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drops greater than 10 mph (16 km/h), disengage until you can get back to cruising speed.
− Use speed control in flat terrain and with light loads to
maximize fuel efficiency.
Towing Tips — Cooling System 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.
SNOWPLOW Snowplow Prep Packages are available as a factory installed option. These packages include components necessary to equip your vehicle with a snowplow. NOTE: Before installation of a snowplow it is highly recommended that the owner/installer obtain and follow the recommendations contained within the current
Dodge Body Builders Guide. See your authorized dealer, installer or snowplow manufacturer for this information. There are unique electrical systems that must be con- nected to properly assure operator safety and prevent overloading vehicle systems.
WARNING!
Attaching a snowplow to this vehicle could adversely affect performance of the airbag system in an acci- dent. Do not expect that the airbag will perform as described earlier in this manual
CAUTION!
The “Lamp Out” indicator could illuminate if exte- rior lamps are not properly installed.
STARTING AND OPERATING 301
level.
Before Plowing • Check the hydraulic system for leaks and proper fluid • Check the mounting bolts and nuts for proper tight- • Check the runners and cutting edge for excessive wear. The cutting edge should be 1/4 to 1/2 in (6 cm to 1.2 cm) above ground in snow plowing position. • Check that snowplow lighting is connected and func-
ness.
tioning properly.
302 STARTING AND OPERATING
Snowplow Prep Package Model Availability For Information about snowplow applications visit www.dodge.com or refer to the current Dodge Body Builders Guide. 1. The maximum number of occupants in the truck should not exceed two. 2. The total GVWR or the Front GAWR or the Rear GAWR should never be exceeded. 3. The snowplow prep packages are not available with the Sport Package. 4. Cargo capacity will be reduced by the addition of options or passengers, etc. The loaded vehicle weight, including the snowplow system, all aftermarket accessories, driver, passengers, options, and cargo, must not exceed either the Gross Vehicle Weight (GVWR) or Gross Axle Weight (GAWR)
ratings. These weights are specified on the Safety Com- pliance Certification Label on the driver’s side door opening. NOTE: Detach the snowplow when transporting pas- sengers. Vehicle front end wheel alignment was set to specifica- tions at the factory without consideration for the weight of the plow. Front end toe-in should be checked and reset if necessary at the beginning and end of the snowplow season. This will help prevent uneven tire wear. The blade should be lowered whenever the vehicle is parked. Maintain and operate your vehicle and snowplow equip- ment following the recommendations provided by the specific snowplow manufacturer.
Over the Road Operation With Snowplow Attached The blade restricts air flow to the radiator and causes the engine to operate at higher than normal temperatures. Therefore, when transporting the plow, angle the blade completely and position it as low as road or surface conditions permit. Do not exceed 40 mph (64 km/h). The operator should always maintain a safe stopping distance and allow adequate passing clearance. Operating Tips Under ideal snow plowing conditions, 20 mph (32 km/h) should be maximum operating speed. The operator should be familiar with the area and surface to be cleaned. Reduce speed and use extreme caution when plowing unfamiliar areas or under poor visibility. NOTE: During snowplow usage on vehicles equipped with an overhead console module, the outside tempera- ture display will show higher temperatures than the
STARTING AND OPERATING 303
outside ambient temperature. The higher displayed tem- perature is due to blocked or reduced airflow to the underhood ambient temperature sensor by the snow- plow. This is common and outside temperature display operation will return to normal when the snowplow is removed. General Maintenance Snowplows should be maintained in accordance with the plow manufacturer’s instructions. Keep all snowplow electrical connections and battery terminals clean and free of corrosion. When plowing snow, to avoid transmission and drive- train damage, the following precautions should be ob- served.
304 STARTING AND OPERATING
• Operate with transfer case in 4L when plowing small or congested areas where speeds are not likely to exceed 15 mph (24 km/h). At higher speeds operate in 4H. • Vehicles with automatic transmissions should use 4L range when plowing deep or heavy snow for extended periods of time to avoid transmission overheating. • Do not shift the transmission unless the engine has returned to idle and wheels have stopped. Make a practice of stepping on the brake pedal before shifting the transmission.
RECREATIONAL TOWING (BEHIND MOTORHOME, ETC.)
CAUTION!
Front or rear wheel lifts should not be used. Internal damage to the transmission or transfer case will occur if a front or rear wheel lift is used when recreational towing.
Recreational Towing – 2-Wheel Drive Models
Recreational towing of 2-Wheel Drive models is not allowed. Towing with the rear wheels on the ground can result in severe transmission damage.
Recreational Towing – 4-Wheel Drive Models
CAUTION!
Failure to follow these requirements can cause severe damage to the transmission and/or transfer case.
NOTE: Both the manual shift and electronic shift trans- fer cases must be shifted into NEUTRAL for recreational towing. Automatic transmissions must be shifted into the PARK position for recreational towing. Refer to the following for the proper transfer case NEUTRAL shifting procedure for your vehicle. Recreational Towing Procedure — Manual Shift Transfer Case — If Equipped Use the following procedure to prepare your vehicle for recreational towing:
STARTING AND OPERATING 305
CAUTION!
It is necessary to follow these steps to be certain that the transfer case is fully in NEUTRAL before recre- ational towing to prevent damage to internal parts.
1. Bring the vehicle to a complete stop. 2. Shut OFF the engine. 3. Depress the brake pedal. 4. Shift transmission into NEUTRAL. 5. Shift transfer case lever into NEUTRAL. 6. Start the engine. 7. Shift transmission into REVERSE. 8. Release brake pedal for five seconds and ensure that there is no vehicle movement.
306 STARTING AND OPERATING
9. Repeat steps 7 and 8 with the transmission in DRIVE. 10. Shut OFF the engine and place the ignition key in the unlocked OFF position. 11. Shift transmission into PARK. 12. Apply the parking brake. 13. Attach vehicle to tow vehicle with tow bar. 14. Release the parking brake.
CAUTION!
Damage to the transmission may occur if the trans- mission is shifted into PARK with the transfer case in NEUTRAL and the engine running. With the transfer case in NEUTRAL ensure that the engine is OFF prior to shifting the transmission into PARK.
Returning to Normal Operation — Manual Shift Transfer Case Use the following procedure to prepare your vehicle for normal usage: 1. Bring the vehicle to a complete stop. 2. Apply the parking brake. 3. Shut OFF the engine. 4. Depress the brake pedal. 5. Shift transmission into NEUTRAL. 6. Shift transfer case lever to desired position. 7. Shift transmission into PARK.
WARNING!
You or others could be injured if you leave the vehicle unattended with the transfer case in the NEUTRAL position without first fully engaging the parking brake. The transfer case NEUTRAL position disengages both the front and rear driveshafts from the powertrain and will allow the vehicle to move, regardless of the transmission position. The parking brake should always be applied when the driver is not in the vehicle.
CAUTION!
• Do not use a bumper-mounted clamp-on tow bar on your vehicle. The bumper face bar will be damaged.
(Continued)
STARTING AND OPERATING 307
CAUTION! (Continued)
• Do not disconnect the rear driveshaft because fluid will leak from the transfer case and damage the internal parts.
Recreational Towing Procedure — Electronic Shift Transfer Case — If Equipped Use the following procedure to prepare your vehicle for recreational towing:
CAUTION!
It is necessary to follow these steps to be certain that the transfer case is fully in NEUTRAL before recre- ational towing, to prevent damage to internal parts.
1. Bring vehicle to a complete stop. 2. Shut OFF the engine.
308 STARTING AND OPERATING
3. Turn the ignition key to the ON position, but do not start the engine. 4. Depress the brake pedal. 5. Shift transmission into NEUTRAL. 6. Using the point of a ballpoint pen or similar object, depress the recessed transfer case NEUTRAL button for four seconds. 7. After shift is completed and the NEUTRAL light comes on, release the NEUTRAL button. 8. Start engine. 9. Shift transmission into REVERSE. 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.
