2006 Dodge RAM Diesel Owners Manual

sible if desired. The reasons for any rapid or unusual wear should be corrected prior to rotation being per- formed.

NOTE: On Canadian vehicles only, if your Ram truck is equipped with All-Season type tires on the front and ON/OFF Road type tires mounted on the rear, do not use a front to back rotation pattern. Instead, rotate your tires side to side at the recommended intervals.

Dual Rear Wheels

The tires used on dual wheel assemblies should be matched for wear to prevent overloading one tire in a set. To check if tires are even, lay a straight edge across all four tires. The straight edge should touch all the tires.

STARTING AND OPERATING 313

CAUTION!

3500 Dual Rear Tires have only one approved direc- tion of rotation. This is to accommodate the asym- metrical design (tread pattern) of the ON/OFF road tire and the use of Outline White Letter (OWL) tires. • When replacing a flat, the spare tire may have to be remounted on the rim or installed at a different location to maintain the correct placement of the tire on the wheel relative to the tire/wheel posi- tion on the truck. For example, if the spare is used to replace an outer rear tire it will have to be remounted on the rim so that the wheel is dished inward. That way the tread design of asymmetri- cal tires and the white writing of the OWL tires will maintain proper position.

314 STARTING AND OPERATING

ENGINE RUNAWAY

WARNING!

In case of engine runaway due to flammable fumes from gasoline spills or turbocharger oil leaks being sucked into the engine do the following to help avoid personal injury and/or vehicle damage: 1. Shut off engine ignition switch. 2. Using a CO2 or dry chemical type fire extin- guisher, direct the spray from the fire extinguisher into the grille on the passenger side so that the spray enters the engine air intake.

FUEL REQUIREMENTS Use good quality diesel fuel from a reputable supplier in your Dodge truck. For most year-round service, No. 2
diesel fuel meeting ASTM specification D-975 will pro- vide good performance. If the vehicle is exposed to extreme cold (below 20°F or -7°C), or is required to operate at colder-than-normal conditions for prolonged periods, use climatized No. 2 diesel fuel or dilute the No. 2 diesel fuel with 50% No. 1 diesel fuel. This will provide better protection from fuel gelling or wax-plugging of the fuel filters.

WARNING!

The inlet for the engine air intake is located behind the passenger side headlamp and receives air through the grille

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

Diesel fuel is seldom completely free of water. To prevent fuel system trouble, drain the accumulated water from the fuel/water separator using the fuel/water separator drain provided. If you buy good quality fuel and follow the cold weather advice above, fuel conditioners should not be required in your vehicle. If available in your area, a high cetane “premium” diesel fuel may offer improved cold-starting and warm-up performance. ADDING FUEL

CAUTION!

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

NOTE: • When the fuel nozzle “clicks” or shuts off, the fuel

tank is full.

STARTING AND OPERATING 315

• Tighten the gas cap until you hear a “clicking” sound. This is an indication that the gas cap is properly tightened. • Make sure that the gas cap is tightened each time the

vehicle is refueled.

WARNING!

A fire may result if fuel is pumped into a container that is inside of a vehicle or in the bed or on the opened tailgate. Always place fuel containers on the ground while filling.

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

316 STARTING AND OPERATING

CAUTION!

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

WARNING!

• Never have any smoking materials lit in or near the vehicle when the gas cap is removed or the tank filled. • Never add fuel to the vehicle when the engine is

running.

Avoid Using Contaminated Fuel Fuel that is contaminated by water or dirt can cause severe damage to the engine fuel system. Proper main- tenance of the engine fuel filter and fuel tank is essential. (See Section 7 for Maintenance Procedures). NOTE: Climatized diesel fuel is a blend of Number 2
and Number 1 Diesel fuel which reduces the temperature at which wax crystals form in the fuel. Bulk Fuel Storage If you store quantities of fuel, good maintenance of the stored fuel is also essential. Fuel contaminated with water will promote the growth of “microbes.” These microbes form “slime” that will clog fuel filters and lines. Drain condensation from the supply tank and change the line filter on a regular basis.

Fuel Specifications The Cummins Turbocharged, Charge Air Cooled, Diesel engine has been developed to take advantage of the high energy content and generally lower cost No. 2 diesel fuel or No. 2 climatized diesel fuels. Experience has shown that it also operates on No. 1 diesel fuels or other fuels within the specifications in the following chart. NOTE: A maximum blend of 5% biodiesel may be used with your Cummins Diesel equipped Dodge Ram Truck. In addition, commercially available fuel addi- NOTE: tives are not necessary for the proper operation of your Cummins Diesel equipped Dodge Ram Truck. NOTE: No. 1 diesel fuel should only be used where extended arctic conditions (-10°F or -23°C) exist.

STARTING AND OPERATING 317

Number 2 Diesel Fuel Specifications Fuel Properties - No. 2 - Diesel Reference Viscosity - 1.9 to 4.1 centistokes (ASTM D-445) Cetane Number - 40 min. (ASTM D613) (ASTM D-2622) Sulfur Content -.05% by weight Water & Sediment - less than (ASTM D-2709) 0.05 % by volume Carbon Residue - Less than.35% Flash Point - 125°F min. Density - 40-34 API gravity Cloud Point 15°F Active Sulfur Copper Strip Corrosion - #3 rating Ash - 0.01% by mass Distillation - curve is smooth & cont.

(Ramsbottom ASTM D-524
(ASTM D-93) (ASTM D-287) (ASTM D-97) (ASTM D-130)

(ASTM D-482) (ASTM D-86)

318 STARTING AND OPERATING

Number 1 Diesel Fuel Specifications Fuel Properties - No. 1 - Diesel Reference Viscosity - 1.3 to 2.4 centistokes (ASTM D-445) Cetane Number - 40 min. (ASTM D613) (ASTM D-2622) Sulfur Content - maximum of.05% by weight Water & Sediment - less than 0.05 % by volume Carbon Residue - Less than.15% Flash Point - 100°F min. Density - 40-34 API gravity Cloud Point - (- 30F°) Active Sulfur Copper Strip Corrosion - #3 rating

(Ramsbottom ASTM D-524
(ASTM D-93) (ASTM D-287) (ASTM D-97) (ASTM D-130)

(ASTM D-2709)

ADDING FUEL — 24–VALVE CUMMINS TURBO DIESEL

WARNING!

