and performance, it should be upshifted as listed in recommended shift speed chart. Shift at the vehicle speeds listed for acceleration. Earlier upshifts during cruise conditions (steady speeds) will result in increased fuel economy, and may be used as indicated. 6 Speed Manual Transmission Shift Speeds in mph
(km//h)
STARTING AND OPERATING 257
Downshifting – All Manual Transmissions Moving from a high gear down to a lower gear is recommended to preserve brakes when driving down steep hills. In addition, downshifting at the right time provides better acceleration when you desire to resume speed. For acceleration at speeds less than 20 mph (30
km/h), 2nd gear is recommended.CAUTION!
When descending a hill, be very careful to downshift one gear at a time to prevent overspeeding the engine which can cause valve damage.
En- gine Axle Mode 1 to 2
15
(24)5.7L ALL
Accel
Cruise
2 to
25
(40)3 to 4 4 to
5 to 6
40
(65)45
(72)50
(81)To prevent clutch and transmission damage, your vehicle should be downshifted at speeds no greater than those listed in the Maximum Recommended Downshifting Speed chart.
258 STARTING AND OPERATING
Maximum Recommended Downshifting Speeds Gear Selec- tion
2nd
3rd
4th
1st
5th
Maxi- mum Speed
16 mph
30 mph
50 mph
(25
(48
(80
km/h)
km/h)
km/h)
76 mph
(122
km/h)105
mph (168
km/h)CAUTION!
Failure to follow the recommended downshifting speeds may cause the engine to over speed and / or damage the clutch disc even if the clutch pedal is depressed.
FOUR-WHEEL- DRIVE OPERATION
Manually Shifted Transfer Case Operating Information/Precautions The transfer case provides 4 mode positions - 2 (rear)- wheel-drive high range, 4-wheel-drive high range, neu- tral, and 4-wheel-drive low range. This transfer case is intended to be driven in the 2-wheel- drive position (2H) for normal street and highway con- ditions such as dry hard surfaced roads. When additional traction is required the transfer case 4H and 4L positions can be used to lock the front and rear driveshafts together and force the front and rear wheels to rotate at the same speed. This is accomplished by simply moving the shift lever to the desired positions. The 4H and 4L positions are intended for loose, slippery
road surfaces only. Driving in the 4H and 4L positions on dry hard surfaced roads may cause increased tire wear and damage to the driveline components. The 4-wheel drive high (4LOCK) and 4–wheel drive low (4LOW) lights, located in the instrument cluster, alert the driver that the vehicle is either in 4-wheel drive high or 4–wheel drive low and that the front and rear driveshafts are locked together. There are no lights for the 2H or N (Neutral) positions. When operating your vehicle in 4L, the engine speed is approximately three times that of the 2H or 4H positions at a given road speed. Take care not to overspeed the engine and do not exceed 25 mph (40 km/h). Proper operation of 4-wheel-drive vehicles depends on tires of equal size, type and circumference on each wheel. Any difference will adversely affect shifting and can cause damage to the transfer case.
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NOTE: Do not attempt to make a shift while only the front or rear wheels are spinning. The transfer case is not equipped with a synchronizer and therefore the front and rear driveshaft speeds must be equal for the shift to take place. Shifting while only the front or rear wheels are spinning can cause damage to the transfer case. Because 4-wheel drive provides improved traction, there is a tendency to exceed safe turning and stopping speeds. Do not go faster than road conditions permit. NOTE: Delayed shifts out of four-wheel drive may be experienced due to uneven tire wear, low or uneven tire pressures, excessive vehicle loading, or cold tempera- tures.
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WARNING!
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 regardless of the transmission position. The parking brake should always be applied when the driver is not in the vehicle.
For additional information on the appropriate use of each transfer case mode position see the information below: 2H Rear Wheel Drive High Range - Normal street and highway driving. Dry hard surfaced roads.
4H 4-Wheel-Drive High Range - Locks the front and rear driveshafts together. Forces the front and rear wheels to rotate at the same speed. Additional traction for loose, slippery road surfaces only. Neutral - Disengages both the front and rear driveshafts from the powertrain. To be used for flat towing behind another vehicle. See Recreational Towing for more infor- mation. 4L 4-Wheel-Drive Low Range - Low speed 4-wheel-drive. Locks the front and rear driveshafts together. Forces the front and rear wheels to rotate at the same speed. Additional traction and maximum pulling power for loose, slippery road surfaces only. Do not exceed 25 mph (40 km/h).
Shifting Procedure - Manually Shifted Transfer Case
Manual Transfer Case Shifter
2H , 4H Shifting between 2H and 4H can be made with the vehicle stopped or in motion. If the vehicle is in motion, shifts can be made up to 55 mph (88 km/h). With the
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vehicle in motion, the transfer case will engage / disen- gage faster if you momentarily release the accelerator pedal after completing the shift. Apply a constant force when shifting the transfer case lever. 2H or 4H , 4L With the vehicle rolling at 2 to 3 mph (3 to 5 km/h), shift an automatic transmission to N (Neutral) or depress the clutch on a manual transmission. While the vehicle is coasting at 2 to 3 mph (3 to 5 km/h), shift the transfer case lever firmly to the desired position. Do not pause in transfer case N (Neutral). NOTE: Pausing in transfer case N (Neutral) in vehicles equipped with an automatic transmission may require shutting the engine OFF to avoid gear clash while completing the shift. If difficulty occurs, shift automatic transmission to N (Neutral), hold foot on brake, and turn engine OFF. Make shift to the desired mode.