12. Shut engine OFF and place ignition key in the unlocked OFF position. 13. Shift transmission into PARK. 14. Apply parking brake. 15. Attach vehicle to tow vehicle with tow bar. 16. Release parking brake. NOTE: • Steps 1 through 5 are requirements that must be met prior to depressing the NEUTRAL selection button, and must continue to be met until the four seconds elapses and the shift has been completed. If any of these requirements (with the exception of 3 - Key ON) are not met prior to depressing the NEUTRAL button or are no longer met during the four second timer, then the NEUTRAL indicator light will flash continuously until all requirements are met or until the NEUTRAL button is released.
• The ignition key must be ON for a shift to take place and for the position indicator lights to be operable. If the key in not ON, the shift will not take place and no position indicator lights will be on or flashing. • Flashing NEUTRAL position indicator light indicates
that shift requirements have not been met.
CAUTION!
Damage to the transmission may occur if the trans- mission is shifted into PARK with the transfer case in NEUTRAL and the engine running. With the transfer case in NEUTRAL ensure, that the engine is OFF prior to shifting the transmission into PARK.
Returning to Normal Operation — Electronic Shift Transfer Case Use the following procedure to prepare your vehicle for normal usage:
STARTING AND OPERATING 309
1. Bring vehicle to a complete stop. 2. Shut OFF the engine. 3. Turn the ignition key to the ON position, but do not start the engine. 4. Depress the brake pedal. 5. Shift transmission into NEUTRAL. 6. Using the point of a ballpoint pen or similar object, depress the recessed transfer case Neutral (N) button for one second. 7. After the Neutral indicator light turns off, release the Neutral (N) button. 8. After the Neutral (N) button has been released, the transfer case will shift to the position identified by the selector switch. 9. Shift transmission into PARK.
310 STARTING AND OPERATING
from the 4AUTO (if equipped) position.
NOTE: • The transfer case cannot be shifted into NEUTRAL • Steps 1 through 5 are requirements that must be met prior to depressing the transfer case Neutral (N) button, and must continue to be met until one second elapses and the shift has been completed. If any of these requirements (with the exception of step 3 - key ON) are not met prior to depressing the Neutral (N) button, or are no longer met during the one second time, then all of the mode position indicator lights will flash continuously until all requirements are met, or until the Neutral (N) button is released. • The ignition key must be ON for a transfer case shift to take place and for the position indicator lights to be operable. If the key is not ON, the shift will not take place and no position indicator lights will be on or flashing.
• Flashing Neutral position indicator light indicates that
shift requirements have not been met.
WARNING!
You or others could be injured if you leave the vehicle unattended with the transfer case in the NEUTRAL position without first fully engaging the parking brake. The transfer case NEUTRAL position disengages both the front and rear driveshafts from the powertrain and will allow the vehicle to move despite the transmission position. The parking brake should always be applied when the driver is not in the vehicle.
CAUTION!
• Do not use a bumper-mounted clamp-on tow bar on your vehicle. The bumper face bar will be damaged. • Do not disconnect the rear driveshaft because fluid will leak from the transfer case and fluid loss will damage internal parts.
STARTING AND OPERATING 311
WHAT TO DO IN EMERGENCIES
CONTENTS
䡵 Hazard Warning Flasher . . . . . . . . . . . . . . . . 314
䡵 Jacking And Tire Changing . . . . . . . . . . . . . . . 315
▫ 3500 Models — If Equipped . . . . . . . . . . . . . 315
▫ Preparations For Jacking . . . . . . . . . . . . . . . 316
▫ Jacking Instructions . . . . . . . . . . . . . . . . . . . 317
䡵 Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326▫ With Portable Starting Unit
䡵 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . 326
. . . . . . . . . . . . . 330
䡵 Freeing A Stuck Vehicle . . . . . . . . . . . . . . . . . 330
䡵 Emergency Tow Hooks — If Equipped . . . . . . 330
䡵 Towing A Disabled Vehicle . . . . . . . . . . . . . . . 331
▫ 4-Wheel Drive Vehicles . . . . . . . . . . . . . . . . 331
▫ 2–Wheel Drive Vehicles . . . . . . . . . . . . . . . . 332314 WHAT TO DO IN EMERGENCIES
HAZARD WARNING FLASHER The Hazard Warning flasher switch is mounted on the top of the steering column.
Hazard Warning Flasher Switch
Press the button on the top of the steering column to turn on the Hazard Warning flasher. When the Hazard Warn- ing flasher is activated, all directional turn signals will flash off and on to warn oncoming traffic of an emer- gency. Press the button a second time to turn off the 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. When you must leave the vehicle to seek assistance, the Hazard Warning flasher will continue to operate even though the ignition switch is OFF. NOTE: With extended use, the Hazard Warning flasher may discharge your battery.
JACKING AND TIRE CHANGING
WARNING!
• Being under a jacked-up vehicle is dangerous. The vehicle could slip off the jack and fall on you. You could be crushed. Never put any part of your body under a vehicle that is on a jack. Never start or run the engine while the vehicle is on a jack. If you need to get under a raised vehicle, take it to a service center where it can be raised on a lift. • The jack is designed to use as a tool for changing tires only. The jack should not be used to lift the vehicle for service purposes. The vehicle should be jacked on a firm level surface only. Avoid ice or slippery areas.
WHAT TO DO IN EMERGENCIES 315
3500 Models — If Equipped The jack and jack tools are stored under the front passenger seat. Lift the flap on the side of the seat for access. Remove the jack and tools by removing the wing bolt and sliding the assembly from under the seat.
Jack Location
316 WHAT TO DO IN EMERGENCIES
WARNING!
After using the jack and tools, always reinstall them in the original carrier and location. While driving you may experience abrupt stopping, rapid accelera- tion, or sharp turns. A loose jack, tools, bracket or other objects in the vehicle may move around with force, resulting in serious injury.
4500/5500 Models These vehicles do not come equipped with a jack.
Jacking and tire changing on 4500/5500 models NOTE: should be performed by an authorized dealer, or knowl- edgeable service personnel with the appropriate heavy duty equipment, like a tire service company.
Preparations For Jacking
1. Park the vehicle on a firm level surface. Avoid ice or slippery areas.
WARNING!
Do not attempt to change a tire on the side of the vehicle close to moving traffic. Pull far enough off the road to avoid the danger of being hit when operating the jack or changing the wheel.
2. Set the parking brake. 3. Place the shift lever into PARK (automatic transmis- sion) or REVERSE (manual transmission). On 4-Wheel drive vehicles, shift the transfer case to the “4L” position. 4. Turn OFF the ignition. 5. Turn on the Hazard Warning flasher.
6. Block both the front and rear of the wheel diagonally opposite the jacking position. For example, if the right front wheel is being changed, block the left rear wheel.
NOTE: Passengers should not remain in the vehicle when the vehicle is being jacked. Jacking Instructions
Instructions
WARNING!
Carefully follow these tire changing warnings to help prevent personal injury or damage to your vehicle:
(Continued)
WHAT TO DO IN EMERGENCIES 317
WARNING! (Continued)
be raised.
• Always park on a firm, level surface as far from the edge of the roadway as possible before raising the vehicle. • Block the wheel diagonally opposite the wheel to • Set the parking brake firmly and set an automatic transmission in PARK; a manual transmission in REVERSE. • Never start or run the engine with the vehicle on a • Do not let anyone sit in the vehicle when it is on a • Do not get under the vehicle when it is on a jack. • Only use the jack in the positions indicated and
jack.
jack.
for lifting this vehicle during a tire change.
(Continued)
318 WHAT TO DO IN EMERGENCIES
WARNING! (Continued)
careful of motor traffic.
• If working on or near a roadway, be extremely • To assure that spare tires, flat or inflated are securely stowed, spares must be stowed with the valve stem facing the ground.
• Turn on the Hazard Warning Flasher.
1. If equipped, remove the spare wheel, jack, and tools from storage. 2. Using the wheel wrench, loosen, but do not remove, the wheel nuts by turning them counterclockwise one turn while the wheel is still on the ground. 3. When changing the front wheel, assemble the jack drive tube to the jack and connect the drive tube to the extension tube. Place the jack under the axle as close to the tire as possible with the drive tubes extending to the front. Connect the jack tube extension and wheel wrench.