A fire may result if fuel is pumped into a portable container that is on a truck bed. You could be burned. Always place fuel containers on the ground while filling.

NOTE: When a diesel engine is allowed to run out of fuel, air is pulled into the fuel system. You may try priming as described below. However, if the engine will not start, refer to the fuel priming procedure in the Service Manual or have the vehicle towed to an authorized Dodge dealer.

WARNING!

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

STARTING AND OPERATING 319

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

Priming if the engine has run out of fuel 1. Add a substantial quantity of fuel to the tank 5 to 10
gallons (19 to 38L). 2. Crank the engine for 1 to 2 seconds. If the engine does not start, then release the key or starter button back to the RUN position (do not turn the key back to the OFF position). The electric fuel transfer pump will continue to run and purge air from the system for about 20 seconds. After 20 seconds, attempt to start the engine again. 3. Start the engine using the Normal Starting Procedure.

CAUTION!

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

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

VEHICLE LOADING

Certification Label As required by National Highway Traffic Safety Admin- istration Regulations, your vehicle has a certification label affixed to the driver’s side door or pillar. This label contains the month and year of manufacture, Gross Vehicle Weight Rating (GVWR), Gross Axle Weight

320 STARTING AND OPERATING

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

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

Inflation Pressure This is the cold tire inflation pressure for your vehicle for all loading conditions up to full GAWR. Curb Weight The curb weight of a vehicle is defined as the total weight of the vehicle with all fluids, including vehicle fuel, at full capacity conditions, and with no occupants or cargo loaded into the vehicle. The front and rear curb weight values are determined by weighing your vehicle on a commercial scale before any occupants or cargo are added. Loading The actual total weight and the weight of the front and rear of your vehicle at the ground can best be determined by weighing it when it is loaded and ready for operation.

STARTING AND OPERATING 321

The entire vehicle should first be weighed on a commer- cial scale to insure that the GVWR has not been exceeded. The weight on the front and rear of the vehicle should then be determined separately to be sure that the load is properly distributed over front and rear axle. Weighing the vehicle may show that the GAWR of either the front or rear axles has been exceeded but the total load is within the specified GVWR. If so, weight must be shifted from front to rear or rear to front as appropriate until the specified weight limitations are met. Store the heavier items down low and be sure that the weight is distributed equally. Stow all loose items securely before driving. Improper weight distributions can have an adverse effect on the way your vehicle steers and handles and the way the brakes operate.

can be computed after the vehicle has been weighed both in its ⴖcurb weightⴖ condition, and in its ⴖloaded and ready for operationⴖ condition. Gross Vehicle Weight Rating (GVWR) 6500 LBS.

322 STARTING AND OPERATING

CAUTION!

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

An EXAMPLE of a loaded vehicle is shown in the following chart. Note that neither GVWR nor GAWR capabilities are exceeded. Overloading can cause poten- tial safety hazards and shorten service life.

NOTE: The weights shown in this chart are not necessarily the weights for your vehicle. Also, the amount of load added to both the front and rear axles

TRAILER TOWING In this section you will find safety tips and information on limits to the type of towing you can reasonably do with your vehicle. Before towing a trailer carefully re- view this information to tow your load as efficiently and safely as possible. To maintain warranty coverage, follow the requirements and recommendations in this manual concerning ve- hicles used for trailer towing. Common Towing Definitions The following trailer towing related definitions will assist you in understanding the following information: Gross Vehicle Weight Rating (GVWR) The GVWR is the total allowable weight of your vehicle. This includes driver, passengers, cargo and tongue weight. The total load must be limited so that you do not exceed the GVWR.

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Gross Trailer Weight (GTW) The gross trailer weight (GTW) is the weight of the trailer plus the weight of all cargo, consumables and equipment (permanent or temporary) loaded in or on the trailer in its ⬙loaded and ready for operation⬙ condition. The recom- mended way to measure GTW is to put your fully loaded trailer on a vehicle scale. The entire weight of the trailer must be supported by the scale. Gross Combination Weight Rating (GCWR) The gross combination weight rating (GCWR) is the total permissible weight of your vehicle and trailer when weighed in combination. (Note that GCWR ratings in- clude a 68 kg (150 lbs) allowance for the presence of a driver).

324 STARTING AND OPERATING

Gross Axle Weight Rating (GAWR) The GAWR is the maximum capacity of the front and rear axles. Distribute the load over the front and rear axles evenly. Make sure that you do not exceed either front or rear GAWR.

WARNING!

It is important that you do not exceed the maximum front or rear GAWR. A dangerous driving condition can result if either rating is exceeded. You could lose control of the vehicle and have an accident.

Tongue Weight (TW) The downward force exerted on the hitch ball by the trailer. In most cases it should not be less than 10% or more than 15% of the trailer load. You must consider this as part of the load on your vehicle.

Frontal Area The maximum height and maximum width of the front of a trailer. Trailer Sway Control The trailer sway control is a telescoping link that can be installed between the hitch receiver and the trailer tongue that typically provides adjustable friction associated with the telescoping motion to dampen any unwanted trailer swaying motions while traveling. Weight-Carrying Hitch A weight-carrying hitch supports the trailer tongue weight, just as if it were luggage located at a hitch ball or some other connecting point of the truck. These kind of hitches are the most popular on the market today and they’re commonly used to tow small- and medium-sized trailers.

Weight-Distributing Hitch A weight-distributing hitch includes a receiver attached to the tow vehicle, plus a removable hitch head and spring bar assembly that fits into the receiver opening and hook up brackets that connect the spring bars to the trailer frame. Fifth-Wheel Hitch A special high platform with a coupling that mounts over the rear axle of the tow vehicle in the truck bed. Connects a vehicle and fifth-wheel trailer with a coupling king pin. Gooseneck Hitch The gooseneck hitch employs a pivoted coupling arm which attaches to a ball mounted in the bed of a pickup truck. The coupling arm connects to the hitch mounted over the rear axle in the truck bed.

