2009 Dodge RAM Diesel Owners Manual

Allowed NOTE: To select the proper gear position for maximum deceleration (engine braking), simply press and hold the switch down (-). The transmission will shift to the range from which the vehicle can best be slowed down.

1-6

1-6

STARTING AND OPERATING 59

Torque Converter Clutch A feature designed to improve fuel economy has been included in the automatic transmission on your vehicle. A clutch within the torque converter engages automati- cally at calibrated speeds. This may result in a slightly different feeling or response during normal operation in the upper gears. When the vehicle speed drops or during acceleration when the transmission downshifts to second gear, the clutch automatically disengages. NOTE: • The torque converter clutch will not engage until the transmission fluid and engine coolant are warm [usu- ally after 1-3 miles (1.6 - 4.8 km) of driving]. Because the engine speed is higher when the torque converter clutch is not engaged, it may seem as if the transmis- sion is not shifting into Overdrive when cold. This is normal. Pressing the TOW HAUL O/D OFF button,

60 STARTING AND OPERATING

when the transmission is sufficiently warm, will dem- onstrate that the transmission is able to shift into and out of Overdrive. • If the vehicle has not been driven in several days, the first few seconds of operation after shifting the trans- mission into gear may seem sluggish. This is due to the fluid partially draining from the torque converter into the transmission. This condition is normal and will not cause damage to the transmission. The torque con- verter will refill within five seconds of shifting from PARK into any other gear position.

Automatic Transmission with Overdrive (AS68RC) – If Equipped (Chassis Cab Only) The shift lever display located in the instrument panel cluster, indicates the transmission gear range (the selector is illuminated for night driving). The shift lever is mounted on the right side of the steering column. You must depress the brake pedal, to pull the shift lever out of

PARK position (Brake Interlock System). To drive, move the shift lever from PARK or NEUTRAL to the desired drive position. Pull the shift lever toward you when shifting into REVERSE, SECOND, FIRST or PARK, or when shifting out of PARK. Gear Ranges DO NOT race the engine when shifting from PARK or NEUTRAL position into another gear range. PARK This gear position supplements the parking brake by locking the transmission. The engine can be started in this range. Never use PARK while the vehicle is in motion. Apply the parking brake when leaving the vehicle in this range. Always apply parking brake first, then place the shift lever in PARK position. On four- wheel drive vehicles be sure that the transfer case is in a drive position.

WARNING!

• Never use the PARK position as a substitute for the parking brake. Always apply the parking brake fully when parked to guard against vehicle movement and possible injury or damage. • Your vehicle could move and injure you and others if it is not completely in PARK. Check by trying to move the shift lever back and forth without first pulling it toward you after you have set it in PARK. Make sure it is in PARK before leaving the vehicle.

(Continued)

STARTING AND OPERATING 61

WARNING! (Continued)

• It is dangerous to move the shift lever out of PARK or NEUTRAL if the engine speed is higher than idle speed. If your foot is not firmly on the brake pedal, the vehicle could accelerate quickly forward or in reverse. You could lose control of the vehicle and hit someone or something. Only shift into gear when the engine is idling normally and when your right foot is firmly on the brake pedal.

62 STARTING AND OPERATING

REVERSE Use this range only after the vehicle has come to a complete stop. NEUTRAL Shift into NEUTRAL when the vehicle is standing for prolonged periods with the engine running. The engine may be started in this range. Set the parking brake if you must leave the vehicle. DRIVE This position provides all forward gears, including 4th gear direct and 5th or 6th (if equipped) gear overdrive (refer to Overdrive Operation, in this section). Use this range for most city and highway driving. THIRD Use this position for driving in slight heavy city traffic or on mountain roads where more precise speed control is desirable. Use it when climbing long grades, and for

engine braking when descending moderately steep grades. To prevent excessive engine speed do not exceed 40 mph (64 km/h) in this range. SECOND Use this position for driving in more severe conditions and lower speeds than THIRD. To prevent excessive engine speed do not exceed 25 mph (40 km/h) in this range. FIRST Use this position for driving up very steep hills and for engine braking at low speeds 12 mph (19 km/h) or less when going downhill. To prevent excessive engine speed, do not exceed 12 mph (19 km/h) in this range. NOTE: Use caution when operating a heavily loaded vehicle in SECOND or FIRST gear selections in high ambients as torque converter slip can impose significant additional heat load on the cooling system.