Jack Warning Label
WHAT TO DO IN EMERGENCIES 319
Front Jacking Locations
Rear Jacking Location
When changing a rear wheel, assemble the jack drive tube to the jack and connect the drive tube to the extension tube. Securely place the jack under the sway bar bracket (unless both tires are flat on one side, then place jack under shock bracket) facing forward in vehicle. Connect the jack tube extension and lug wrench.
Before raising the wheel off the ground, make sure that the jack will not damage surrounding truck parts and adjust the jack position as required.
If the jack will not lower by turning the dial NOTE: (thumbwheel) by hand, it may be necessary to use the jack drive tube in order to lower the jack.
320 WHAT TO DO IN EMERGENCIES
4. By rotating the wheel wrench clockwise, raise the vehicle until the wheel just clears the surface.
WARNING!
Raising the vehicle higher than necessary can make the vehicle unstable and cause an accident. It could slip off the jack and hurt someone near it. Raise the vehicle only enough to remove the tire.
5. Remove the wheel nuts and pull the wheel off. Install the spare wheel and wheel nuts with the cone shaped end of the nuts toward the wheel on single rear wheel (SRW) models. On dual rear wheel models (DRW) the lug nuts are a two-piece assembly with a flat face. Lightly tighten the nuts. To avoid risk of forcing the vehicle off the jack, do not fully tighten the nuts until the vehicle has been lowered.
6. Using the wheel wrench, finish tightening the nuts using a crisscross pattern. Correct nut tightness is 135 ft lbs (183 N·m) torque for single rear wheel (SRW) models and 145 ft lbs (197 N·m) for dual rear wheel models. If in doubt about the correct tightness, have them checked with a torque wrench by your authorized dealer or at a service station.
WARNING!
A loose tire or jack thrown forward in a collision or hard stop could injure someone in the vehicle. Al- ways stow the jack parts and the extra tire and wheel in the places provided.
7. Install wheel center cap (if equipped) and remove wheel blocks. Do not install chrome or aluminum wheel center caps on the spare wheel. This may result in cap damage. 8. Lower the jack to its fully closed position. If the jack will not lower by turning the dial (thumbwheel) by hand, it may be necessary to use the jack drive tube in order to lower the jack. Stow the replaced tire, jack, and tools as previously described. 9. Adjust the tire pressure when possible. NOTE: Do not oil wheel studs. For chrome wheels, do not substitute with chrome plated wheel nuts. Hub Caps/Wheel Covers — If Equipped The hub caps must be removed before raising the vehicle off the ground.
WHAT TO DO IN EMERGENCIES 321
For single rear wheel (SRW) models, use the blade on the end of the lug wrench to pry the hub cap off. Insert the blade end into the pry off notch and carefully pop off the hub cap with a back and forth motion. On 3500 models with dual rear wheels (DRW), you must first remove the hub caps. The jack handle driver has a hook at one end that will fit in the pry off notch of the rear hub caps. Position the hook and pull out on the ratchet firmly. The hub cap should pop off. The wheel skins can now be removed. For the front hub cap on models use the blade on the end of the lug wrench to pry the caps off. The wheel skin can now be removed.
322 WHAT TO DO IN EMERGENCIES
CAUTION!
• Use a back and forth motion to remove the hub cap. Do not use a twisting motion when removing the hub cap, damage to the hub cap; finish may occur. • The rear hub caps on the dual rear wheel has two pry off notches. Make sure that the hook of the jack handle driver is located squarely in the cap notch before attempting to pull off.
You must use the flat end of the lug wrench to pry off the wheel skins. Insert the flat tip completely and using a back and forth motion, loosen the wheel skin. Repeat this procedure around the tire until the skin pops off. Replace the wheel skins first using a rubber mallet. When replacing the hub caps, tilt the cap retainer over the lug
nut bolt circle and strike the high side down with a rubber mallet. Be sure that the hub caps and wheel skins are firmly seated around the wheel. Dual Rear Wheels Dual wheels are flat mounted, center piloted. The lug nuts are a two-piece assembly. When the tires are being rotated or replaced, clean these lug nuts and add two drops of oil at the interface between the hex and the washer.
WHAT TO DO IN EMERGENCIES 323
Dual wheel models require a special heavy-duty lug nut tightening adapter (included with the vehicle) to cor- rectly tighten the lug nuts. Also, when it is necessary to remove and install dual rear wheels, use a proper vehicle lifting device. NOTE: When installing a spare tire (if equipped) as part of a dual rear wheel end combination, the tire diameter of the two individual tires must be compared. If there is a significant difference, the larger tire should be installed in a front location. Correct direction of rotation for dual tire installations must also be observed.
Oiling Location
Slots in the wheels will assist in properly orienting the inner and outer wheels. Align these slots when assem- bling the wheels for best access to the tire valve on the inner wheel. The tires of both dual wheels must be completely off the ground when tightening to insure wheel centering and maximum wheel clamping.
324 WHAT TO DO IN EMERGENCIES
These dual rear wheels should be tightened as follows:
Tightening Pattern (8 Studs)
Tightening Pattern (10 Studs)
1. Tighten the wheel nuts in the numbered sequence to a snug fit. 2. Retighten the wheel nuts in the same sequence to the torques listed in the table. Go through the sequence a
WHAT TO DO IN EMERGENCIES 325
second time to verify that specific torque has been achieved. Retighten to specifications at 100 miles (160 km) and after 500 miles (800 km). It is recommended that wheel stud nuts be kept torqued to specifications at all times. Torque wheel stud nuts to specifications at each lubrication interval. Wheel Nut Torque All wheel nuts should be tightened occasionally to elimi- nate the possibility of wheel studs being sheared or the
bolt holes in the wheels becoming elongated. This is especially important during the first few hundred miles/ kilometers of operation to allow the wheel nuts to become properly set. All nuts should first be firmly seated against the wheel. The nuts should then be tightened to recommended torque. Tighten the nuts to final torque in increments. Progress around the bolt circle, tightening the nut opposite to the nut just previ- ously tightened until final torque is achieved. Recom- mended torques are shown in the following chart.
Disc Wheels
Type Nut
Stud Size
Torque Ft Lbs
Cone Flanged
9/16-18
9/16-18120-150
130-160Torque Newton Meters 160-200
190-220326 WHAT TO DO IN EMERGENCIES
To Stow The Flat Or Spare — If Equipped Refer to Upfitters Body Builders Guide for information on stowing your spare tire (if equipped).
HOISTING A conventional floor jack may be used at the jacking locations. Refer to the graphics that show jacking loca- tions. However, a floor jack or frame hoist must never be used on any other parts or the underbody.
CAUTION!
Never use a floor jack directly under the differential housing of a loaded truck or damage to your vehicle may result.
JUMP STARTING
WARNING!
• To prevent personal injury or damage to clothing, do not allow battery fluid to contact eyes, skin or fabrics. Do not lean over a battery when connect- ing jumper cables or allow cable clamps to touch each other. Keep open flames or sparks away from battery vent holes. Always wear eye protection when working with batteries. • Do not use a booster battery or any other booster source that has a greater than 12-Volt system, i.e., do not use a 24-Volt power source.
NOTE: Replacement batteries should both be of equal size to prevent damage to the vehicle’s charging system.
Your vehicle is equipped with two 12-Volt batteries. If it becomes necessary to use a booster battery with jumper cables to start a vehicle’s engine because its batteries are discharged, the following procedure should be used: Set the parking brake and place the transmission in PARK. Turn off lights, heater and other electrical loads. Observe charge indicator (if equipped) in both batteries. If the indicator (if equipped) is light or yellow on either battery, replace that battery.
WHAT TO DO IN EMERGENCIES 327
CAUTION!
Use the Jump-Start Procedure only when the charge indicator (if equipped) in both batteries is dark in the center. Do not attempt jump-starting when either battery charge indicator (if equipped) is bright or yellow. If the charge indicator (if equipped) has a green dot in the center, failure to start is not due to a discharged battery and cranking system should be checked.
1. Attach one jumper cable to the positive terminal of booster battery and the other end of the same cable to the positive terminal of the discharged battery.
328 WHAT TO DO IN EMERGENCIES
WARNING!
Do not permit vehicles to touch each other as this could establish a ground connection and personal injury could result.