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Trailer Hitch Classification The rear bumper is intended to tow trailers up to 2,000
lbs (907 kg) without added equipment or alterations to the standard equipment. Your vehicle may be factory equipped for safe towing of trailers weighing over 2,000
lbs (907 kg) with the optional Trailer Tow Prep Package. See your dealer for package content. The following chart provides the industry standard for the maximum trailer weight a given trailer hitch class can tow and should be used to assist you in selecting the correct trailer hitch for your intended towing condition. Refer to “Trailer Towing Weights (Maximum Trailer Weight Ratings)” for the website address that contains the necessary information for your specific drivetrain.

Trailer and Tongue Weight Always load a trailer with 60% to 65% of the weight in the front of the trailer. This places 10% to 15% of the Gross Trailer Weight (GTW) on the tow hitch of your vehicle. Loads balanced over the wheels or heavier in the rear can cause the trailer to sway severely side to side which will cause loss of control of vehicle and trailer. Failure to load trailers heavier in front is the cause of many trailer accidents.

326 STARTING AND OPERATING

Trailer Hitch Classification

Class

Max. GTW (Gross Trailer Wt.)

2,000 lbs (907 kg) 3,500 lbs (1587 kg) 5,000 lbs (2268 kg) 10,000 lbs (4540 kg)

Class I - Light Duty Class II - Medium Duty Class III - Heavy Duty Class IV - Extra Heavy Duty Fifth Wheel/Gooseneck Greater than 10,000 lbs (4540 kg) All trailer hitches should be professionally installed on your vehicle. Trailer Towing Weights (Maximum Trailer Weight Ratings) NOTE: For additional trailer towing information (maxi- mum trailer weight ratings) refer to the following website addresses: • http:// www.dodge.com/towing. • http:// www.dodge.ca (Canada).

Never exceed the maximum tongue weight stamped on your bumper or trailer hitch.

STARTING AND OPERATING 327

put in or on your vehicle.

Consider the following items when computing the weight on the rear axle of the vehicle: • The tongue weight of the trailer. • The weight of any other type of cargo or equipment • The weight of the driver and all passengers. NOTE: Remember that everything put into or on the trailer adds to the load on your vehicle. Also, additional factory-installed options, or dealer-installed options, must be considered as part of the total load on your vehicle. Refer to the Tire and Loading Information plac- ard in the Tire Safety Information Section of this manual.

328 STARTING AND OPERATING

Towing Requirements To promote proper break-in of your new vehicle driv- etrain components the following guidelines are recom- mended:

CAUTION!

• Avoid towing a trailer for the first 500 miles (805
km) of vehicle operation. Doing so may damage your vehicle. • During the first 500 miles (805 km) of trailer

towing, limit your speed to 50 mph (80 km/h).

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

WARNING!

Improper towing can lead to an injury accident. Follow these guidelines to make your trailer towing as safe as possible: Make certain that the load is secured in the trailer and will not shift during travel. When trailering cargo that is not fully secured, dynamic load shifts can occur that may be difficult for the driver to control. You could lose control of your vehicle and have an accident. • When hauling cargo or towing a trailer, do not over- load your vehicle or trailer. Overloading can cause a loss of control, poor performance or damage to brakes, axle, engine, transmission, steering, suspension, chas- sis structure or tires.

• Safety chains must always be used between your vehicle and trailer. Always connect the chains to the frame or hook retainers of the vehicle hitch. Cross the chains under the trailer tongue and allow enough slack for turning corners. • Vehicles with trailers should not be parked on a grade. When parking, apply the parking brake on the tow vehicle. Put the tow vehicle automatic transmission in P for Park. With a manual transmission, shift the transmission into reverse. And with four-wheel-drive vehicles, make sure the transfer case is not in neutral. Always, block or ⬙chock⬙ the trailer wheels.

• GCWR must not be exceeded. • Total weight must be distributed between the tow vehicle and the trailer such that the following four ratings are not exceeded: 1. GVWR

STARTING AND OPERATING 329

2. GTW 3. GAWR 4. Tongue weight rating for the trailer hitch utilized (This requirement may limit the ability to always achieve the 10% to 15% range of tongue weight as a percentage of total trailer weight).

Towing Requirements — Tires − Do not attempt to tow a trailer while using a compact

spare tire.

− Proper tire inflation pressures are essential to the safe and satisfactory operation of your vehicle. Refer to the Tires–General Information section of this manual on Tire Pressures for proper tire inflation procedures.

− Also, check the trailer tires for proper tire inflation

pressures before trailer usage.

330 STARTING AND OPERATING

− Check for signs of tire wear or visible tire damage before towing a trailer. Refer to the Tires–General Information section of this manual on Tread Wear Indicators for the proper inspection procedure.

− When replacing tires refer to the Tires–General Infor- mation section of this manual on Replacement Tires for proper tire replacement procedures. Replacing tires with a higher load carrying capacity will not increase the vehicle’s GVWR and GAWR limits. Towing Requirements — Trailer Brakes − Do not interconnect the hydraulic brake system or vacuum system of your vehicle with that of the trailer. This could cause inadequate braking and possible personal injury.

− An electronically actuated trailer brake controller is required when towing a trailer with electronically

actuated brakes. When towing a trailer equipped with a hydraulic surge actuated brake system, an electronic brake controller is not required.

− Trailer brakes are recommended for trailers over 1,000
lbs (454 kg) and required for trailers in excess of 2,000
lbs (907 kg).

CAUTION!

If the trailer weighs more than 1,000 lbs (454 kg) loaded, it should have its own brakes and they should be of adequate capacity. Failure to do this could lead to accelerated brake lining wear, higher brake pedal effort, and longer stopping distances.

WARNING!

Do not connect trailer brakes to your vehicle’s hy- draulic brake lines. It can overload your brake sys- tem and cause it to fail. You might not have brakes when you need them and could have an accident. Towing any trailer will increase your stopping dis- tance. When towing you should allow for additional space between your vehicle and the vehicle in front of you. Failure to do so could result in an accident.