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NOTE: Shifting into or out of 4L is possible with the vehicle completely stopped, however difficulty may oc- cur due to the mating clutch teeth not being properly aligned. Several attempts may be required for clutch teeth alignment and shift completion to occur. The pre- ferred method is with the vehicle rolling 2 to 3 mph (3 to 5 km/h). Avoid attempting to engage or disengage 4L with the vehicle moving faster than 2 to 3 mph (3 to 5
km/h). NOTE: Do not attempt to shift to or from 4L while the transmission is in gear or clutch is engaged. Transfer Case Reminder Light The four-wheel-drive operating light (4LOCK), located in the instrument cluster, is used to alert the driver that the front axle is fully engaged and all four wheels are driving.LIMITED-SLIP DIFFERENTIAL — IF EQUIPPED The limited-slip differential provides additional traction on snow, ice, mud, sand and gravel, particularly when there is a difference between the traction characteristics of the surface under the right and left rear wheels. During normal driving and cornering, the limited-slip unit per- forms similarly to a conventional differential. On slip- pery surfaces, however, the differential delivers more of the driving effort to the rear wheel having the better traction. The limited-slip differential is especially helpful during slippery driving conditions. With both rear wheels on a slippery surface, a slight application of the accelerator will supply maximum traction. When starting with only one rear wheel on an excessively slippery surface, slight momentary application of the parking brake may be necessary to gain maximum traction.
WARNING!
On vehicles equipped with a limited-slip differen- tial, never run the engine with one rear wheel off the ground, since the vehicle may drive through the rear wheel remaining on the ground. You could lose control of the vehicle.
Care should be taken to avoid sudden accelerations when both rear wheels are on a slippery surface. This could cause both rear wheels to spin, and allow the vehicle to slide sideways on the crowned surface of a road or in a turn.
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DRIVING ON SLIPPERY SURFACES 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.
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Axle Locker System Dodge Power Wagons are equipped with electronically locking front and rear axles. Locking the axles provides greater traction in severe low traction conditions or in rock climbing environments where one wheel is likely to not be in contact with the ground.
CAUTION!
Do not lock the front or rear axle on hard surfaced roads. The ability to steer the vehicle is reduced and damage to the drivetrain may occur when the axles are locked on hard surfaced roads.
CAUTION!
Do not try to lock the rear axle if the vehicle is stuck and the tires are spinning. You can damage driv- etrain components. Lock the rear axle before at- tempting situations or navigating terrain, which could possibly cause the vehicle to become stuck.
The locking axles are controlled by the axle locker switch located on the center console.
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rear axles are unlocked. In the REAR LOCK position, the rear axle is locked. In the FRONT/REAR position, the front and rear axles are locked. NOTE: Even when the axles are in the AXLE UNLOCK position, the limited slip differential in the rear axle still provides torque biasing capability for moderate low traction environments. During the command to lock the axle, the indicator light will flash until the axle is locked. After the lock command has been successfully executed, the light will remain on solid. To lock the rear axle, place the vehicle in 4LO by following the procedure in Four Wheel Drive Operation, located in this section of the manual. Move the axle locker switch position to REAR LOCK while traveling less than 3 MPH (5 KM/H). The RR indicator light will remain on when the rear axle is locked.
Rotary Locking Axle Switch
The switch has three positions, AXLE UNLOCK, REAR LOCK, and FRONT/REAR. Under normal driving con- ditions the switch should be left in the AXLE UNLOCK position. In the AXLE UNLOCK position, the front and
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NOTE: Left to right wheel speed difference may be necessary to allow the axle to fully lock. If the indicator light is flashing after placing the switch in the REAR LOCK or FRONT/REAR position, drive the vehicle in a turn or on loose gravel to expedite the locking action.
WARNING!
Do not use the locked axle position for normal driving. A locked front axle is intended for off-road driving only. Locking the front axle during on-road driving will reduce the steering ability. This could cause an accident and you may be seriously injured.
To lock the front axle move the axle locker switch to FRONT/REAR while traveling less than 3 MPH (5
KM/H). The indicator light will be solid when the front axle is locked.NOTE: The rear axle must be locked before the front axle will lock. To unlock the front axle move the axle locker switch to REAR LOCK. The FRONT/REAR indicator light will go out when the axle is unlocked. NOTE: The axle lockers could be torque locked due to side to side loads on the axle. Driving slowly while turning the steering wheel from a left hand turn to a right hand turn or driving in reverse for a short distance may be required to release the torque lock and unlock the axles. To unlock the rear axle move the axle locker switch to AXLE UNLOCK. The REAR LOCK indicator light will go out when the rear axle is unlocked.
Stabilizer/Sway Bar System Power Wagon vehicles are equipped with an electronic disconnecting stabilizer/sway bar. This system allows greater front suspension travel in off-road situations. This system is controlled by the electronic control sway bar switch located on the instrument panel.
Electronic Control Sway Bar Switch
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The switch has two positions, on-road and off-road. The system is normally in on-road mode, indicated by a solid green light. The stabilizer/sway bar should remain in on-road mode during normal driving conditions.
WARNING!
Do not disconnect the stabilizer bar and drive on hard surfaced roads or at speeds above 18 MPH, you may lose control of the vehicle, which could result in serious injury. The front stabilizer bar enhances vehicle stability and is necessary for maintaining control of the vehicle. The system monitors vehicle speed and will attempt to reconnect the stabilizer bar at speeds over 18 MPH. This is indicated by a flashing off road light and solid on road light. Once vehicle speed is reduced below 14 MPH the system will once again attempt to return to off road mode.
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To disconnect the stabilizer/sway bar, shift to either 4HI or 4LO as shown in Four Wheel Drive Operation and press the top of the stabilizer/sway bar button to obtain the off-road position. The amber indicator light will flash until the stabilizer/sway bar has been fully disconnected. NOTE: The stabilizer/sway bar may be torque locked due to left and right suspension height differences. This condition is due to driving surface differences or vehicle loading. to disconnect/reconnect, the right and left halves of the bar must be aligned. This alignment may require that the vehicle be driven onto level ground or rocked from side to side. To return to on-road mode press the bottom of the stabilizer/sway bar button.
the stabilizer/sway bar
In order
for
WARNING!
If stabilizer/sway bar will not return to on-road mode, vehicle stability is greatly reduced. Do not attempt to drive vehicle over 18 mph (29 km/h). Driving faster than 18 mph (29 km/h) may cause loss of control of the vehicle, which could result in serious injury. Contact your local service center for assistance.