Attaching Booster Cables
1 — Discharged Battery 2 — Booster Battery
2. Connect one end of the other jumper cable to negative (-) post of booster battery. Connect the other end of the jumper cable to a good ground on the engine block of the
vehicle with the discharged battery. Make sure a good connection is made, free of dirt and grease.
4. After the engine is started or if the engine fails to start, cables must be disconnected in the following order:
WHAT TO DO IN EMERGENCIES 329
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 be- low freezing point, electrolyte in a discharged battery may freeze. Do not attempt jump-starting because the battery could rupture or explode. The battery temperature must be brought up above freezing point before attempting to jump-start.
3. Take care that the clamps from one cable do not inadvertently touch clamps from the other cable. Do not lean over the battery when making connection. The negative connection must provide good electrical con- ductivity and current carrying capacity.
a. Disconnect the negative cable at the engine ground. b. Disconnect the negative cable at the negative post on booster battery. c. Disconnect the cable from the positive post of both batteries.
WARNING!
the battery vent;
Any procedure other than above could result in: • Personal injury caused by electrolyte squirting out • Personal injury or property damage due to battery • Damage to charging system of booster vehicle or
explosion;
of immobilized vehicle.
330 WHAT TO DO IN EMERGENCIES
With Portable Starting Unit There are many types of these units available. Follow the manufacturer’s instructions for necessary precautions and operation.
CAUTION!
It is very important that the starting unit operating voltage does not exceed 12-Volts DC or damage to battery, starter motor, alternator, or electrical system may occur.
FREEING A STUCK VEHICLE If the vehicle becomes stuck in snow, sand, or mud, it can often be moved by a rocking motion. Move the shift lever rhythmically between DRIVE and REVERSE while ap- plying slight pressure to the accelerator.
In general, the least amount of accelerator pedal pressure to maintain the rocking motion without spinning the wheels or racing the engine, is most effective. Racing the engine or spinning the wheels, due to the frustration of not freeing the vehicle, may lead to transmission over- heating and failure. Allow the engine to idle with the shift lever in NEUTRAL for at least one minute after every five rocking-motion cycles. This will minimize overheating and reduce the risk of transmission failure during prolonged efforts to free a stuck vehicle.
EMERGENCY TOW HOOKS — IF EQUIPPED Your vehicle may be equipped with emergency tow hooks. NOTE: For off-road recovery, it is recommended to use both of the front tow hooks to minimize the risk of damage to the vehicle.
WARNING!
• Chains are not recommended for freeing a stuck vehicle. Chains may break, causing serious injury or death. • Stand clear of vehicles when pulling with tow hooks. Tow straps and chains may break, causing serious injury.
CAUTION!
Tow hooks are for emergency use only to rescue a vehicle stranded off-road. Do not use tow hooks for tow truck hookup or highway towing. You could damage your vehicle.
WHAT TO DO IN EMERGENCIES 331
TOWING A DISABLED VEHICLE Proper towing or lifting equipment is required to prevent damage to your vehicle. Use only tow bars and other equipment designed for the purpose, following equip- ment manufacturer’s instructions. Use of safety chains is mandatory. Attach a tow bar or other towing device to the main structural members of the vehicle—not to bumpers or associated brackets. State and local laws applying to vehicles under tow must be observed. 4-Wheel Drive Vehicles
CAUTION!
To avoid damage to the transfer case while towing, always use one of the following methods.
332 WHAT TO DO IN EMERGENCIES
NOTE: The transfer case must be in the neutral position, and the transmission must be in PARK (automatic trans- mission), or in gear (manual transmission) to tow a 4-Wheel Drive vehicle with one end of the vehicle raised. The manufacturer recommends towing with all wheels OFF the ground. Acceptable methods are to tow the vehicle on a flatbed or with one end of vehicle raised and the opposite end on a towing dolly. 2–Wheel Drive Vehicles Provided that the transmission is operable, tow with the transmission in NEUTRAL and the ignition key in the OFF position along with the front wheels raised and the rear wheels on the ground. Speed must not exceed 30 mph (50 km/h) and distance must not exceed 15 miles (25 km).
CAUTION!
Towing faster than 30 mph (50 km/h) or for more than 15 miles (25 km) can cause severe damage to the transmission.
If the vehicle is to be towed faster than 30 mph (50 km/h) or more than 15 miles (25 km) the vehicle must be towed with the rear wheels raised and the front wheels on the ground. It may also be towed on a flatbed or with the front wheels raised and the rear wheels on a dolly.
MAINTAINING YOUR VEHICLE
CONTENTS
䡵 Engine Compartment— 5.7L . . . . . . . . . . . . . . 335
䡵 Onboard Diagnostic System (OBD II) . . . . . . . 336
▫ Loose Fuel Filler Cap Message . . . . . . . . . . . 336
䡵 Replacement Parts . . . . . . . . . . . . . . . . . . . . . 337
䡵 Dealer Service . . . . . . . . . . . . . . . . . . . . . . . . 337
䡵 Maintenance Procedures . . . . . . . . . . . . . . . . . 338
▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 338
▫ Engine Air Cleaner Filter . . . . . . . . . . . . . . . 340
▫ Maintenance Free Battery . . . . . . . . . . . . . . 341▫ Air Conditioner Maintenance . . . . . . . . . . . . 342
▫ Body Lubrication . . . . . . . . . . . . . . . . . . . . 343
▫ Windshield Wiper Blades . . . . . . . . . . . . . . . 344
▫ Adding Washer Fluid . . . . . . . . . . . . . . . . . 344
▫ Exhaust System . . . . . . . . . . . . . . . . . . . . . 345
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . 348
▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . 353
▫ Rear Axle And 4X4 Front Driving Axle FluidLevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
334 MAINTAINING YOUR VEHICLE
▫ Transfer Case — If Equipped . . . . . . . . . . . . 356
▫ Automatic Transmission . . . . . . . . . . . . . . . 356
▫ Appearance Care And Protection FromCorrosion . . . . . . . . . . . . . . . . . . . . . . . . . . 359
䡵 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
▫ Integrated Power Module . . . . . . . . . . . . . . 364
䡵 Vehicle Storage . . . . . . . . . . . . . . . . . . . . . . . 369
䡵 Replacement Light Bulbs . . . . . . . . . . . . . . . . 370䡵 Bulb Replacement
. . . . . . . . . . . . . . . . . . . . . 370
▫ Headlight (Halogen)/Front Park And Turn
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
▫ Fog Lights . . . . . . . . . . . . . . . . . . . . . . . . . 374
▫ Cab Top Clearance Lights — If Equipped . . . 375
䡵 Fluid And Capacities . . . . . . . . . . . . . . . . . . . 377
䡵 Fluids, Lubricants And Genuine Parts . . . . . . . 378
▫ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
▫ Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . 379ENGINE COMPARTMENT— 5.7L
MAINTAINING YOUR VEHICLE 335
1 — Air Cleaner Filter 2 — Automatic Transmission Dipstick 3 — Engine Oil Fill 4 — Brake Fluid Reservoir 5 — Battery 6 — Integrated Power Module
7 — Engine Oil Dipstick 8 — Power Steering Fluid Reservoir 9 — Washer Fluid Reservoir 10 — Engine Coolant Reservoir 11 — Coolant Pressure Cap
336 MAINTAINING YOUR VEHICLE
ONBOARD DIAGNOSTIC SYSTEM (OBD II) Vehicles with 5.7L engines are equipped with a sophisti- cated onboard diagnostic system called OBD II. This system monitors the performance of the emissions, en- gine, and automatic transmission control systems. When these systems are operating properly, your vehicle will provide excellent performance and fuel economy, as well as engine emissions well within current government regulations. If any of these systems require service, the OBD II system will turn on the Malfunction Indicator Light (MIL). It will also store diagnostic codes and other information to assist your service technician in making repairs. Al- though your vehicle will usually be driveable and not need towing, see your authorized dealer for service as soon as possible.
CAUTION!
Prolonged driving with the MIL on could cause further damage to the emission control system. It could also affect fuel economy and driveability. The vehicle must be serviced before any emissions tests can be performed. If the MIL is flashing, severe catalytic converter damage and power loss will soon occur. Immediate service is required.