Towing Requirements — Trailer Lights & Wiring Whenever you pull a trailer, regardless of the trailer size, stop lights and turn signals on the trailer are required for motoring safety. The Trailer Tow Package may include a 4 and 7 pin wiring harness. Use a factory approved trailer harness and connector.

STARTING AND OPERATING 331

NOTE: Do not cut or splice wiring into the vehicles wiring harness. The electrical connections are all complete to the vehicle but you must mate the harness to a trailer connector. Refer to the following illustrations.

4 - Pin Connector

332 STARTING AND OPERATING

7- Pin Connector

Towing Tips Before setting out on a trip, practice turning, stopping and backing the trailer in an area away from heavy traffic.

If using a manual transmission vehicle for trailer towing, all starts must be in FIRST gear to avoid excessive clutch slippage. Towing Tips — Automatic Transmission The “D” range can be selected when towing. However, if frequent shifting occurs while in this range, the “TOW HAUL” or “OD/OFF” range should be selected. NOTE: Using the “TOW HAUL” or “OD/OFF” range while operating the vehicle under heavy operating con- ditions will improve performance and extend transmis- sion life by reducing excessive shifting and heat build up. This action will also provide better engine braking. The automatic transmission fluid and filter should be changed if you REGULARLY tow a trailer for more than 45 minutes of continuous operation. See Schedule “B” in section 8 of this manual for transmission fluid change intervals.

NOTE: Check the automatic transmission fluid level before towing. Towing Tips — Tow/Haul (If Equipped) To reduce potential for automatic transmission overheat- ing, turn the “TOW HAUL OD/OFF” feature ON when driving in hilly areas or shift the transmission to Drive position 2 on more severe grades. Towing Tips — Electronic Speed Control (If Equipped) − Don’t use in hilly terrain or with heavy loads. − When using the speed control, if you experience speed 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.

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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. − refer to Cooling System Operating information in the Maintenance section of this manual for more informa- tion.

334 STARTING AND OPERATING

Trailer Towing Mirrors — If Equipped These mirrors are designed with an adjustable mirror head to provide a greater vision range when towing extra-wide loads. To change position inboard or out- board, the mirror head should be rotated (flipped Out or In). A small blindspot mirror is integrated onto the main mirror surface. NOTE: rearward prior to entering an automated car wash.

Fold the 7 x 10 inch trailer towing mirrors

CAUTION!

Do not attempt to fold the 7 x 10 inch trailer towing mirrors forward. The 7 x 10 inch trailer towing mirrors are not designed to be folded forward and doing so will damage the mirrors and/or vehicle.

Blindspot Mirror

STARTING AND OPERATING 335

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 cur- rent Dodge BODY BUILDER’S GUIDE. See your dealer, installer or snowplow manufacture for this information. There are unique electrical systems that must be con- nected to properly assure operator safety and prevent overloading vehicle systems.

Trailer Towing Position

336 STARTING AND OPERATING

WARNING!

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

CAUTION!

The “Lamp Out” indicator could illuminate if exte- rior lamps are not properly installed.

Before plowing • Check the hydraulic system for leaks and proper fluid • Check the mounting bolts and nuts for proper tight-

level.

ness.

• Check the runners and cutting edge for excessive wear. The cutting edge should be 1/4 to 1/2 inch above ground in snow plowing position. • Check that snowplow lighting is connected and func-

tioning properly.

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 tow-in should be checked and reset the beginning and end of the snowplow season. This will help prevent uneven tire wear.

if necessary at

STARTING AND OPERATING 337

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.

338 STARTING AND OPERATING

Methods For Removing Snow

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 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 driv- etrain damage, the following precautions should be ob- served.

• 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 48RE 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.

STARTING AND OPERATING 339

RECREATIONAL TOWING (BEHIND MOTORHOME, ETC.)

Recreational Towing – 2 Wheel Drive Models

Recreational towing 2 Wheel Drive 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 se- vere damage to the transmission and/or transfer case.

340 STARTING AND OPERATING

CAUTION!

CAUTION!

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

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

NOTE: Both the Manual Shift and Electronic Shift transfer cases must be shifted into Neutral (N) for recreational towing. Automatic transmissions must be placed in P (Park) position for recreational towing. Manual transmissions must be left in gear (not in neutral) for recreational towing. Refer below for the proper trans- fer 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:

1. Bring the vehicle to a complete stop. 2. Shut OFF the engine. 3. Depress the brake pedal. 4. Shift automatic transmission to N (NEUTRAL), or depress the clutch on manual transmissions. 5. Shift transfer case lever into N (NEUTRAL). 6. Start the engine. 7. Shift automatic transmission into Reverse (R).

8. Release brake pedal for five seconds and ensure that there is no vehicle movement. 9. Repeat steps 7 and 8 with the transmission in Drive (D). 10. Shut OFF the engine and place the ignition key to the unlocked OFF position. 11. Shift automatic transmission into P (PARK). 12. Apply the parking brake. 13. Attach vehicle to tow vehicle with tow bar. 14. Release the parking brake.

STARTING AND OPERATING 341

CAUTION!

Damage to the automatic transmission may occur if the transmission is shifted into P (PARK) with the transfer case in N (NEUTRAL) and the engine RUN- NING. With the transfer case in N (NEUTRAL) ensure that the engine is OFF prior to shifting the transmission into P (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.

342 STARTING AND OPERATING

5. Shift automatic transmission to N (NEUTRAL), or depress the clutch on manual transmissions. 6. Shift transfer case lever to desired position. 7. Shift automatic transmission into P (Park).

WARNING!

You or others could be injured if you leave the vehicle unattended with the transfer case in the N (NEUTRAL) position without first fully engaging the parking brake. The transfer case N (NEUTRAL) position disengages both the front and rear drive- shafts from the powertrain and will allow the ve- hicle to move regardless of the transmission posi- tion. 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 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 (N) before recreational towing to prevent damage to internal parts.

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 automatic transmission to Neutral (N) or depress clutch on manual transmission.