POWER WAGON – SAFE OFF-ROAD DRIVING
Off-Road Driving Tips and Vehicle Characteristics The Power Wagon has excellent on and off-road capabili- ties. These off-road capabilities will allow you to explore those wilderness trails where few travel, providing a source of exciting and satisfying recreation. Before you venture out you should contact your local governmental agency to determine what are the designated off-road
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High Mobility Characteristics The Power Wagon has high off-road mobility character- istics with an approach angle A= 35 degrees, a break-over angle B= 25.5 degrees, a running ground clearance C= 14.5 inches, a departure angle D= 26.5 degrees, an axle to ground clearance E= 8.4 inches front/E= 8.25 rear and has a ramp travel index (with the smart bar in off-road mode) of 655. Also the Power Wagon has a grade-ability of a 60% (31 degree) slope.
vehicle (ORV) trails or recreation areas. You should always tread lightly and only use established roads, trails or ORV recreational areas. The National Forest Service, Bureau of Land Management or local Department of Natural Resources are a wealth of information and usu- ally have maps with marked trails. Ramp Travel Index (RTI) The ramp travel index is the distance, in inches, that you can drive your vehicle with one wheel on a 20-degree ramp without lifting any other wheel off the ground. This distance up the ramp divided by the wheelbase of the vehicle and multiplied by 1000 is the RTI. The Power Wagon has an RTI of 655, which means you can articulate one front wheel 32 inches in the air while the other three wheels remain in contact with the ground.
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Angles A, B, C, and D
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Water Fording
Water Fording Characteristics Water fording characteristic is the vehicle’s ability to cross a body of still water, where the powertrain and drivetrain are safe from water ingestion. The Power Wagon has high water fording characteristics with the ability to cross a pool of water, without stopping, 24
inches deep at a maximum speed of 10 mph and a pool ofFront and Rear (Shown) Differential Height E
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water 30 inches deep at a maximum speed of 5 mph, both with an entrance ramp angle of 1.3 degrees.
CAUTION!
The door sill height is 25 inches. Water may intrude into the interior of the vehicle at greater depths.
Simultaneous Brake And Throttle Operation Many off-road driving conditions require the simulta- neous use of the brake and throttle (two footed driving). When climbing rocks, logs, or other stepped objects, using light brake pressure with light throttle will keep the vehicle from jerking or lurching. This technique is also used when you need to stop and restart a vehicle on a steep incline.
The Basics Of Off-Road Driving You will encounter many types of terrain driving off- road. You should be familiar with the terrain and area before proceeding. There are many types of surface conditions: hard packed dirt, gravel, rocks, grass, sand, mud, snow and ice. Every surface has a different effect on your vehicle’s steering, handling and traction. Control- ling your vehicle is one of the keys to successful off-road driving, so always keep a firm grip on the steering wheel and maintain a good driving posture. Avoid sudden accelerations, turns or braking. In most cases there are no road signs, posted speed limits or signal lights. Therefore you will need to use your own good judgment on what is safe and what isn’t. When on a trail you should always be looking ahead for surface obstacles and changes in terrain. The key is to plan your future driving route while remembering what you are currently driving over.
CAUTION!
Never park your vehicle over dry grass or other combustible materials. The heat from your vehicle exhaust system could cause a fire.
WARNING!
Always wear your seat belt and firmly tie down cargo. Unsecured cargo can become projectiles in an off-road situation.
When To Use Low Range When driving off-road, shift into 4L (Low range) for additional traction or to improve handling and control on slippery or difficult terrain. Due to the lower gearing, low range will allow the engine to operate in a higher power range. This will allow you to idle over obstacles and
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down hills, with improved control and less effort. Also, use 4L (Low range) in rain, ice, snow, mud, sand, to get heavy loads rolling, improve traction, or whenever 4H (High range) traction will not do the job. Driving in Snow, Mud and Sand There is a drastic reduction in traction when driving in snow, mud or sand. The vehicle will be less responsive to steering, acceleration and braking inputs. Therefore you should accelerate slowly, leave greater stopping distances and avoid abrupt vehicle maneuvers. You want to keep a slow constant steady pace. The key is to maintain the vehicle’s momentum. † Snow – In heavy snow or for additional control and traction at slower speeds, shift the transmission to a low gear and shift the transfer case to 4L (Low) if necessary. Don’t shift to a lower gear than necessary to maintain headway. Over-revving the engine can spin the wheels and traction will be lost. If you start to slow
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to a stop, try turning your steering wheel no more than a 1⁄4 turn quickly back and forth, while still applying throttle. This will allow the tires to get a fresh 9bite9
and help maintain your momentum.CAUTION!
On icy or slippery roads, do not downshift at high engine rpm’s or vehicle speeds because engine brak- ing may cause skidding and loss of control. † Mud – Deep mud creates a great deal of suction around the tires and is very difficult to get through. You should use 4L (low range) with a gear low enough to maintain your momentum without shifting. If you start to slow to a stop, try turning your steering wheel no more than a 1⁄4 turn quickly back and forth for additional traction. Mud holes pose an increased threat of vehicle damage and getting stuck. They are
normally full of debris from previous vehicles getting stuck. As a good practice before entering any mud hole, get out and determine how deep it is, if there are any hidden obstacles and if the vehicle can be safely recovered if stuck. † Sand – Soft sand is very difficult to travel through with full tire pressure. When crossing soft sandy spots in a trail maintain your vehicle’s momentum and do not stop. The key to driving in soft sand is to use the appropriate tire pressure, accelerating slowly, avoid- ing abrupt maneuvers and maintaining the vehicle’s momentum. If you are going to be driving on large soft sandy areas or dunes, reduce your tire pressure to a minimum of 15 psi (103 kPa) to allow for a greater tire surface area. Reduced tire pressure will drastically improve your traction and handling, while driving on the soft sand, but you must return the tires to normal
air pressure before driving on pavement or other hard surfaces. Be sure you have a way to air the tires back up prior to reducing the pressure.
CAUTION!