Loose Fuel Filler Cap Message
If the vehicle’s diagnostic system determines that the fuel filler cap is loose, improperly installed, or damaged, a gASCAP message will be displayed in the instrument cluster. Tighten the gas cap until a “clicking” sound is heard. This is an indication that the gas cap is properly tightened. Press the odometer reset button to turn the message off. If the problem persists, the message will
appear the next time the vehicle is started. This might indicate a damaged cap. If the problem is detected twice in a row, turn on the Malfunction Indicator Light (MIL). Resolving the problem will turn the MIL light off.
the system will
REPLACEMENT PARTS Use of genuine MOPAR威 parts for normal/scheduled maintenance and repairs is highly recommended to en- sure the designed performance. Damage or failures caused by the use of non-MOPAR威 parts for maintenance and repairs will not be covered by the manufacturer’s warranty.
DEALER SERVICE Your authorized dealer has the qualified service person- nel, special tools and equipment to perform all service operations in an expert manner. Service Manuals are
MAINTAINING YOUR VEHICLE 337
available which include detailed service information for your vehicle. Refer to these manuals before attempting any procedure yourself. NOTE: systems can result against you.
Intentional tampering with emissions control in civil penalties being assessed
WARNING!
You can be badly injured working on or around a motor vehicle. Do only that service work for which you have the knowledge and the proper equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent mechanic.
338 MAINTAINING YOUR VEHICLE
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 Oil Level To assure proper lubrication of your vehicle’s engine, the engine oil must be maintained at the correct level. Check the oil level at regular intervals. The best time to check the oil level is before starting the engine after it has been parked overnight. When checking oil after operating the
engine, first ensure the engine is at full operating tem- perature, then wait for 15 minutes after engine shutdown to check the oil. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level readings. Always maintain the oil level within the SAFE zone on the dipstick. Adding one quart of oil when the reading is at the bottom of the SAFE zone will result in a reading at the top of the safe zone on these engines.
CAUTION!
Overfilling or underfilling the crankcase will cause oil aeration or loss of oil pressure. This could damage your engine.
Never operate the engine with oil level below the “ADD” mark or above the upper “SAFE” mark.
Change Engine Oil Refer to the “Maintenance Schedule” in Section 8 for the proper maintenance intervals. Engine Oil Selection For best performance and maximum protection under all types of operating conditions, the manufacturer only recommends engine oils that are API certified and meet the requirements of Chrysler Material Standard MS-6395. American Petroleum Institute (API) Engine Oil Identification Symbol
This symbol means that the oil has been certified by the American Petroleum Institute (API). The manufacturer only recommends API Certified engine oils.
MAINTAINING YOUR VEHICLE 339
Engine Oil Viscosity (SAE Grade) For trucks with a 5.7L engine operating under a gross combined weight rating of 14,000 lbs (6,350 kg) or greater, SAE 5W-30 engine oil is recommended for all operating temperatures. For all other trucks with a 5.7L engine operating under a gross weight rating less than 14,000 lbs (6,350 kg) SAE 5W-20 engine oil is recommended for all operating tem- peratures. These engine oils improve low temperature starting and vehicle fuel economy. Your engine oil filler cap also shows the recommended engine oil viscosity for your vehicle. For information on engine oil filler cap location, refer to “Engine Compartment” in this section. Lubricants which do not have both the engine oil certi- fication mark and the correct SAE viscosity grade num- ber should not be used.
340 MAINTAINING YOUR VEHICLE
Synthetic Engine Oils You may use synthetic engine oils provided the recom- mended oil quality requirements are met, and the recom- mended maintenance intervals for oil and filter changes are followed. Materials Added to Engine Oil Do not add supplemental materials, other than leak detection dyes, to your engine oil. Engine oil is an engineered product and its performance may be im- paired by supplemental additives. Engine Oil Filter The engine oil filter should be changed at every engine oil change. Refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct part number.
Disposing Of Used Engine Oil And Filter Care should be taken in disposing of the used engine fluids from your vehicle. Used fluids, indiscriminately discarded, can present a problem to the environment. Contact an authorized dealer, service station, or govern- mental agency for advice on recycling programs and where used fluids and filters can be safely discarded in your area. Engine Air Cleaner Filter Refer to the “Maintenance Schedule” in Section 8 of this manual for the proper maintenance intervals.
WARNING!
The air induction system (air cleaner, hoses, etc) can provide a measure of protection in the case of engine backfire. Do not remove the air induction system (air cleaner, hoses, etc) unless such removal is necessary for repair or maintenance. Make sure that no one is near the engine compartment before starting the vehicle with the air induction system (air cleaner, hoses, etc) removed. Failure to do so can result in serious personal injury.
Engine Air Cleaner Filter Selection The quality of replacement engine air cleaner filters varies considerably. Only high quality filters should be used to assure most efficient service. MOPAR威 engine air cleaner filters are a high quality filter and are recommended.
MAINTAINING YOUR VEHICLE 341
Maintenance Free Battery The top of the maintenance free battery is permanently sealed. You will never have to add water, nor is periodic maintenance required.
WARNING!
• Battery fluid is a corrosive acid solution and can burn or even blind you. Do not allow battery fluid to contact your eyes, skin or clothing. Do not lean over a battery when attaching clamps. If acid splashes in eyes or on skin, flush the area imme- diately with large amounts of water. • Battery gas is flammable and explosive. Keep flame or sparks away from the battery. Do not use a booster battery or any other booster source with an output greater than 12 Volts. Do not allow cable clamps to touch each other.
(Continued)
342 MAINTAINING YOUR VEHICLE
WARNING! (Continued)
• Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.
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. • If a “fast charger” is used while battery is in vehicle, disconnect both vehicle battery cables before connecting the charger to battery. Do not use a “fast charger” to provide starting voltage.
Air Conditioner Maintenance For best possible performance, your air conditioner should be checked and serviced by an authorized dealer at the start of each warm season. This service should include cleaning of the condenser fins and a performance test. Drive belt tension should also be checked at this time.
WARNING!
• Use only refrigerants and compressor lubricants approved by the manufacturer for your air condi- tioning system. Some unapproved refrigerants are flammable and can explode, injuring you. Other unapproved refrigerants or lubricants can cause the system to fail, requiring costly repairs. Refer to Section 3 of the Warranty Information Book for further warranty information.
(Continued)
WARNING! (Continued)
• 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 repair person.
NOTE: Use only manufacturer approved A/C System Sealers, Stop Leak Products, Seal Conditioners, Compres- sor Oil, or Refrigerants. Refrigerant Recovery and Recycling R-134a air conditioning refrigerant is a hydrofluoro- carbon (HFC) that is endorsed by the Environmental Protection Agency and is an ozone-saving product. How- ever, the manufacturer recommends that air conditioning service be performed by authorized dealers or other service facilities using recovery and recycling equipment.
MAINTAINING YOUR VEHICLE 343
Body Lubrication Locks and all body pivot points, including such items as seat tracks, door hinge pivot points and rollers, liftgate, tailgate, sliding doors and hood hinges, should be lubri- cated periodically with a lithium based grease such as MOPAR威 Spray White Lube to assure quiet, easy opera- tion and to protect against rust and wear. Prior to the application of any lubricant, the parts concerned should be wiped clean to remove dust and grit; after lubricating excess oil and grease should be removed. Particular attention should also be given to hood latching compo- nents to 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 MOPAR威 Lock Cylinder Lubricant directly into the lock cylinder.
344 MAINTAINING YOUR VEHICLE
Windshield Wiper Blades Clean the rubber edges of the wiper blades and the windshield periodically with a sponge or soft cloth and a mild nonabrasive cleaner. This will remove accumula- tions of salt or road film. Operation of the wipers on dry glass for long periods may cause deterioration of the wiper blades. Always use washer fluid when using the wipers to remove salt or dirt from a dry windshield. Avoid using the wiper blades to remove frost or ice from the windshield. Keep the blade rubber out of contact with petroleum products such as engine oil, gasoline, etc.
Adding Washer Fluid The fluid reservoir is located under the hood and should be checked for fluid level at regular intervals. Fill the reservoir with windshield washer solvent only (not ra- diator antifreeze). When refilling the washer fluid reser- voir, take some washer fluid and apply it to a cloth or towel and wipe clean the wiper blades; this will help blade performance. To prevent freeze-up of your windshield washer system in cold weather, select a solution or mixture that meets or exceeds the temperature range of your climate. This rating information can be found on most washer fluid containers. The washer fluid reservoir will hold a full gallon/liter of fluid when the “Low Washer Fluid Light” illuminates.