STARTING AND OPERATING 343

6. Using the point of a ballpoint pen or similar object, depress the recessed transfer case Neutral (N) button for 4 seconds. 7. After shift is completed and the Neutral (N) light comes on release Neutral (N) button. 8. Start engine. 9. Shift automatic transmission into Reverse (R). 10. Release brake pedal for five seconds and ensure that there is no vehicle movement. 11. Repeat steps 9 and 10 with the transmission in Drive (D). 12. Shut engine OFF and place ignition key to the unlocked OFF position. 13. Shift automatic transmission into Park (P). 14. Apply parking brake.

344 STARTING AND OPERATING

15. Attach vehicle to tow vehicle with tow bar. 16. Release parking brake. Items 1 through 5 are requirements that must be NOTE: met prior to depressing the Neutral (N) selection button, and must continue to be met until the 4 seconds elapses and the shift has been completed. If any of these require- ments (with the exception of 3 - Key ON) are not met prior to depressing the Neutral (N) button or are no longer met during the 4 second timer, then the Neutral (N) indicator light will flash continuously until all re- quirements are met or until the Neutral (N) button is released. NOTE: The ignition key must be ON for a shift to take place and for the position indicator lights to be operable. If the key in not ON, the shift will not take place and no position indicator lights will be on or flashing.

NOTE: Flashing neutral (N) position indicator light indicates that shift requirements have not been met.

CAUTION!

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

Returning to Normal Operation — Electronic Shift Transfer Case Use the following procedure to prepare your vehicle for normal usage. 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 automatic transmission to Neutral (N) or depress clutch on manual transmission. 6. Using the point of a ballpoint pen or similar object, depress the recessed transfer case Neutral (N) button for 1 second. 7. After the Neutral (N) indicator light turns off release the Neutral (N) button. 8. After the Neutral (N) button has been released the transfer case will shift to the position identified by the selector switch. 9. Shift automatic transmission into P (Park). NOTE: The transfer case can not be shifted into Neutral (N) from the 4Auto (if equipped) position.

STARTING AND OPERATING 345

Items 1 through 5 are requirements that must be NOTE: met prior to depressing the Neutral (N) selection button, and must continue to be met until 1 second elapses and the shift has been completed. If any of these requirements (with the exception of 3 - key ON) are not met prior to depressing the Neutral (N) button or are no longer met during the 1 second time, then all of the mode position indicator lights will flash continuously until all require- ments are met or until the Neutral (N) button is released. NOTE: The ignition key must be ON for a shift to take place and for the position indicator lights to be operable. If the key is not ON, the shift will not take place and no position indicator lights will be on or flashing. NOTE: Flashing neutral (N) position indicator light indicates that shift requirements have not been met.

346 STARTING AND OPERATING

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 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.

DRIVING OFF-ROAD Care should be taken when attempting to climb steep hills or driving diagonally across a hill or slope. If natural obstacles force you to travel diagonally up or down a hill, choose a mild angle and keep as little side tilt as possible. Keep the vehicle moving and make turns slowly and cautiously.

If you must back down a hill, back straight down using REVERSE gear. Never back down in NEUTRAL, or diagonally across the hill. When driving over sand, mud, and other soft terrain, shift to low gear and drive steadily. Apply the accelerator slowly to avoid spinning the wheels. DO NOT REDUCE the tire pressures for this type of driving. NOTE: After off-road usage, particularly in sand or mud, inspect the underside of the vehicle for accumu- lated dirt at the propeller shaft, axles, U-joints, brake rotors and calipers. Use a hose to clean off any accumulation of dirt or mud. Check the exhaust system and all exposed components for any sign of damage.

STARTING AND OPERATING 347

If you experience unusual vibration after driving in mud, slush or similar conditions, check the wheels for im- pacted material. Impacted foreign material can cause a wheel imbalance. Removing the foreign material from the wheels will correct the situation.

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

348 STARTING AND OPERATING

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.

ENGINE DATA PLATE Use the information from the engine data plate when discussing service or sourcing parts for your engine. The engine data plate is located on the intake side of the breather cover.

WHAT TO DO IN EMERGENCIES

CONTENTS

䡵 Hazard Warning Lights . . . . . . . . . . . . . . . . . . 350
䡵 Jack Location . . . . . . . . . . . . . . . . . . . . . . . . . . 351
▫ All Models . . . . . . . . . . . . . . . . . . . . . . . . . . 351
䡵 Changing A Flat Tire . . . . . . . . . . . . . . . . . . . . 352
▫ Removing The Spare Tire . . . . . . . . . . . . . . . . 352
▫ Tire Changing Procedure . . . . . . . . . . . . . . . . 353
䡵 Hoisting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

▫ With Portable Starting Unit

䡵 Jump-Starting . . . . . . . . . . . . . . . . . . . . . . . . . 363
. . . . . . . . . . . . . . 366
䡵 Freeing A Stuck Vehicle . . . . . . . . . . . . . . . . . . 366
䡵 Emergency Tow Hooks — If Equipped . . . . . . . . 367
䡵 Towing A Disabled Vehicle . . . . . . . . . . . . . . . . 368
▫ 4-Wheel- Drive Vehicles . . . . . . . . . . . . . . . . . 368
▫ 2–Wheel- Drive Vehicles . . . . . . . . . . . . . . . . 368

350 WHAT TO DO IN EMERGENCIES

HAZARD WARNING LIGHTS The Hazard Warning switch is mounted on the top of the steering column as shown in the illustration.

Hazard Light Warning Switch

To engage the Hazard Warning lights, depress the button on the top of the steering column. When the Hazard Warning switch is activated, all directional turn signals will flash off and on to warn oncoming traffic of an emergency. Push 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 lights will continue to operate even though the ignition switch is OFF. NOTE: With extended use, the Hazard Warning lights may discharge your battery.

JACK LOCATION

All Models The jack and jack tools are stored under the passenger seat. Lift the flap on the side of the seat for access. Remove the jack and tools by loosening the thumb screw and sliding the assembly from under the seat.

WHAT TO DO IN EMERGENCIES 351

WARNING!

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, unless suitable sup- ports are placed under the vehicle as a safety mea- sure. The vehicle should be jacked on a firm level surface only. Avoid ice or slippery areas.

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.