Overdrive Operation The Overdrive automatic transmission contains an elec- tronically controlled 5th and 6th (if equipped) speed (Overdrive). The transmission will automatically shift from DRIVE to Overdrive if the following conditions are present: • the shift lever is in DRIVE; • the engine coolant has reached normal operating tem- • vehicle speed is above approximately 38 mph (61 km/h) for 5th gear and 50 mph (80 km/h) for 6th gear; • the “TOW HAUL O/D OFF” switch has not been • transmission temperature.

activated;

operating

perature;

reached

normal

has

STARTING AND OPERATING 63

If the vehicle is started in extremely cold tem- NOTE: peratures, the transmission shift schedule initially re- stricts transmission operation in forward gear ranges to 3rd gear until the transmission fluid temperature rises to a suitable level. During this condition, the ability of the vehicle to accelerate under heavily loaded conditions may be reduced. Refer to the “Note” under “Torque Converter Clutch” in this section. If the transmission temperature gets extremely hot, the transmission will automatically select the most desirable gear for operation at this temperature. If the transmission temperature becomes hot enough, the “Transmission Temperature Warning Light” may illuminate and the transmission may downshift out of Overdrive until the transmission cools down. After cool down, the transmis- sion will resume normal operation. The transmission will downshift from Overdrive to Drive if the accelerator pedal is fully depressed at vehicle

64 STARTING AND OPERATING

speeds above approximately 35 to 40 mph (57 to 65 km/h) for 6th to 5th and 22 to 25 mph (36 to 40 km/h) for 5th to 4th. When To Use “TOW HAUL” and “O/D OFF” Modes When driving in hilly areas, towing a trailer, carrying a heavy load, etc., and frequent transmission shifting oc- curs, press the “TOW HAUL O/D OFF” switch once to select TOW HAUL. This will improve performance and reduce the potential for transmission overheating or failure due to excessive shifting. When operating in “TOW HAUL” mode, 6th gear (if equipped) is disabled and 2-3 and 3-4 and 4–5 shift patterns are modified. Shifts into Overdrive (5th gear) are allowed during steady cruise (for improved fuel economy). Pressing the “TOW HAUL O/D OFF” switch a second time to select O/D OFF will disable 5th and 6th gear completely, which should eliminate any excessive transmission shifting.

Tow Haul O/D Off Switch

The “TOW HAUL” or “O/D OFF” Indicator Light will illuminate in the instrument cluster to indicate when the switch has been activated. Pressing the switch a third time restores normal operation. If the “TOW HAUL” or “O/D OFF” modes are desired, the switch must be pressed each time the engine is started.

WARNING!

Do not use the Tow Haul feature when driving in icy or slippery conditions. The increased engine braking can cause the rear wheels to slide, and the vehicle to swing around with the possible loss of vehicle con- trol, which may cause an accident possibly resulting in personal injury or death.

When To Lock Out Overdrive When driving in hilly areas, towing a trailer, carrying a heavy load, etc., and frequent 6–5–6 or 5–4–5 transmis- sion shifting occurs, press the “TOW HAUL” switch. This will improve performance and reduce the potential for transmission overheating or failure due to excessive shifting. Torque Converter Clutch A feature designed to improve fuel economy has been included in the automatic transmission on your vehicle.

STARTING AND OPERATING 65

A clutch within the torque converter engages automati- cally at calibrated speeds. This may result in a slightly different feeling or response during normal operation in high gear. When the vehicle speed drops or during acceleration when the transmission downshifts to 1st gear, the clutch automatically disengages. NOTE: • The torque converter clutch will not engage until the transmission fluid and engine coolant are warm [usu- ally after 1-3 miles (1.6 - 4.8 km) of driving]. Because the engine speed is higher when the torque converter clutch is not engaged, it may seem as if the transmis- sion is not shifting into Overdrive when cold. This is normal. Pressing the “TOW HAUL” switch when the transmission is sufficiently warm will demonstrate that the transmission is able to shift into and out of Overdrive.

66 STARTING AND OPERATING

• If the vehicle has not been driven in several days, the first few seconds of operation after shifting the trans- mission into gear may seem sluggish. This is due to the fluid partially draining from the torque converter into the transmission. This condition is normal and will not cause damage to the transmission. The torque con- verter will refill within five seconds of shifting from PARK into any other gear position.

MANUAL TRANSMISSION — IF EQUIPPED

WARNING!

You or others could be injured if you leave the vehicle unattended without having the parking brake fully applied. The parking brake should al- ways be applied when the driver is not in the vehicle, especially on an incline.

CAUTION!