WARNING!
Commercially available windshield washer solvents are flammable. They could ignite and burn you. Care must be exercised when filling or working around the washer solution.
After the engine has warmed, operate the defroster for a few minutes to reduce the possibility of smearing or freezing the fluid on the cold windshield. MOPAR威 All Weather Windshield Washer Solution, used with water as directed on the container, aids cleaning action, reduces the freezing point to avoid line clogging, and is not harmful to paint or trim. Exhaust System The best protection against carbon monoxide entry into the vehicle body is a properly maintained engine exhaust system.
MAINTAINING YOUR VEHICLE 345
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 parts 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.
346 MAINTAINING YOUR VEHICLE
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.
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
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 exhaust system. Do not park or operate your vehicle in areas where your exhaust system can contact anything that can burn.
In unusual situations involving grossly malfunctioning engine operation, a scorching odor may indicate severe and abnormal catalyst overheating. If this occurs, the vehicle should be stopped, the engine shut off and the vehicle allowed to cool. Thereafter, service, including a tune-up to manufacturer’s specifications, should be ob- tained immediately.
MAINTAINING YOUR VEHICLE 347
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.
348 MAINTAINING YOUR VEHICLE
Cooling System
WARNING!
You or others can be badly burned by hot engine coolant (antifreeze) or steam from your radiator. If you see or hear steam coming from under the hood, do not open the hood until the radiator has had time to cool. Never try to open a cooling system pressure cap when the radiator is hot.
Engine Coolant Checks Check the engine coolant (antifreeze) protection every 12 months (before the onset of freezing weather, where applicable). If the engine coolant (antifreeze) is dirty or rusty in appearance, the system should be drained, flushed and refilled with fresh engine coolant (anti- freeze). Check the front of the A/C condenser for any
accumulation of bugs, leaves, etc. If dirty, clean by gently spraying water from a garden hose vertically down the face of the condenser. Check the coolant recovery bottle tubing for brittle rub- ber, cracking, tears, cuts and tightness of the connection at the bottle and radiator. Inspect the entire system for leaks. With the engine at normal operating temperature (but not running), check the cooling system pressure cap for proper vacuum sealing by draining a small amount of engine coolant (antifreeze) from the radiator drain cock. If the cap is sealing properly, the engine coolant (anti- freeze) will begin to drain from the coolant recovery bottle. DO NOT REMOVE THE COOLANT PRESSURE CAP WHEN THE COOLING SYSTEM IS HOT.
Cooling System — Drain, Flush and Refill If the engine coolant (antifreeze) is dirty or contains a considerable amount of sediment, clean and flush with a reliable cooling system cleaner. Follow with a thorough rinsing to remove all deposits and chemicals. Properly dispose of the old engine coolant (antifreeze) solution. Refer to the “Maintenance Schedule” in Section 8 of this manual for the proper maintenance intervals. Selection Of Coolant Use only the manufacturers recommended engine cool- ant (antifreeze). Refer to “Fluids, Lubricants, and Genu- ine Parts” in this section for the correct fluid type.
MAINTAINING YOUR VEHICLE 349
CAUTION!
• Mixing of engine coolant (antifreeze) other than specified HOAT engine coolant (antifreeze), may result in engine damage and may decrease corro- sion protection. If a non-HOAT engine coolant (antifreeze) is introduced into the cooling system in an emergency, it should be replaced with the specified engine coolant (antifreeze) as soon as possible. • Do not use water alone or alcohol-based engine coolant (antifreeze) products. Do not use addi- tional rust inhibitors or antirust products, as they may not be compatible with the radiator engine coolant (antifreeze) and may plug the radiator.
(Continued)
350 MAINTAINING YOUR VEHICLE
CAUTION! (Continued)
• This vehicle has not been designed for use with (anti- Propylene Glycol based engine coolant freeze). Use of Propylene Glycol based engine coolant (antifreeze) is not recommended.
Adding Coolant Your vehicle has been built with an improved engine coolant (antifreeze) that allows extended maintenance intervals. This engine coolant (antifreeze) can be used up to 5 Years or 102,000 miles (170 000 km) before replace- ment. To prevent reducing this extended maintenance period, it is important that you use the same engine coolant (antifreeze) throughout the life of your vehicle. Please review these recommendations for using Hybrid Organic Additive Technology (HOAT) engine coolant (antifreeze).
When adding engine coolant (antifreeze): • The manufacturer
recommends using MOPAR威 Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology). • Mix a minimum solution of 50% HOAT engine coolant (antifreeze) and distilled water. Use higher concentra- tions (not to exceed 70%) if temperatures below -34°F (-37°C) are anticipated. • Use only high purity water such as distilled or deion- ized water when mixing the water/engine coolant (antifreeze) solution. The use of lower quality water will reduce the amount of corrosion protection in the engine cooling system.
Please note that it is the owner’s responsibility to main- tain the proper level of protection against freezing ac- cording to the temperatures occurring in the area where the vehicle is operated.
NOTE: Mixing engine coolant (antifreeze) types will decrease the life of the engine coolant (antifreeze) and will require more frequent engine coolant (antifreeze) changes. Cooling System Pressure Cap The cap must be fully tightened to prevent loss of engine coolant (antifreeze), and to ensure that engine coolant (antifreeze) will return to the radiator from the coolant recovery bottle. The cap should be inspected and cleaned if there is any accumulation of foreign material on the sealing surfaces.
MAINTAINING YOUR VEHICLE 351
WARNING!
• The warning words “DO NOT OPEN HOT” on the cooling system pressure cap are a safety pre- caution. Never add engine coolant (antifreeze) when the engine is overheated. Do not loosen or remove the cap to cool an overheated engine. Heat causes pressure to build up in the cooling system. To prevent scalding or injury, do not remove the pressure cap while the system is hot or under pressure. • Do not use a pressure cap other than the one specified for your vehicle. Personal injury or en- gine damage may result.
352 MAINTAINING YOUR VEHICLE
Disposal of Used Engine Coolant Used ethylene glycol based engine coolant (antifreeze) is a regulated substance requiring proper disposal. Check with your local authorities to determine the disposal rules for your community. To prevent ingestion by ani- mals or children, do not store ethylene glycol based engine coolant (antifreeze) in open containers or allow it to remain in puddles on the ground. If ingested by a child, contact a physician immediately. Clean up any ground spills immediately. Coolant Level The coolant bottle provides a quick visual method for determining that the coolant level is adequate. With the engine cold, the level of the engine coolant (antifreeze) in the coolant recovery bottle should be between the ranges indicated on the bottle. The radiator normally remains completely full, so there is no need to remove the radiator cap unless checking for
engine coolant (antifreeze) freeze point or replacing en- gine coolant (antifreeze). Advise your service attendant of this. As long as the engine operating temperature is satisfactory, the coolant bottle need only be checked once a month. When additional engine coolant (antifreeze) is needed to maintain the proper level, it should be added to the coolant bottle. Do not overfill. Points To Remember NOTE: When the vehicle is stopped after a few miles (a few kilometers) of operation, you may observe vapor coming from the front of the engine compartment. This is normally a result of moisture from rain, snow, or high humidity accumulating on the radiator and being vapor- ized when the thermostat opens, allowing hot engine coolant (antifreeze) to enter the radiator.
If an examination of your engine compartment shows no evidence of radiator or hose leaks, the vehicle may be safely driven. The vapor will soon dissipate. • Do not overfill the coolant recovery bottle. • Check engine coolant (antifreeze) freeze point in the radiator and in the coolant recovery bottle. If engine coolant (antifreeze) needs to be added, contents of coolant recovery bottle must also be protected against freezing. • If frequent engine coolant (antifreeze) additions are required, or if the level in the coolant recovery bottle does not drop when the engine cools, the cooling system should be pressure tested for leaks. • Maintain engine coolant (antifreeze) concentration at 50% HOAT engine coolant (antifreeze) (minimum) and distilled water for proper corrosion protection of your engine, which contains aluminum components.