352 WHAT TO DO IN EMERGENCIES

CHANGING A FLAT TIRE

Removing The Spare Tire Remove the spare tire before attempting to jack the truck. Attach the wheel wrench to the jack extension tube. Insert the tube through the access hole between the lower tailgate and the top of the bumper and into the winch mechanism tube. Rotate the wheel wrench handle coun- terclockwise until the spare tire is on the ground with enough cable slack to allow you to pull it out from under the vehicle. When the spare is clear, tilt the retainer at the end of the cable and pull it through the center of the wheel.

It is recommended that you stow the flat or spare to avoid tangling the loose cable. NOTE: The winch mechanism is designed for use with the jack extension tube only. Use of an air wrench or other power tools is not recommended and can damage the winch.

Tire Changing Procedure

WARNING!

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

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

WHAT TO DO IN EMERGENCIES 353

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

WARNING!

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

354 WHAT TO DO IN EMERGENCIES

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

the right

if

vehicle is being jacked.

Instructions

WARNING!

raised.

Carefully follow these tire changing warnings to help prevent personal injury or damage to your vehicle: • Always park on a firm, level surface as far from the edge of the roadway as possible before raising the vehicle. • Block the wheel diagonally opposite the wheel to be • Apply the parking brake firmly before jacking. • Never start the engine with the vehicle on a jack. • Do not let anyone sit in the vehicle when it is on a • Do not get under the vehicle when it is on a jack. • Only use the jack in the positions indicated. • If working on or near a roadway, be extremely

jack.

careful of motor traffic.

1. 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. For 2500/3500 4x2 series trucks, when changing a front wheel, place the bottle jack under the frame rail behind the wheel. Locate the jack as far forward as possible on the straight part of the frame. For 2500/3500 4x4 series trucks, 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.

WHAT TO DO IN EMERGENCIES 355

When changing a rear wheel, assemble the jack drive tube to the jack and connect the drive tube to the extension tube. Place the jack under the axle between the spring and the shock absorber with the drive tubes extending to the rear. Connect the jack tube extension and wheel 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.

356 WHAT TO DO IN EMERGENCIES

If the jack will not lower by turning the dial NOTE: (thumb wheel) by hand, it may be necessary to use the jack drive tube in order to lower the jack.

2500/3500 4X2 Jacking

WHAT TO DO IN EMERGENCIES 357

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 2500/3500 single rear wheel (SRW) models. On 3500 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 2500/3500 single rear wheel

4. By rotating the wheel wrench clockwise, raise the vehicle until the wheel just clears the surface.

358 WHAT TO DO IN EMERGENCIES

(SRW) models and 145 ft. lbs. (197 N·m) for 3500 dual rear wheel models. If in doubt about the correct tightness, have them checked with a torque wrench by your 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. Always stow the jack parts and the extra tire and wheel in the places provided.

7. Install wheel center cap and remove wheel blocks. Do not install chrome or aluminum wheel center caps on the spare wheel. This may result in cap damage. 8. Lower the jack to its fully closed position. If the jack will not lower by turning the dial (thumb wheel) 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 The hub caps must be removed before raising the vehicle off the ground. For 2500/3500 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 pryoff 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 3500
models use the blade on the end of the lug wrench to pry the caps off. The wheel skin can now be removed.

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.

WHAT TO DO IN EMERGENCIES 359

CAUTION!

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 lugnut 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.

360 WHAT TO DO IN EMERGENCIES

8-Stud — 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 2 drops of oil at the interface between the hex and the washer.

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. 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 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 instal- lations must also be observed.

These dual rear wheels should be tightened as follows:

WHAT TO DO IN EMERGENCIES 361

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 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 Nuts 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 of operation to allow the wheel nuts to become properly set. All nuts should first be firmly seated against the

362 WHAT TO DO IN EMERGENCIES

wheel. The nuts should then be tightened to recom- mended torque. Tighten the nuts to final torque in increments. Progress around the bolt circle, tightening the nut opposite to the nut just previously tightened until final torque is achieved. Recommended torques are shown in the following chart. Disc Wheels

Type Nut Stud Size Torque Ft. Lbs.

Cone Flanged

9/16-18
9/16-18

120-150
130-160

To Stow The Flat Or Spare Turn the wheel so that the valve stem is down. Slide the wheel retainer through the center of the wheel and position it properly across the wheel opening. For convenience in checking the spare tire inflation, stow with the valve stem toward the rear of the vehicle.

Torque Newton Meters 160-200
190-220

Attach the wheel wrench to the extension tube. Rotate the winch mechanism until the wheel is drawn into place against the underside of the vehicle. Continue to rotate until you feel the winch mechanism slip or click 3 or 4
times. It cannot be overtightened. Push against the tire several times to be sure it is firmly in place.

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 connecting 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 work- ing 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.

WHAT TO DO IN EMERGENCIES 363

NOTE: Replacement batteries should both be of equal size to prevent damage to the vehicles 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 followed: Set the parking brake and place an automatic transmis- sion in PARK (or NEUTRAL for a manual transmission). Turn off lights, heater and other electrical loads. Observe charge indicator (if equipped) in both batteries. If indica- tor (if equipped) is light or yellow on either battery, replace that battery.

364 WHAT TO DO IN EMERGENCIES

CAUTION!

WARNING!

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

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 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.

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.

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 jump start.

WHAT TO DO IN EMERGENCIES 365

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. 4. After the engine is started or if the engine fails to start, cables must be disconnected in the following order:

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.

366 WHAT TO DO IN EMERGENCIES

WARNING!

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

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 D.C. or damage to battery, starter motor, alternator, or electrical system may occur.

FREEING A STUCK VEHICLE If vehicle becomes stuck in snow, sand, or mud, it can often be moved by a rocking motion. Move the gear selector rhythmically between DRIVE and REVERSE (automatic transmissions) and between 1st and RE- VERSE (manual transmissions), while applying 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 transmission selector in NEUTRAL for at least one minute after every five rocking-motion cycles. This will minimize overheating and reduce the risk of transmis- sion failure during prolonged efforts to free a stuck vehicle.