Reduced tire pressures may cause tire unseating and total loss of air pressure. To reduce the risk of tire unseating, while at a reduced tire pressure, reduce your speed and avoid sharp turns or abrupt maneu- vers.
Crossing Obstacles (Rocks And Other High Points) While driving off road, you will encounter many types of terrain. These varying types of terrain bring different types of obstacles. Before proceeding review the path ahead to determine the correct approach and your ability to safely recover the vehicle if something goes wrong.
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Keeping a firm grip on the steering wheel, bring the vehicle to a complete stop and then inch the vehicle forward until it makes contact with the object. Apply the throttle lightly while holding a light brake pressure and ease the vehicle up and over the object.
WARNING!
Crossing obstacles can cause abrupt steering system loading which could cause you to loose control of your vehicle.
Using A Spotter There are many times where it is hard to see the obstacle or determine the correct path. Determining the correct path can be extremely difficult when you are confronting many obstacles. In these cases have someone guide you over, through, or around the obstacle. Have the person
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stand a safe distance in front of you where they can see the obstacle, watch your tires and undercarriage, and guide you through. Crossing Large Rocks When approaching large rocks, choose a path which ensures you drive over the largest of them with your tires. This will lift your undercarriage over the obstacle. The tread of the tire is tougher and thicker than the side wall and is designed to take the abuse. Always look ahead and make every effort to cross the large rocks with your tires.
CAUTION!
Never attempt to straddle a rock that is large enough to strike your axles or undercarriage.
CAUTION!
Never attempt to drive over a rock which is large enough to contact the door sills.
Crossing A Ravine, Gully, Ditch, Washout Or Rut When crossing a ravine, gully, ditch, washout or a large rut, the angled approach is the key to maintaining your vehicle’s mobility. Approach these obstacles at a 45- degree angle and let each tire go through the obstacle independently. You need to use caution when crossing large obstacles with steep sides. Do not attempt to cross any large obstacle with steep sides at an angle great enough to put the vehicle at risk of a roll over. If you get caught in a rut, dig a small trench to the right or left at a 45-degree angle ahead of the front tires. Use the removed dirt to fill the rut ahead of the turnout you just created. You should now be able to drive out following the trench you just created at a 45-degree angle.
WARNING!
CAUTION!
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There is an increased risk of roll over when crossing an obstacle, at any angle, with steep sides.
Crossing Logs To cross a log, approach it at a slight angle (approxi- mately 10 to 15 degrees). This allows one front tire to be on top of the log while the other just starts to climb the log. While climbing the log, modulate your brake and accelerator to avoid spinning the log out from under your tires. Then ease the vehicle off the log using your brakes.
Do not attempted to cross a log with a greater diameter than the running ground clearance or the vehicle will become high centered.
Getting High Centered If you get hung up or high centered on an object, get out of the vehicle and try to determine what the vehicle is hung up on, where it is contacting the underbody and what is the best direction to recover the vehicle. Depend- ing on what you are in contact with, jack the vehicle up and place a few rocks under the tires so the weight is off of the high point when you let the vehicle down. You can also try rocking the vehicle or winching the vehicle off the object.
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CAUTION!
Winching or rocking the vehicle off hard objects increases the risk of underbody damage.
Hill Climbing Hill climbing requires good judgment and a good under- standing of your abilities and your vehicle’s limitations. Hills can cause serious problems. Some are just too steep to climb and should not be attempted. You should always feel confident with the vehicle and your abilities. You should always climb hills straight up and down. Never attempt to climb a hill on an angle. † Before Climbing A Steep Hill – As you approach a hill consider its grade or steepness. Determine if it is too steep. Look to see what the traction is on the hill side trail. Is the trail straight up and down? What is on top and the other side? Are there ruts, rocks, branches
or other obstacles on the path? Can you safely recover the vehicle if something goes wrong? If everything looks good and you feel confident, then change trans- mission into a lower gear, shift the transfer case into 4L (Low) and proceed with caution. You should use first gear and 4L (Low) for very steep hills. † Driving Up Hill – Once you have determined your ability to proceed and have shifted into the appropri- ate gear, line your vehicle up for the straightest possible run. Accelerate with an easy constant throttle and apply more power as you start up the hill. Do not race forward into a steep grade, the abrupt change of grade could cause you to lose control. If the front end begins to bounce, ease off the throttle slightly to bring all four tires back on the ground. As you approach the crest of the hill ease off the throttle and slowly proceed over the top. If the wheels start to slip as you approach the crest of a hill, ease off the accelerator and maintain headway by turning the steering wheel no more than
a 1⁄4 turn quickly back and forth. This will provide a fresh 9bite9 into the surface and will usually provide enough traction to complete the climb. If you do not make it to the top, place the vehicle in reverse and back straight down the grade using engine resistance along with the vehicle brakes.
WARNING!
Never attempt to climb a hill at an angle or turn around on a steep grade. Driving across an incline increases the risk of a roll over, which may result in severe injury. † Driving Down Hill – Before driving down a steep hill you need to determine if it is too steep for a safe descent. What is the surface traction? Is the grade too steep to maintain a slow controlled descent? Are there obstacles? Is it a straight descent? Is there plenty of
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distance at the base of the hill to regain control if the vehicle descends to fast? If you feel confident in your ability to proceed then make sure you are in 4L (Low) with the transmission in 1st gear (manually select 1st gear on automatic transmissions) and proceed with caution. Allow engine braking to control the descent and apply your brakes if necessary, but do not allow the tires to lock.
WARNING!
Do not descend a steep grade in neutral. Use vehicle brakes in conjunction with engine braking. De- scending a grade too fast could cause you to lose control and be seriously injured. † Driving Across An Incline – If at all possible avoid driving across an incline. If it is necessary, know your vehicle’s abilities. Driving across an incline places
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more weight on the down hill wheels, which increases the possibilities of a down hill slide or roll over. Make sure the surface has good traction with firm and stable soils. If possible transverse the incline at an angle heading slightly up or down.
WARNING!