Never drive with your foot resting on the clutch pedal, or attempt to hold the vehicle on a hill with the clutch pedal partially engaged, as this will cause abnormal wear on the clutch.

NOTE: During cold weather, you may experience in- creased effort in shifting until the transmission fluid warms up. This is normal.

Shifting

Shift Pattern

Truck models with manual transmission are equipped with a clutch interlocking ignition system. The clutch pedal must be fully depressed to start the vehicle.

STARTING AND OPERATING 67

Fully depress the clutch pedal before shifting gears. As you release the clutch pedal, lightly depress the accelera- tor pedal. This transmission has a “creeper” 1st gear (L=low) which should be used to start from a standing position when carrying a payload or towing a trailer. Damage to the clutch can result from starting in 2nd or 3rd gear with a loaded vehicle. An unloaded vehicle may be launched in 2nd gear. Use each gear in numerical order – do not skip a gear. You should use 1st gear when starting from a standing position if under heavy load or when pulling a trailer. Recommended Vehicle Shift Speeds To utilize your manual transmission efficiently for both fuel economy and performance, it should be upshifted as listed in recommended shift speed chart. Shift at the vehicle speeds listed for acceleration. When heavily loaded or pulling a trailer these recommended up-shift speeds may not apply.

68 STARTING AND OPERATING

Maximum Recommended Up-shift Speeds

L to 2

Gear Selec- tion Maxi- mum Speed km/h) Downshifting

7 mph

(11

2 to 3

3 to 4

4 to 5

5 to 6

15 mph

25 mph

40 mph

45 mph

(24

km/h)

(40

km/h)

(64

km/h)

(72

km/h)

Moving from a high gear down to a lower gear is recommended to preserve brakes when driving down steep hills. In addition, downshifting at the right time provides better acceleration when you desire to resume speed. Downshift progressively. Do not skip gears to avoid overspeeding the engine and clutch.

WARNING!

Do not downshift for additional engine braking on a slippery surface. The drive wheels could lose their grip and the vehicle could skid.

CAUTION!

When descending a hill, be very careful to downshift one gear at a time to prevent overspeeding the engine which can cause valve damage, and / or clutch disc damage even if the clutch pedal is depressed.

Maximum Recommended Downshift Speeds

CAUTION!

Failure to follow the recommended downshifting speeds may cause the engine to overspeed and/or damage the clutch disc even if the clutch pedal is depressed.

Maximum Recommended Downshifting Speeds

Gear Selec- tion Maxi- mum Speed

6 to 5

5 to 4

4 to 3

3 to 2

2 to L

68 mph

(109
km/h)

50 mph

32 mph

19 mph

10 mph

(80

(51

(31

(16

km/h)

km/h)

km/h)

km/h)

STARTING AND OPERATING 69

Reverse Shifting To shift into REVERSE (R), bring the vehicle to a com- plete stop. Depress the clutch and pause briefly to allow the gear train to stop rotating. Beginning from the NEUTRAL (N) position, move the shift lever in one quick smooth motion straight across and into the REVERSE (R) area (the driver will feel a firm “click” as the shifter passes the “knock-over”). Complete the shift by pulling the shift lever into REVERSE (R). The “knock-over” prevents the driver from accidentally entering the REVERSE (R) shift area and warns the driver that they are about to shift the transmission into RE- VERSE (R). Due to this feature, a slow shift to REVERSE (R) can be perceived as a high shift effort. To shift out of REVERSE bring the vehicle to a complete stop and depress the clutch. Shifting out of REVERSE prior to a complete stop may cause high shift effort.

70 STARTING AND OPERATING

POWER TAKE OFF OPERATION – IF EQUIPPED (CHASSIS CAB ONLY) This vehicle when equipped with either the automatic six-speed or manual G-56 six-speed transmissions, will allow for an aftermarket upfit with a transmission driven PTO (power take off). The customer will have the ability to operate the PTO in either a “stationary” or “mobile” mode. The vehicles will be factory set to the “stationary” mode. In order to select the “mobile” mode an authorized dealership is required to modify the vehicle’s settings using their proprietary authorized dealer service tool. Stationary Mode

To operate the PTO in this mode the vehicle must meet the following conditions: • Be in PARK position (vehicles equipped with auto- • Upfitter provider (on/off) switch has been activated

matic transmission)

manual transmission)