EMERGENCY TOW HOOKS — IF EQUIPPED Your vehicle may be equipped with emergency tow hooks.

WARNING!

Chains are not recommended for freeing a stuck vehicle. Chains may break, causing serious injury or death.

WHAT TO DO IN EMERGENCIES 367

WARNING!

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.

368 WHAT TO DO IN EMERGENCIES

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.

NOTE: The Transfer Case must be in the neutral posi- tion, and the transmission must be in Park (Automatic Transmission), or in gear (Manual Transmission) to tow a 4WD vehicle with one end of the vehicle raised. The manufacturer recommends towing with all wheels OFF the ground. Acceptable methods are to tow 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.

WHAT TO DO IN EMERGENCIES 369

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 . . . . . . . . . . . . . . . . . . . . 374
▫ 5.9L HO Cummins Turbo Diesel . . . . . . . . . . . 374
䡵 Onboard Diagnostic System (OBD II) . . . . . . . . . 375
䡵 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 375
䡵 Dealer Service . . . . . . . . . . . . . . . . . . . . . . . . . 376
䡵 Service Information . . . . . . . . . . . . . . . . . . . . . 376
䡵 Maintenance Procedures . . . . . . . . . . . . . . . . . . 379
▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 379
▫ Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 385

▫ Engine Air Cleaner Filter . . . . . . . . . . . . . . . . 385
▫ Draining Fuel/Water Separator Filter . . . . . . . 387
▫ Maintenance Free Batteries . . . . . . . . . . . . . . . 390
▫ Air Conditioner Maintenance . . . . . . . . . . . . . 391
▫ Power Steering — Fluid Check . . . . . . . . . . . . 392
▫ Front Suspension Ball Joints . . . . . . . . . . . . . . 393
▫ Steering Linkage — Inspection . . . . . . . . . . . . 393
▫ Front Prop Shaft Lubrication . . . . . . . . . . . . . 394

372 MAINTAINING YOUR VEHICLE

▫ Front Axle Universal Drive Joints And Pivot

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
▫ Body Lubrication . . . . . . . . . . . . . . . . . . . . . 394
▫ Windshield Wiper Blades . . . . . . . . . . . . . . . . 395
▫ Windshield Washers . . . . . . . . . . . . . . . . . . . 395
▫ Exhaust System . . . . . . . . . . . . . . . . . . . . . . 396
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . . . 397
▫ Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
▫ Charge Air Cooler (Inter-Cooler) . . . . . . . . . . 402
▫ Hoses And Vacuum/Vapor Harnesses . . . . . . . 402
▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . . 403
▫ Clutch Linkage . . . . . . . . . . . . . . . . . . . . . . . 405
▫ Clutch Hydraulic System . . . . . . . . . . . . . . . . 405

▫ Rear Axle And 4X4 Front Driving Axle Fluid

Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
▫ Transfer Case — If Equipped . . . . . . . . . . . . . 406
▫ Manual Transmission — If Equipped . . . . . . . 406
▫ Automatic Transmission . . . . . . . . . . . . . . . . 407
▫ Front Wheel Bearings . . . . . . . . . . . . . . . . . . 409
▫ Selection Of Lubricating Grease . . . . . . . . . . . 410
▫ Noise Control System Required Maintenance &

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . 411

▫ Appearance Care And Protection From

Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
䡵 Integrated Power Module . . . . . . . . . . . . . . . . . 420
䡵 Vehicle Storage . . . . . . . . . . . . . . . . . . . . . . . . 423
䡵 Replacement Light Bulbs . . . . . . . . . . . . . . . . . 424

䡵 Bulb Replacement

. . . . . . . . . . . . . . . . . . . . . . 424

▫ Headlight (Halogen)/Front Park And

Turn Lights

. . . . . . . . . . . . . . . . . . . . . . . . . 424
▫ Tail, Stop, Turn And Backup Lights . . . . . . . . . 428
▫ Center High-Mounted Stoplight With

Cargo Light

. . . . . . . . . . . . . . . . . . . . . . . . . 430
▫ Cab Top Clearance Lights — If Equipped . . . . 431
▫ Tailgate ID Lights (Dual Rear Wheels) —

If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . 433

MAINTAINING YOUR VEHICLE 373

▫ Rear Light Bar ID Marker (Dual Rear Wheel) –

If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . 434
▫ Side Marker Lights (Dual Rear Wheels) . . . . . . 435
▫ Fog Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 436
䡵 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . 437
䡵 Fluids, Lubricants And Genuine Parts . . . . . . . . 438
▫ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
▫ Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439

374 MAINTAINING YOUR VEHICLE

ENGINE COMPARTMENT

5.9L HO CUMMINS TURBO DIESEL

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

MAINTAINING YOUR VEHICLE 375

CAUTION!

Prolonged driving with the “Malfunction Indicator Light” on could cause further damage to the emis- sion control system. It could also affect fuel economy and driveability. The vehicle must be serviced before any emissions tests can be performed. If the “Malfunction Indicator Light” is flashing, severe catalytic converter damage and power loss will soon occur. Immediate service is required.

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

376 MAINTAINING YOUR VEHICLE

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

SERVICE INFORMATION Mopar Fluids, Lubricants and Parts are available from your dealer and will help you keep your vehicle operat- ing at its best. Your dealer also has the qualified service personnel, special tools and equipment to perform all service operations in an expert manner. Service manuals are available which include detailed service information for your vehicle. Refer to these manuals before attempt- ing any procedure yourself. See Service Publications information at the back of this manual.

CAUTION!

To maintain your vehicle safely follow these guide- lines: • Watch your vehicle’s mileage and check your Mainte- nance Schedules regularly for required servicing. Ex- cessive wear or damage to certain vehicle components can result if required services are not performed.

• If you have your vehicle undercoated,

inspect for undercoating material on the propeller shafts. Such material could cause the shafts to become unbalanced and result in drivetrain vibrations. Remove any under- coating with solvent. • If you have your vehicle undercoated, make sure no undercoating material is sprayed on the exhaust sys- tem or components of the seat belt system.

MAINTAINING YOUR VEHICLE 377

It is not possible for the manufacturer and NOTE: Cummins, Inc. to anticipate every possible circumstance that can involve a potential hazard.