MAINTAINING YOUR VEHICLE 353
• Make sure that the radiator and coolant recovery bottle overflow hoses are not kinked or obstructed. • Keep the front of the radiator clean. If your vehicle is equipped with air conditioning, keep the front of the condenser clean. • Do not change the thermostat for Summer or Winter install operation. If replacement is ever necessary, ONLY the correct type thermostat. Other designs may result in unsatisfactory cooling performance, poor gas mileage, and increased emissions.
Brake System
Brake Master Cylinder – Brake Fluid Level Check The fluid level of the master cylinder should be checked when performing under the hood service, or immedi- ately if the brake system warning lamp indicates system failure.
354 MAINTAINING YOUR VEHICLE
The brake master cylinder has a translucent plastic reservoir. On the outboard side of the reservoir, there is a “MAX” mark and an “MIN” mark (4500/5500 vehicles only). The fluid level must be kept within these two marks. Do not add fluid above the full mark because leakage may occur at the cap. With disc brakes, the fluid level can be expected to fall as the brake linings wear. However, an unexpected drop in fluid level may be caused by a leak and a system check should be conducted. Refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct fluid type.
WARNING!
• Use of a brake fluid that may have a lower initial boiling point, or unidentified as to specification, may result in sudden brake failure during hard prolonged braking. You could have an accident. • Overfilling the brake fluid reservoir can result in spilling brake fluid on hot engine parts and the brake fluid catching fire.
Use only brake fluid that has been in a tightly closed or sealed container to avoid contamination from foreign matter or moisture.
CAUTION!
Do not allow a petroleum-based fluid to contaminate the brake fluid. Seal damage and loss of brake performance may result.
Rear Axle And 4x4 Front Driving Axle Fluid Level For models with 9.25 in Front Axles and 11.5 in Rear Axles, refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct fluid type. For normal service, periodic fluid level checks are not required. When the vehicle is serviced for other reasons, the exterior surfaces of the axle assembly should be inspected. When checking the fluid level (4500/5500 only), the vehicle should be in a level position. The fluid level should be 1/4 in ± 1/4 in (6.4 mm ± 6.4 mm) below the fill hole on the front axle. The fluid level should be level with the bottom of the fill hole on the rear axle. Drain And Refill On 4500/5500 vehicles, remove the lower bolt to drain the axle fluid.
MAINTAINING YOUR VEHICLE 355
1 — 4500/5500 Rear Axle Fluid Fill Plug 2 — 4500/5500 Rear Axle Fluid Drain Plug
Refer to the “Maintenance Schedule” in Section 8 of this manual for the proper maintenance intervals.
356 MAINTAINING YOUR VEHICLE
Lubricant Selection Refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct fluid type. NOTE: The presence of water in the gear lubricant will result in corrosion and possible failure of differential components. Operation of the vehicle in water, as may be encountered in some off-highway types of service, will require draining and refilling the axle to avoid damage. Limited-Slip Differentials DO NOT REQUIRE any limited slip oil additive (friction modifiers). NOTE: Slight noise and mild shuddering may be evi- dent while turning a vehicle with limited slip differential on concrete or dry pavement. These conditions should be considered normal operation of limited slip differential.
the
Transfer Case — If Equipped
Drain And Refill Refer to the “Maintenance Schedule” in Section 8 of this manual for the proper maintenance intervals. Lubricant Selection Refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct fluid type. Fluid Level Check This fluid level can be checked by removing the filler plug. The fluid level should be to the bottom edge of the filler plug hole with the vehicle in a level position. Automatic Transmission
Selection Of Lubricant It is important that the proper lubricant is used in the transmission to assure optimum transmission perfor- mance. Use only manufacturer’s recommended transmis- sion fluid. Refer to “Fluids, Lubricants, and Genuine
Parts” in this section for the correct fluid type. It is important that the transmission fluid be maintained at the prescribed level using the recommended fluid.
CAUTION!
Using a transmission fluid other than the manufac- turer’s recommended fluid may cause deterioration in transmission shift quality and/or torque converter shudder. Using a transmission fluid other than the manufacturer’s recommended fluid will result in more frequent fluid and filter changes. Refer to “Fluids, Lubricants, and Genuine Parts” in this sec- tion for the correct fluid type.
Fluid Level Check – 545RFE Transmission Check the fluid level while the transmission is at normal operating temperature 180°F (82°C). This occurs after at least 15 miles (25 km) of driving. At normal operating
MAINTAINING YOUR VEHICLE 357
temperature, the fluid on the end of the dipstick cannot be held comfortably between the fingertips. Procedure For Checking Fluid Level To properly check the automatic transmission fluid level, the following procedure must be used: 1. Operate the engine at idle speed and normal operating temperature. 2. The vehicle must be on level ground. 3. Fully apply parking brake. 4. Place the shift lever momentarily in each gear position ending with the lever in PARK. 5. Remove the dipstick, wipe it clean and reinsert it until seated.
358 MAINTAINING YOUR VEHICLE
6. Remove the dipstick again and note the fluid level on both sides. The fluid level should be between the HOT (upper) reference holes on the dipstick at normal operat- ing temperature. Verify that a solid coating of oil is seen on both sides of the dipstick. If the fluid is low, add as required into the dipstick tube. Do not overfill. After adding any quantity of oil through the dipstick tube, wait a minimum of two minutes for the oil to fully drain into the transmission before rechecking the fluid level. If it is necessary to check the transmission below NOTE: the operating temperature, the fluid level should be between the two cold (lower) holes on the dipstick with the fluid at approximately 70°F (21°C) (room tempera- ture). If the fluid level is correctly established at room temperature, it should be between the HOT (upper) reference holes when the transmission reaches 180°F (21°C). Remember it is best to check the level at the normal operating temperature.
CAUTION!
Be aware that if the fluid temperature is below 50°F (10°C), it may not register on the dipstick. Do not add fluid until the temperature is elevated enough to produce an accurate reading.
7. Check for leaks. Release the parking brake. NOTE: To prevent dirt and water from entering the transmission after checking or replenishing fluid, make certain that the dipstick cap is properly reseated. It is normal for the dipstick cap to spring back slightly from its fully seated positions, as long as its seal remains engaged in the dipstick tube. Automatic Transmission Fluid and Filter Change Refer to the “Maintenance Schedule” in Section 8 of this manual for the proper maintenance intervals.
If the transmission is disassembled for any
NOTE: reason, the fluid and filter should be changed. It is important that proper lubricant is used in the transmission. Refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct fluid type. Special Additives Automatic Transmission Fluid (ATF) is an engineered product and its performance may be impaired by supple- mental additives. Therefore, do not add any fluid addi- tives to the transmission. The only exception to this policy is the use of special dyes to aid in detecting fluid leaks. In addition, avoid using transmission sealers as they may adversely affect seals. Appearance Care and Protection from Corrosion
Protection of Body and Paint from Corrosion Vehicle body care requirements vary according to geo- graphic locations and usage. Chemicals that make roads
MAINTAINING YOUR VEHICLE 359
passable in snow and ice, and those that are sprayed on trees and road surfaces during other seasons, are highly corrosive to the metal in your vehicle. Outside parking, which exposes your vehicle to airborne contaminants, road surfaces on which the vehicle is operated, extreme hot or cold weather and other extreme conditions will have an adverse affect on paint, metal trim, and under- body protection. The following maintenance recommendations will enable you to obtain maximum benefit from the corrosion resistance built into your vehicle. What Causes Corrosion? Corrosion is the result of deterioration or removal of paint and protective coatings from your vehicle. The most common causes are: • Road salt, dirt and moisture accumulation. • Stone and gravel impact.
360 MAINTAINING YOUR VEHICLE
• Insects, tree sap and tar. • Salt in the air near seacoast localities. • Atmospheric fallout/industrial pollutants. Washing • Wash your vehicle regularly. Always wash your ve- hicle in the shade using MOPAR威 Car Wash or a mild car wash soap, and rinse the panels completely with clear water. • If insects, tar or other similar deposits have accumu- lated on your vehicle, use MOPAR威 Super Kleen Bug and Tar Remover to remove. • Use MOPAR威 Cleaner Wax to remove road film, stains and to protect your paint finish. Take care never to scratch the paint.