Driving across an incline increases the risk of a roll over, which may result in severe injury. † If You Stall Or Begin To Lose Headway – If you stall or begin to lose headway while climbing a steep hill, allow your vehicle to come to a stop and immediately apply the brake. Restart the engine and shift to R (Reverse). Back slowly down the hill allowing the compression braking of the engine and transmission to
help regulate your speed. If the brakes are required to control vehicle speed, apply them lightly and avoid locking or skidding the tires.
WARNING!
If the engine stalls or you lose headway or cannot make it to the top of a steep hill or grade, never attempt to turn around. To do so may result in tipping and rolling the vehicle, which may result in severe injury. Always back carefully straight down a hill in R (Reverse) gear. Never back down a hill in N (Neutral) or with the clutch pedal depressed using only the vehicle brakes. Never drive diagonally across a hill, always drive straight up or down.
Driving Through Water Extreme care should be taken crossing any type of water. Water crossings should be avoided if possible and only be attempted when necessary, in a safe responsible manner. You should only drive through areas which are desig- nated and approved. You should tread lightly and avoid damage to the environment. You should know your vehicles abilities and be able to recover it if something goes wrong. You should never stop or shut a vehicle off when crossing deep water unless you ingested water into the engine air intake. If the engine stalls do not attempt to restart it. Determine if it has ingested water first. The key to any crossing is low and slow. You want to use 1st gear in 4L (low) and proceed very slowly with a constant slow speed (3-5 mph maximum) and light throttle. Keep the vehicle moving; do not try to accelerate through the crossing. After crossing any water higher than the bottom of the axle differentials, you should inspect all of the vehicle fluids for signs of water ingestion.
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CAUTION!
Water ingestion into the axles, transmission, transfer case, engine or vehicle interior can occur if you drive too fast or through too deep of water. Water can cause permanent damage to engine, driveline or other vehicle components and your brakes will be less effective once wet and/or muddy † Before You Cross Any Type Of Water – As you approach any type of water you need to determine if you can cross it safely and responsibly. If necessary, get out and walk through the water or probe it with a stick. You need to be sure of its depth, approach angle, current and bottom condition. Be careful of murky or muddy waters, check for hidden obstacles. Make sure you will not be intruding on any wildlife and you can recover the vehicle if necessary. The key to a safe
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crossing is the water depth, current and bottom con- ditions. On soft bottoms the vehicle will sink in, effectively increasing the water level on the vehicle. Be sure to consider this when determining the depth and the ability to safely cross. † Crossing Puddles, Pools, Flooded Areas Or Other Standing Water – Puddles, pools, flooded or other standing water areas normally contain murky or muddy waters. These water types normally contain hidden obstacles and make it difficult to determine an accurate water depth, approach angle, and bottom condition. Murky or muddy water holes are where you want to hook up tow straps prior to entering. This makes for a faster, cleaner and easier vehicle recovery. If you are able to determine you can safely cross, than proceed using the low and slow method.
CAUTION!
Muddy waters can reduce the cooling system effec- tiveness by depositing debris onto the radiator. † Crossing Ditches, Streams, Shallow Rivers Or Other Flowing Water – Flowing water can be extremely dangerous. Never attempt to cross a fast running stream or river even in shallow water. Fast moving water can easily push your vehicle downstream sweeping it out of control. Even in very shallow water, a high current can still wash the dirt out from around your tires putting you and your vehicle in jeopardy. There is still a high risk of personal injury and vehicle damage with slower water currents in depths greater than the vehicle’s running ground clearance. You should never attempt to cross flowing water which is deeper than the vehicle’s running ground clearance. Even the slowest current can push the heaviest vehicle
downstream out of control if the water is deep enough to push on the large surface area of the vehicle’s body. Before you proceed determine the speed of the current, the water’s depth, approach angle, bottom condition and if there are any obstacles, then cross at an angle heading slightly upstream using the low and slow technique.
WARNING!
Never drive through fast moving deep water. It can push your vehicle downstream, sweeping it out of control. This could put you and your passengers at risk of injury or drowning.
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Airing Down For Off-Road Driving Running lower tire pressure off-road can improve your ride comfort and vehicle traction. Reducing the tire air pressure allows the tire to bulge slightly, improving its surface area for better flotation and ability to mold or form to the ground contour. Different terrain, tires, and vehicles require different tire pressure. Hard surfaces like rock and heavier vehicles require higher pressures than softer surfaces such as sand and lighter vehicles. You will need to experiment to determine what is right for your situation. It is easier and faster to let air out than it is to replace it so, start high and lower it as required. Remem- ber you must return the tires to normal air pressure before driving on road or at highway conditions. Be sure you have a way to return the tires to their normal on road air pressure.
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CAUTION!
Reduced tire pressure increases the risk of tire dam- age and may cause tire unseating with total loss of air pressure. To reduce the risk of tire unseating, while at a reduced tire pressure, drive at slower speeds and avoid sharp turns or abrupt maneuvers.
Vehicle Recovery If you drive off-road, you may encounter a situation where you will need to recover your vehicle. Vehicle recovery should always be given consideration before attempting a questionable obstacle. You should never go off-road driving without the ability to recover your vehicle from a situation. Having another vehicle with you usually works best for most situations. The first thing to do is assess the situation. Why are you stuck? Are you hung up on something? Would it be easier to go forward or to go backward? Can you still move the
vehicle? Is there an anchor point to winch to? Are you alone or do you have another vehicle to help? Is there high risk of vehicle damage during the recovery process? Answering these questions will help you determine the best method of recovery. If you can still move the vehicle slightly and the only issue is slick ground, then rock cycling your vehicle would be the first choice. If you have ample room, an additional vehicle and there is low risk of vehicle impingement on the surroundings, then using a tow strap to the vehicle tow hooks would be fast and easy. If the vehicle is severely hung up or in a situation where great care needs to be taken during the recovery, then nothing can do the job better than a winch. If you are severely hung up on something you should jack the vehicle up and stack something under the wheels to allow the vehicle to roll off the object without causing further damage. This should be tried before attempting any recovery method.