WARNING!

To maintain your vehicle safely and avoid personal injury, follow these guidelines: • Never spray or pour diesel fuel, flammable liquid or starting fluids (ether) into the air cleaner assembly, air intake piping or turbocharger inlet in an attempt to start the vehicle. • Do not use alcohol or gasoline as a fuel blending agent. They can be unstable under certain conditions and be hazardous or explosive when mixed with diesel fuel.

378 MAINTAINING YOUR VEHICLE

will stay hot after the engine is shut off.

• If an engine has been operating and the coolant is hot, allow the engine to cool before you slowly loosen the filler cap and relieve the pressure from the cooling system. • To avoid burns, remember that the engine components • Do not use gasoline or other flammable materials to clean parts. Always use approved cleaning solvents. • Relieve all pressure in the fuel, oil and cooling systems before any lines, fittings or related items are removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal injury.

WARNING!

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

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

MAINTAINING YOUR VEHICLE 379

Engine Oil

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

380 MAINTAINING YOUR VEHICLE

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

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

Change Engine Oil

CAUTION!

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

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

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

MAINTAINING YOUR VEHICLE 381

Engine Oil Selection

1. Engine Oil Quality

Use only oils conforming to API Ser- vice CI-4. A sulfated ash limit is speci- fied for lubrication oil used in Cum- mins engines. Oils with a high ash content may produce deposits on valves that can progress to guttering and valve burning. A maximum sul- fated ash content of 1.85 mass % is recommended for all oil used in the engine. 2. Engine Oil Viscosity (SAE Grade) The proper SAE viscosity of engine oil for the expected ambient temperature range should be selected, as indi- cated in the following chart:

382 MAINTAINING YOUR VEHICLE

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

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

WARNING!

Hot oil can cause personal injury.

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

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

MAINTAINING YOUR VEHICLE 383

CAUTION!

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

CAUTION!

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

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

384 MAINTAINING YOUR VEHICLE

CAUTION!

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

Install the filter as specified by the filter manufacturer. Turn the filter 3/4 to one full turn after making contact with the gasket. Check the condition of the threads and sealing surface on the oil pan and drain plug. Install the drain plug and sealing washer and tighten to 37 ft-lbs. (50 N·m). Use only high-quality multi-grade lubricating oil in your Cummins Diesel Engine. Choose the correct oil for your operating conditions as outlined in the Selection of Engine Oil.

Cummins Turbo Diesel Fill the engine with the correct grade of new oil. The engine capacity is 11 quarts (10.4 liters) in the crankcase and 1 quart (.95 liter) in the lubricating oil filter. Start the engine and operate it at idle for several minutes. Check for leaks at the lubricating oil filter and oil pan drain plug. Run the engine until it has reached operating tempera- ture, stop the engine. Wait approximately 15 minutes to let the oil in the upper parts of the engine drain back to the pan. Check the oil level again. Add oil as necessary to bring the level to the “SAFE” mark on the dipstick. Disposing Of Used Engine Oil And Filter Care should be taken in disposing of the used engine fluids from your vehicle. Used fluids, indiscriminately discarded, can present a problem to the environment.

Contact your local dealer, service station, or governmen- tal agency for advice on recycling programs and where used fluids and filters can be safely discarded in your area. Drive Belt

able.

Inspection Check the belt for intersecting cracks. • Transverse (across the belt width) cracks are accept- • Longitudinal (direction of belt length) cracks that intersect with transverse cracks are NOT acceptable. Replace the belt if it has unacceptable cracks, is frayed or has pieces of material missing. The engine speed sensor, located near the damper, should be inspected for damage if a belt is frayed.

MAINTAINING YOUR VEHICLE 385

Engine Air Cleaner Filter

CAUTION!

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

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

386 MAINTAINING YOUR VEHICLE

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

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

cleaner filter becomes clogged and air pressure drop across the filter element increases, a yellow disc travels along a graduated scale on the side of the Filter Minder™. The yellow disc will always show the greatest restriction experienced by the filter element. When the disc reaches the red zone, the filter element may need to be replaced. There is no other time or mileage interval for changing the air cleaner filter element. If the vehicle experiences a sudden loss of engine power when being driven in heavy snow or rain or when plowing snow, check the Filter Minder™ • If the Filter Minder™ is showing a plugged filter, the filter should be visually inspected for snow/ice build up or extreme water saturation. • The filter is not damaged, remove all snow/ice, rein-

stall filter and reset the Filter Minder™.

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

CAUTION!

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

MAINTAINING YOUR VEHICLE 387

CAUTION!

Many aftermarket performance air filter elements do not adequately filter the air entering the engine. Use of such filters can severely damage your engine.

Draining Fuel/Water Separator Filter

388 MAINTAINING YOUR VEHICLE

CAUTION!

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

Drain a small amount from the fuel/water separator filter periodically or when the WATER IN FUEL indicator lamp is on. Pull outward on the drain valve lever, located on the side of the filter, and allow any accumulated water to drain. Hold the drain valve open until all water and contaminants have been removed. Close the drain release valve, by returning it to the inward position, when clean fuel is visible. NOTE: The Fuel / Water separator drain valve is identified by its yellow handle and is located on the inboard side of the fuel filter housing.

If more than a couple ounces of fuel has been drained, follow the directions below for “Priming if the engine has run out of fuel.”

WARNING!

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

Priming if the engine has run out of fuel 1. Add a substantial quantity of fuel to the tank 5 to 10
gallons (19L to 38L). 2. Crank the engine for 1 to 2 seconds. If the engine does not start, then release the key or starter button back to the RUN position (do not turn the key back to the OFF position). The electric fuel transfer pump will continue to

run and purge air from the system for about 25 seconds. After 25 seconds, attempt to start the engine again. 3. Start the engine using the Normal Starting Procedure. 4. Repeat the procedure if the engine does not start.

MAINTAINING YOUR VEHICLE 389

CAUTION!

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

CAUTION!

WARNING!

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

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

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

390 MAINTAINING YOUR VEHICLE

CAUTION!

Due to lack of lubricants in alcohol or gasoline, the