• Avoid using abrasive compounds and power buffing that may diminish the gloss or thin out the paint finish.
CAUTION!
Do not use abrasive or strong cleaning materials such as steel wool or scouring powder, which will scratch metal and painted surfaces.
Special Care • If you drive on salted or dusty roads, or if you drive near the ocean, hose off the undercarriage at least once a month. • It is important that the drain holes in the lower edges of the doors, rocker panels and trunk be kept clear and open.
• If you detect any stone chips or scratches in the paint, touch them up immediately. The cost of such repairs is considered the responsibility of the owner. • If your vehicle is damaged due to an accident or similar cause which destroys the paint and protective coating, have your vehicle repaired as soon as pos- sible. The cost of such repairs is considered the respon- sibility of the owner. • If you carry special cargo such as chemicals, fertilizers, de-icer salt, etc., be sure that such materials are well packaged and sealed. • If a lot of driving is done on gravel roads, consider • Use MOPAR威 Touch Up Paint on scratches as soon as possible. Your authorized dealer has touch up paint to match the color of your vehicle.
mud or stone shields behind each wheel.
MAINTAINING YOUR VEHICLE 361
Wheel and Wheel Trim Care All wheels and wheel trim, especially aluminum and chrome plated wheels should be cleaned regularly with a mild soap and water to prevent corrosion. To remove heavy soil and/or excessive brake dust, use MOPAR威 Wheel Cleaner (05066247AB) or equivalent or, select a nonabrasive, non-acidic cleaner. Do not use scouring pads, steel wool, a bristle brush, or metal polishes. Only MOPAR威 or equivalent is recommended. Do not use oven cleaner. Avoid automatic car washes that use acidic solutions or harsh brushes that may damage the wheels’ protective finish. YES Essentials威 Fabric Cleaning Procedure – If equipped YES Essentials威 seats may be cleaned in the following manner: • Remove as much of the stain as possible by blotting
with a clean, dry towel.
362 MAINTAINING YOUR VEHICLE
• Blot any remaining stain with a clean, damp towel. • For tough stains, apply MOPAR威 Total Clean or a mild soap solution to a clean, damp cloth and remove stain. Use a fresh, damp towel to remove soap residue. • For grease stains, apply MOPAR威 Multi-Purpose Cleaner to a clean, damp cloth and remove stain. Use a fresh, damp towel to remove soap residue. • Do not use any solvents or protectants on YES Essen-
tials威 products.
Interior Care Use MOPAR威 Total Clean to clean fabric upholstery and carpeting. Use MOPAR威 Total Clean to clean vinyl upholstery. MOPAR威 Total Clean is specifically recommended for leather upholstery.
Your leather upholstery can be best preserved by regular cleaning with a damp soft cloth. Small particles of dirt can act as an abrasive and damage the leather upholstery and should be removed promptly with a damp cloth. Stubborn soils can be removed easily with a soft cloth and MOPAR威 Total Clean. Care should be taken to avoid soaking your leather upholstery with any liquid. Please do not use polishes, oils, cleaning fluids, solvents, deter- gents, or ammonia-based cleaners to clean your leather upholstery. Application of a leather conditioner is not required to maintain the original condition.
WARNING!
Do not use volatile solvents for cleaning purposes. Many are potentially flammable, and if used in closed areas they may cause respiratory harm.
Cleaning Headlights Your vehicle has plastic headlights that are lighter and less susceptible to stone breakage than glass headlights. Plastic is not as scratch resistant as glass and therefore different lens cleaning procedures must be followed. To minimize the possibility of scratching the lenses and reducing light output, avoid wiping with a dry cloth. To remove road dirt, wash with a mild soap solution fol- lowed by rinsing. Do not use abrasive cleaning components, solvents, steel wool or other aggressive material to clean the lenses. Glass Surfaces All glass surfaces should be cleaned on a regular basis with MOPAR威 Glass Cleaner or any commercial household-type glass cleaner. Never use an abrasive type cleaner. Use caution when cleaning the inside rear win- dow equipped with electric defrosters or the right rear
MAINTAINING YOUR VEHICLE 363
quarter window equipped with the radio antenna. Do not use scrapers or other sharp instruments which may scratch the elements. When cleaning the rearview mirror, spray cleaner on the towel or rag that you are using. Do not spray cleaner directly on the mirror. Cleaning Plastic Instrument Cluster Lenses The lenses in front of the instruments in this vehicle are molded in clear plastic. When cleaning the lenses, care must be taken to avoid scratching the plastic. 1. Clean with a wet soft rag. A mild soap solution may be used, but do not use high alcohol content or abrasive cleaners. If soap is used, wipe clean with a clean damp rag. 2. Dry with a soft tissue.
364 MAINTAINING YOUR VEHICLE
Seat Belt Maintenance Do not bleach, dye or clean the belts with chemical solvents or abrasive cleaners. This will weaken the fabric. Sun damage can also weaken the fabric. If the belts need cleaning, use a mild soap solution or lukewarm water. Do not remove the belts from the vehicle to wash them. Replace the belts if they appear frayed or worn or if the buckles do not work properly. Dry with a soft tissue.
FUSES
Integrated Power Module The integrated power module is located in the engine compartment near the battery. This center contains car- tridge fuses and mini fuses. A description of each fuse
and component may be stamped on the inside cover, otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart.
Integrated Power Module
Cavity Cartridge
Fuse
Mini Fuse 20 Amp Yellow 20 Amp Yellow
— 15 Amp Blue 20 Amp Yellow 10 Amp Red — 10 Amp Red
Description
Power Outlet Console
Cabin Compartment Node (CCN) Door Locks — Aisin Transmission Controls (Diesel Only) Power Sunroof
Vistronic Fan/ Wastegate Solenoid — Heated Mirrors
Cavity Cartridge
Fuse 30 Amp Pink
10
11
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Mini Fuse
5 Amp Orange
20 Amp Yellow
Description
Off Road Module Power Trx-Off Rd Pkg Sen (Gas Engine Only) NOTE: Insert 5 amp fuse in this cavity to enable the TRX capa- bility (If Equipped). Ignition Off Draw (IOD)-Cabin Com- partment Node (CCN)/Radio/Under Hood Lamp/Wireless Control Module (WCM)/Satellite Digi- tal Audio Receiver (SDARS)/Hands Free Module (HFM)/EOM
366 MAINTAINING YOUR VEHICLE
Cavity Cartridge
Fuse 30 Amp Pink
Mini Fuse
25 Amp Natural
15 Amp Blue 20 Amp Yellow 15 Amp Blue —
Description
Electric Brake
Power-Battery RWAL/ABS Module Feed Park Lights Left
Trailer Park Lights
Park Lights Right
— ABS Pump
Trailer Tow Battery Feed
Cavity Cartridge
Fuse
20
21
22
23
24
25
26
20 Amp Blue
Mini Fuse 10 Amp Red 10 Amp Red 2 Amp Gray 10 Amp Red
10 Amp Red 20 Amp Yellow
Description
Occupant Restraints Controller (ORC) 2
Occupant Restraints/ Pass Disable Switch IGN Switch FeedHVAC
AISIN Relay Feed (Diesel Only) Power Mirror/T-Case Brake Brake Switch/Center High Mount Stop Light (CHMSL)/ Aftermarket CHMSL
40 Amp Green 30 Amp Pink
12
13
14
15
16
17
1819
Cavity Cartridge
Fuse 40 Amp Green
27
28
29
30
31
Mini Fuse
10 Amp Red
10 Amp Red 15 Amp Blue
10 Amp Red
Description
Power Seats
Power Run/Start- PCM/Steering Angle Sensor 4X4 Switch/Pass Dr Switch/EC Mirror Power Run/Start- ABS/RWAL/Smart Bar/YAW Sensor/ Universal Exhaust Gas Oxygen (Uego) Sensor Controller PCM (Gas)/TCM (Diesel 58RFE)
Cavity Cartridge
Fuse
32
33
34
3536
37
38
MAINTAINING YOUR VEHICLE 367
Mini Fuse 10 Amp Red
10 Amp Red — 15 Amp Blue
25 Amp