CAUTION!
Pulling the vehicle off an obstacle, without first clearing the object, may result in additional under- body damage. † Rock Cycling Your Vehicle – Rock cycling your ve- hicle is one of the easiest, fastest and most commonly used methods. This simply involves shifting your vehicle from drive to reverse, while applying throttle after each shift. During this process, for additional traction, try turning your steering wheel quickly back and forth no more than a 1⁄4 turn. If you are stuck in mud, sand, or snow try spinning your tires during this process to clean the debris from the tread and improve the traction. You want to create a rocking motion with the vehicle. This helps build vehicle momentum, which hopefully gets you out. Remember to ease off and on the accelerator before and after the shift. If after
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a few rock cycles your vehicle is not free, stop and try another method of recovery. Continuous rock cycling will only cause unnecessary damage to your vehicle and the environment.
CAUTION!
Damage can occur when spinning your tires at an excessive high speed. Do not spin your tires faster than an indicated 35 mph † Using The Tow Hooks With A Tow Strap – Tow straps are a quick and easy way to recover your vehicle from minor situations if you have a secondary vehicle which is not stuck. The tow hooks on your vehicle are designed to take the abusive force gener- ated during vehicle recovery. Do not use the bumper or any other vehicle component as an attachment point. Using tow straps requires coordination between
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the two drivers. Good communication and line of sight are required for a safe recovery. First connect the tow strap to the correct attachment points on both vehicles. There should be a least 20 to 30 feet between the vehicles to allow for a safe recovery. If necessary join two tow straps together using a 1 1⁄2 inch hard wood dowel. This will keep the straps from becoming knot- ted and is safer than using a clevis pin if the strap breaks. Next have the tow vehicle backup, leaving 2 to 3 feet worth of slack in the strap. Then the tow vehicle, using light throttle, should accelerate tightening the strap providing the pulling force needed to free the vehicle. The vehicle being recovered should assist in the recovery, at the time of the snap, by slowly spinning the tires in the same direction as the pulling vehicle. After the vehicle becomes free, the driver of the previously stuck vehicle should signal they are free and should hit their brakes stopping both vehicles. The driver of the pulling vehicle should let off the
throttle without using the brakes, once signaled by the other driver. This sequence is important to avoid having the recovered vehicle hit the pulling vehicle.
WARNING!
Never use tow straps with end hooks or link two straps with a clevis pin. These heavy metal objects could become projectiles if a strap breaks, which could cause severe injury. Never leave more than 2 or 3 feet of slack in the strap. More slack than this greatly increases the risk of injury and vehicle dam- age. Always keep everyone at least 30 feet away from a strapping or winching situation. † Winching (see the section on “Winch Operation” for additional information on the Power Wagon’s winch) – Winching is most commonly used in the following situations: there is no support vehicle available, a high
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left on the drum, and place a floor mat or something else over the strung out cable. Placing something over the strung out cable helps keep the cable on the ground if it breaks. Next, place the vehicle in 1st gear and apply a very light throttle as you power the winch in. Be careful not to allow slack in the cable as you recover the vehicle. Do not try to guide the cable into the drum. If it starts to bunch up on one end, let it. You can re-spool the cable afterwards. Never use a winch cable as a tow strap and always stand back while winching.
controlled force is required to recover the vehicle, there is a high risk of environmental or vehicle dam- age, or where nothing else seemed to work. A winch can deliver a high pulling force with a great deal of control. It allows you to walk the vehicle out of the situation in a slow controlled manor. This control works well for avoiding further vehicle damage. Once you decide it is time to use the winch look for a good anchor point. It needs to be strong enough to hold more than the vehicle’s weight and provide a direction of pull as straight as possible. Use block and tackle if necessary to improve the angle of pull or increase the winch’s pulling force. If the anchor point is a tree use a strap around its base and hook the cable to the strap. If it is another vehicle, then place that vehicle in park and block the front tires. If you cannot find an anchor point within reach try using your spare tire by burying it. Once you have determined an anchor point hook up the cable, ensuring there are a least five wraps of cable
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WARNING!
Winch cables are under high tension when in use and can become a projectile if they fail. Never stand over or straddle the winch cable. Never jerk or overload the winch cable. Never stand in front of the vehicle while winching. Failure to follow these in- structions can result in serious or fatal injury.
After Driving Off-Road Off-road operation puts more stress on your vehicle than does most on-road driving. After driving off-road, it is always a good idea to check for damage. † Completely inspect the underbody of your vehicle. Check tires, body structure, steering, suspension, and exhaust system for damage.
† Check threaded fasteners for looseness, particularly on the chassis, drivetrain components, steering, and sus- pension. Retighten them, if required, and torque to the values specified in the Service Manual. † Check for accumulations of plants or brush. These things could be a fire hazard, or they might hide damage to fuel lines, brake hoses, axle pinion seals, and propeller shafts. † After extended operation in mud, sand, water, or similar dirty conditions, have brake drums and rotors, brake linings, and axle yokes inspected and cleaned as soon as possible. † If you experience unusual vibration after driving in mud, slush or similar conditions, check the wheels for packed material. Packed foreign material can cause a wheel imbalance and cleaning the wheels will correct the situation.
WARNING!
Abrasive material in any part of the brakes may cause excessive wear or unpredictable braking. You might not have full braking power when you need it to prevent an accident. If you have been operating your vehicle in dirty conditions, get your brakes checked and cleaned as necessary. Failure to do so may result is serious injury.
WINCH USAGE – IF EQUIPPED
Things To Know Before Using Your Winch
General Winch Information Your vehicle is equipped with an electric vehicle recovery winch. This winch uses the electrical power from the vehicle charging system to power a motor that winds wire rope into the winch drum via planetary gear reduc- tion. By nature, a winch is capable of generating very
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high forces and should be used with care. Do not operate the winch without reading and understanding the com- plete winch owner’s manual. Tensioning the Wire Rope The winch rope must be properly tensioned before use. Follow the instructions below to tension the rope: 1. Un-spool the wire rope leaving 5 wraps of rope on the winch drum. 2. Attach the hook to a suitable anchor point.