• Parking brake applied (vehicles equipped with • Vehicle engine must be running • No vehicle, brake or clutch switch faults present • PTO must be correctly installed using the vehicle

provided circuits

The customer has the choice to operate the PTO by utilizing the cruise control switches or by utilizing a remote control (provided by the PTO supplier). To oper- ate the feature using the cruise control switches, the customer must first activate the upfitter-provided on/off switch. Next, the cruise control ON switch is selected. Following this step the SET switch must be depressed. The vehicle is now in the PTO mode and is ready for use. In order to increase or decrease the engine idle speed, to optimize the PTO function, the RESUME/ACCEL and DECEL cruise switches can be used respectively. To

disengage PTO operation and return to “standard vehicle operation” simply turn the upfitter-provided on/off switch to the OFF position or press the CANCEL cruise switch. To operate the PTO via a remote switch the customer must make sure the above conditions are met. It is vital for proper operation that the PTO and remote have been installed correctly, paying special attention to ensure the vehicle provided wiring has been connected properly. This is the responsibility of the installer of the PTO and switches/remote system. It is the responsibility of the PTO manufacturer to ensure that their electrical (switches and remote) system is compatible with the vehicle’s electrical architecture and software functionality.

Mobile Mode

STARTING AND OPERATING 71

via authorized dealer proprietary service tool

To operate the PTO in this mode the vehicle must meet the following conditions: • Authorized dealer-selected “mobile” mode activated • Upfitter-provided (on/off) switch has been activated • Vehicle must be in PARK or DRIVE position (vehicles • Parking brake must not be applied • No vehicle, brake or clutch switch faults present • Vehicle engine must be running • PTO must be correctly installed using the vehicle

equipped with automatic transmission)

provided circuits

72 STARTING AND OPERATING

The customer may choose to use the PTO while the vehicle is moving. To do so, the PTO function must be activated prior to taking the vehicle out of PARK. This is accomplished by activating the upfitter-provided PTO on/off switch. At this point, the customer may place the vehicle in a forward or reverse gear and have PTO operation. To disengage PTO operation and return to “standard vehicle operation” simply turn the upfitter- provided on/off switch to the OFF position. NOTE: For application specific information with respect to PTO and pump requirements and additional vehicle information (wiring schematics, preset idle values, en- gine speed limits, and vehicle hardware and software requirements) please refer to the Dodge Body Builders Guide by accessing “www.dodge.com/bodybuilder” and choosing the appropriate links.

Power Take Off – Aftermarket Installation If you did not order the PTO (Power Take Off) Prep Package from the factory and want to convert your vehicle, at www.dodge.com/bodybuilder or contact the manufac- turer directly at [email protected] (e-mail), 866–205– 4102 (toll free) or 313–493–2020.

the Body Builders Guide

refer

to

FUEL REQUIREMENTS Use good quality diesel fuel from a reputable supplier in your vehicle. Federal law requires that you must fuel this vehicle with Ultra Low Sulfur Highway Diesel fuel (15
ppm Sulfur maximum) and prohibits the use of Low Sulfur Highway Diesel fuel (500 ppm Sulfur maximum) to avoid damage to the emissions control system. For most year-round service, No. 2 diesel fuel meeting ASTM specification D-975 Grade S15 will provide good perfor- mance. 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!

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.

STARTING AND OPERATING 73

Fuel Specifications The Cummins威 diesel engine has been developed to take advantage of the high energy content and generally lower cost No. 2 Ultra Low Sulfur diesel fuel or No. 2
Ultra Low Sulfur climatized diesel fuels. Experience has shown that it also operates on No. 1 Ultra Low Sulfur diesel fuels or other fuels within specification. NOTE: • A maximum blend of 5% biodiesel meeting ASTM specification D-6751 may be used with your Cum- mins威 diesel engine. • In addition, commercially available fuel additives are not necessary for the proper operation of your Cum- mins威 diesel engine. • No. 1 Ultra Low Sulfur diesel fuel should only be used where extended arctic conditions (-10°F or -23°C) exist.

74 STARTING AND OPERATING

ENGINE RUNAWAY

ADDING FUEL

WARNING!

CAUTION!

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

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

tank is full.

NOTE: • When the fuel nozzle “clicks” or shuts off, the fuel • 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 portable container that is on a truck bed. You could be burned. Always place fuel containers on the ground while filling.

Fuel Filler Cap (Gas Cap)

If the gas cap is lost or damaged, be sure the replacement cap is for use with this vehicle.

CAUTION!

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

STARTING AND OPERATING 75

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. Refer to “Maintenance Procedures” in Section 7 of this manual.