CAUTION!
Be certain the anchor will withstand the load re- quired to tension the wire rope.
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3. Apply at least 500 lbs. of tension to the rope while winding the rope in. Always use care to ensure the rope does not pile up on one side of the drum and is neatly wound onto the drum.
CAUTION!
Wire rope must spool on the winch drum in the direction indicated on the drum rotation decal on the winch.
Low Voltage Interrupt Your winch is equipped with a device that will interrupt winch function if the vehicle charging system voltage
drops to a low level. The winch will not power-in or out for 30 seconds if this device is tripped. If the interrupt is tripped, the vehicle should be operated at high idle for a few minutes to allow the vehicle charging system to recover before continuing to winch. Winch Motor Thermal Protection Your winch is equipped with a thermal protection device in the motor. If the winch is operated for an excessive duration, the device may interrupt motor function to protect the winch motor. During this time the winch will power-out but will not power-in. Allow the winch motor to cool for a few minutes before continuing to winch. The winch will resume normal function once the motor cools.
UNDERSTANDING THE FEATURES OF YOUR WINCH
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Winch Components
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1. Motor: The winch motor is powered by the vehicle charging system and features a thermal protection switch that automatically stops motor function in the power-in direction if the motor gets too hot. 2. Remote Socket: The remote socket allows the remote control to be attached to the control pack to allow the winch to function. 3. Winch Drum w/ Integral Brake: The winch drum allows the wire rope to be stored on the winch and transmits force to the wire rope. The winch is equipped with an integral brake that will stop rotation of the winch drum if the winch motor is stopped. 4. 3 Stage Planetary Gear Set: Provides balance between speed and pulling power. 5. Wire Rope: The wire rope allows the winch to be connected to an anchor to provide a pulling force.
6. Clutch Lever: The clutch lever allows the winch drum to be disconnected from the winch motor to allow the wire rope to be pulled from the winch by hand. 7. Remote Control: The remote control provides the interface between the winch operator and the winch. The remote control provides the ability to power the winch in, out, and stop the winch. To operate the winch, the toggle switch is pressed down to power the winch in and up to power the winch out. The winch will stop if the switch is left in the neutral (center) position.
CAUTION!
If not installed, the hook strap must be placed on the hook.
Fairlead: The fairlead acts as a guide for the wire rope and minimizes damage to the rope.
WINCH ACCESSORIES
The following accessories are necessary to attach the winch to anchors, change direction of pull, and for safe winching.
Gloves: Wire rope, through use, will develop 9barbs9
which can slice skin. It is ex- tremely important to wear protective gloves while oper- ating the winch or handling the wire rope. Avoid loose fit- ting clothes or anything that could become entangled in the wire rope and other mov- ing parts.STARTING AND OPERATING 293
Snatch/Block Pulley: Used properly, the multi-purpose snatch block allows you to (1) increase our winch’s pulling power; and (2) change your direction without pulling damaging the wire rope. Proper use of the snatch block is covered in 9Before You Pull.9
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The Clevis/D-Shackles: D-Shackle is a safe means of connecting the looped ends of cables, and snatch blocks. The shackle’s pin is threaded to allow easy re- moval.
straps
Tree Trunk Protector: Typi- cally made of tough, high- quality nylon, it provides the operator an attachment point for the winch rope to a wide variety of anchor points and objects, as well as protect liv- ing trees.
OPERATING YOUR WINCH
WARNING!
wire rope drum is moving.
† Always use supplied hook strap to hold hook when spooling wire rope in or out. † Never use as a hoist. † Never use to move persons. † Never exceed winch or wire rope rated capacity. † Always wear heavy leather gloves when handling the wire rope. † Never touch wire rope or hook while in tension or under load. † Never engage or disengage clutch if winch is under load, wire rope is in tension, or † Always stand clear of wire rope and load and keep others away during winching. † Always keep hands and clothing clear of the wire rope, hook and fairlead opening † Never wrap wire rope back onto itself. Always use a choker chain, wire choker rope or † Never attach a recovery strap to the winch hook to increase the length of a pull. † Never attempt to tow a vehicle with the recovery strap attached directly to the winch † Never use (bungee( straps that develop tremendous and potentially dangerous † Always disconnect the remote control when not in use. † Never winch when there are less than 5 wraps of wire rope around the winch drum. † Always pass remote control through a window to avoid pinching lead in door, then † Never leave the remote control plugged into the winch while free spooling, rigging or
during operation and when spooling.
tree trunk protector on the anchor.
amounts of force when stretched.
using remote inside a vehicle.
hook.
sitting idle.
Failure to observe any of these warnings regarding proper winch usage may result in severe injury.
General Information Practice using your winch before you get stuck. Some key points to remember when using your winch are: 1. Always take your time to assess the situation and plan your pull carefully. 2. Always take your time when using a winch. 3. Use the right equipment for the situation. 4. Always wear leather gloves and do not allow the wire rope to slip through your hands when handling the rope. 5. Only the operator should handle the wire rope and remote control. 6. Think safety at all times.
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Vehicle Recovery Using the Winch:
CAUTION!
† Always Know Your Winch: Take time to fully read and understand the included Installation and Operations Guide, and Basic Guide to Winching Techniques, in order to understand your winch and the winching operation. † Always inspect winch installation and wire rope con- dition before operating winch. Frayed, kinked or dam- aged wire rope must be replaced immediately. Loose or damaged winch installation must be corrected imme- diately. † Always be sure any element which can interfere with safe winching operations is removed prior to initiating winching. † Always keep remote control lead clear of the drum, † Inspect for cracks, pinches, frayed wires, or loose
wire rope and rigging.
connections. Replace if damaged.
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CAUTION!