76 STARTING AND OPERATING

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. NOTE: When a diesel engine is allowed to run out of fuel, air is pulled into the fuel system. If the vehicle will not start, refer to “Maintenance Procedures/Priming If The Engine Has Run Out Of Fuel” in Section 7 of this manual.

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.

WHAT TO DO IN EMERGENCIES

CONTENTS

䡵 Jump-Starting

▫ With Portable Starting Unit

. . . . . . . . . . . . . . . . . . . . . . . . 78
. . . . . . . . . . . . . 81

78 WHAT TO DO IN EMERGENCIES

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 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 the indicator (if equipped) is light or yellow on either battery, replace that battery.

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.

WHAT TO DO IN EMERGENCIES 79

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.

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

80 WHAT TO DO IN EMERGENCIES

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 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. 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.

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.

WHAT TO DO IN EMERGENCIES 81

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.

MAINTAINING YOUR VEHICLE

CONTENTS

䡵 Engine Compartment — 6.7L Diesel . . . . . . . . . 85
䡵 Maintenance Procedures . . . . . . . . . . . . . . . . . . 86
▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 86
▫ Engine Air Cleaner Filter . . . . . . . . . . . . . . . . 90
▫ Draining Fuel/Water Separator Filter . . . . . . . 92
▫ Priming If The Engine Has Run

Out Of Fuel

. . . . . . . . . . . . . . . . . . . . . . . . . 95

▫ Intervention Regeneration Strategy –

EVIC Message Process Flow . . . . . . . . . . . . . . 96

▫ Maintenance-Free Batteries . . . . . . . . . . . . . . 99
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . 100
▫ Charge Air Cooler — Inter-Cooler . . . . . . . . 105
▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . 106
▫ Clutch Hydraulic System . . . . . . . . . . . . . . . 107
▫ Transfer Case — If Equipped . . . . . . . . . . . . 107
▫ Manual Transmission — If Equipped . . . . . . 107

84 MAINTAINING YOUR VEHICLE

▫ Automatic Transmission — If Equipped ▫ Noise Control System Required Maintenance

& Warranty . . . . . . . . . . . . . . . . . . . . . . . . 112
. . . . . . . . . . . . . . . . . . . . . 116

䡵 Fluid Capacities

. . . 108

䡵 Fluids, Lubricants And Genuine Parts

. . . . . . 117
. . . . . . . . . . . . . . . . . . . . . . . . . . . 117
. . . . . . . . . . . . . . . . . . . . . . . . . . 119

▫ Engine ▫ Chassis

ENGINE COMPARTMENT — 6.7L DIESEL

MAINTAINING YOUR VEHICLE 85

1 — Battery 2 — Engine Oil Fill 3 — Engine Oil Dipstick 4 — Automatic Transmission Dipstick 5 — Brake Fluid Reservoir 6 — Clutch Master Cylinder (Manual Transmission Only) 7 — Battery

8 — Washer Fluid Reservoir 9 — Integrated Power Module 10 — Engine Coolant Reservoir 11 — Power Steering Fluid Reservoir 12 — Coolant Pressure Cap 13 — Air Cleaner Filter

86 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 30 minutes after engine shutdown to check the oil.

1 — ADD Range 2 — Full Mark 3 — SAFE Range

Checking the oil while the vehicle is on level ground will 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 qts (1.9L).

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 “Oil Change Required” under “Overhead Con- sole with Electronic Vehicle Information Center/System Status (EVIC Displays)” in Section 3 of this manual for recommended engine oil change intervals.

MAINTAINING YOUR VEHICLE 87

Engine Oil Selection For best performance and maximum protection under all types of operating conditions, the manufacturer only recommends engine oils that are API CJ-4 certified and meet the requirements of Chrysler LLC. Use MOPAR威 or an equivalent oil meeting Chrysler Material Standard MS-10902. Products meeting Cummins威 CES 20081 may also be used. The identification of these engine oils are typically located on the back of the oil container. American Petroleum Institute (API) Engine Oil Identification Symbol

This symbol means that the oil has been certified by the American Petro- leum Institute (API). The manufac- turer only recommends API Certified engine oils.

CAUTION!

Failure to use SAE 5W-40 synthetic engine oil in ambient temperatures below 0°F (-18°C) could result in severe engine damage.