Be careful not the Winch Cable Collar through the rollers. Watch and listen to Winch for proper snugness.
to pull
1. Inspect the winch, winch mount, and wire rope for damage. Do not use the winch if the mount is loose or rope shows excessive wear or damage. 2. Put on gloves. 3. Disengage clutch to allow free spooling of the winch drum, rotate the clutch lever on the winch to disengage. Freespooling conserves battery power.
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4. Free the winch hook and attach hook strap. Free the winch hook from its anchor point. Attach hook strap to the hook (if not attached).
Hook Strap
5. Pull wire to anchor point. Pull out enough wire rope to reach your anchor point. Be sure to keep a certain amount of tension on the wire as it can become twisted and
Free Spool
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over-wrap when slackened, leading to wire rope damage. To prevent losing the end, hold the hook strap while you work.
6. Secure to the anchor point. Once you’ve established your anchor point, secure the tree-trunk protector or choker-chain around the object.
Always be certain the anchor you select will with- stand the load.
Tree Trunk Protector
CAUTION!
NOTE: How to choose an anchor point: A secure anchor is critical to winching operations. An anchor must be strong enough to hold while winching. Natural an- chors include trees, stumps and rocks. Hook the cable as low as possible. If no natural anchors are available when recovering another vehicle, your vehicle becomes the anchor point. In this case, be sure to put the transmission in neutral, apply the hand brake and block its wheels to prevent your vehicle from moving. Ideally, you’ll want an anchor point that will enable you to pull straight in the direction the vehicle will move. This allows the wire rope to wind tightly and evenly onto the spooling drum. An anchor point as far away as possible will provide the winch with its greatest pulling power. 7. Attach the Clevis/D-shackle and Tree Trunk Protector. Attach the shackle to the two ends of the strap or chain and through the hook loop, being careful not to over tighten (tighten and back-off 1/2 turn).
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Clevis/D-Shackles
8. Lock the clutch. Lock the winch drum by rotating the clutch lever on the winch to engage. NOTE: Always ensure the clutch is fully engaged or disengaged.
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9. Connect the remote control to the winch control box, located behind the front bumper. Be careful not to let the remote control cord dangle in front of the winch. If you choose to control the winch from inside your vehicle, always pass the remote through a window to avoid pinching the cord in the door. Always disconnect the remote control when not in use.
10. Put wire rope under tension. Using the remote con- trol switch, slowly wind the wire rope until no slack remains. Once the wire rope is under tension, stand well clear and never step over it.
11. Check your anchor. Make sure all connections are secured and free of debris before continuing with the winching procedure.
12. Check wire rope. The wire rope should be neatly wound around the spooling drum. Improper winding can cause damage to the wire rope.
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13. In certain situations you may decide to throw a heavy blanket or similar object over the wire rope. A heavy blan- ket can absorb energy should the wire rope break. Place it on the wire rope midway be- tween the winch and the an- chor point. Do this before the wire rope is put under ten- sion. Do not approach or move the blanket once tension is applied. Do not allow it to get pulled into the fairlead. If necessary to move or remove the blanket, slack the tension on the wire rope first. 14. Establish (no people( zones: Make your intentions clear. Be sure that everyone in the immediate vicinity surrounding the winching operation is completely aware of your intentions before you pull. Declare where the spectators should not stand - never behind or in front of
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the vehicle and never near the wire rope or snatch block. Your situation may have other (no people( zones.
For additional assistance, the winched vehicle can be slowly driven while being pulled by the winch. Continue pulling until the vehicle is on stable ground. If you are able to drive the vehicle, the winching operation is complete.
No People Zones
15. Begin winching. With the winching vehicles engine on and light tension already on the wire rope, begin winching slowly and steadily. Be sure that the wire rope is winding evenly and tightly around the spooling drum.
Using The Remote Control
NOTE: Avoid overheating the winch motor. For ex- tended winching, stop at reasonable intervals to allow the winch motor to cool down. NOTE: What to look for under load: The wire rope must always spool onto the drum as indicated by the drum rotation decal on the winch. As you power-in, make sure the wire rope winds evenly and tightly on the drum. This prevents the outer wire wraps from drawing into the inner wraps, binding and damaging the wire rope. Avoid shock loads by using the control switch intermittently to take up wire rope slack. Shock loads can momentarily far exceed the winch and wire rope ratings. During side pulls the wire rope tends to stack up at one
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end of the drum. This stack can become large enough to cause serious damage to the winch. So, line up pulls as straight ahead as possible and stop winching if the wire rope comes close to the tie rods or mounting plate. To fix an uneven stack, spool out that section of the rope and reposition it to the opposite end of the drum, which will free up space for continued winching. 16. Secure vehicle. Once recovery of the vehicle is com- plete, be sure to secure the vehicle’s brakes and put the transmission in 9park9 (automatic) or 9low9 gear for 9manual9 transmissions. Release tension in the wire rope. 17. Disconnect wire rope. Disconnect from the anchor.
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18. Rewind wire rope. The person handling the wire rope should walk the rope in and not let it slide through the hand, control the winch at all times.
WARNING!
To prevent serious injury, NEVER put your fingers inside the hook area as you are powering-in.
NOTE: How to spool under no load: Arrange the remote control lead so it cannot be caught in the winch. Arrange the wire rope so it will not kink or tangle when spooled. Be sure any wire rope already on the spooling drum is wound tightly and evenly layered. Tighten and straighten the layer if necessary. Keep the wire rope under light tension and spool the wire rope back and onto the winch drum in even layers. Stop frequently to tighten and straighten the layers as necessary. Repeat this process until the winch hook is the same distance as the full length of the remote control from the winch. Pinch the hook between your thumb and forefinger and attach the hook strap. Hold the hook strap between the thumb and forefinger to keep tension on the wire rope. Walk the
wire rope towards the fairlead, carefully spooling in the remaining wire rope. By pulsing the remote control switch. 19. Store the hook on the most outboard loop of the tow hook.
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20. Disconnect remote control. Disconnect the remote control cord from the control box and store in a clean and dry place. Winching operations are now complete. Put the cap on the solenoid plug-in. NOTE: Always store the remote control in a protected, clean, dry area. RIGGING TECHNIQUES