88 MAINTAINING YOUR VEHICLE

Oils with a high ash content may produce deposits on valves that can progress to guttering and valve burning. A maximum sulfated ash content of 1.00 mass % is recommended for all oil used in the engine. The same oil change interval is to be followed for synthetic oil as for petroleum based oil. Also, synthetic oil must meet the same performance specifications as petro- leum oil. Engine Oil Viscosity (SAE Grade) Use SAE 15W-40 engine oil that meets Chrysler Materials Standard MS-10902 and the API CJ-4 engine oil category. In ambient temperatures below 0°F (-18°C), SAE 5W-40
synthetic engine oil that meets Chrysler Materials Stan- dard MS-10902 and the API CJ-4 engine oil category is required.

Engine oil not designated by the Chrysler or Cummins威 Material Standards and API CJ-4 should not be used, as engine and exhaust system durability may be compro- mised. The engine oil filler cap also shows the recom- mended engine oil viscosity for your engine. For infor- mation on engine oil filler cap location, refer to “Engine Compartment” in this section. 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 The manufacturer strongly recommends against the ad- dition of any additives (other than leak detection dyes or lube odorants) to the engine oil. Engine oil is an engi- neered product and its performance may be impaired by supplemental additives.

MAINTAINING YOUR VEHICLE 89

Engine Oil Filter Refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct part number. The engine oil filter should be changed at every engine oil change. 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.

90 MAINTAINING YOUR VEHICLE

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 condition of the air cleaner filter is monitored by the Engine Control Module. The Electronic Vehicle Informa- tion Center (EVIC) will display SERVICE AIR FILTER when service is required. Do not remove the top of the air filter housing to inspect the filter element on your diesel engine under normal operating conditions.

The EVIC message SERVICE AIR FILTER could be dis- played periodically. This is because engine air flow requirements change based on driving conditions. As the filter becomes more restrictive and air flow requirements increase the EVIC message SERVICE AIR FILTER will be displayed. The message may not be displayed in subse- quent drive cycles if the same conditions are not met. The air filter element should be replaced within 250 miles (402 km) from the first time this message is displayed to ensure proper engine operation during all driving con- ditions.

CAUTION!

Driving with a restricted air filter can cause engine damage.

If the vehicle experiences a sudden loss of engine power when being driven in heavy snow, rain or when plowing snow, and the EVIC message center states SERVICE AIR FILTER is showing a plugged filter, then visually inspect the air filter for snow/ice build up or extreme water saturation. If the air filter is not damaged, remove all snow/ice and reinstall air filter. If the air filter is dam- aged, replace filter element. NOTE: The air filter housing contains a Mass Air Flow sensor. This sensor is critical to proper engine operation and component longevity. Any damage or modification to this sensor could result in major engine and/or exhaust aftertreatment damage. This includes the use of non-approved air filters. Use only MOPAR威 approved air filters or equivalent.

MAINTAINING YOUR VEHICLE 91

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 Engine Control Module to determine when a filter change is necessary.

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.

92 MAINTAINING YOUR VEHICLE

Draining Fuel/Water Separator Filter The fuel filter and water separator assembly is located on the driver’s side of the engine. The best access to the water drain valve is through the driver’s side wheel well.

CAUTION!

• Do not drain the fuel/water separator filter when • Diesel fuel will damage blacktop paving surfaces.

the engine is running.

Drain the filter into an appropriate container.

If water is detected in the water separator while the engine is running or while the key is in the ON position, the “Water In Fuel Indicator Light” will illuminate and an audible chime will be heard five times. At this point you should stop the engine and drain the water from the separator.

CAUTION!

If the “Water In Fuel Indicator Light” remains on, DO NOT START the engine before you drain water from the fuel filter to avoid engine damage.

Fuel/Water Separator

If the “Water In Fuel Indicator Light” comes on and a single chime is heard while you are driving, or with the key in the ON position, there may be a problem with your water separator wiring or sensor. See your autho- rized dealer for service. Upon proper draining of the water from the fuel filter, the “Water In Fuel Indicator Light” will remain illuminated for approximately 10 seconds. If the water was drained while the engine was running, the “Water In Fuel Indi- cator Light” may remain on for approximately three minutes. NOTE: Care should be taken in disposing of used fluids from your vehicle. Used fluids, indiscriminately dis- carded, can present a problem to the environment. Con- tact an authorized dealer, service station, or government agency for advice on recycling programs and for where used fluids and filters can be properly disposed of in your area.

MAINTAINING YOUR VEHICLE 93

Drain the fuel/water separator filter when the “Water In Fuel Indicator Light” is ON. Within 10 minutes of vehicle shutdown, turn the drain valve (located on the bottom of the filter) counterclockwise two complete turns, turn the key to the ON position, and allow any accumulated water to drain. Leave the drain valve open until all water and contaminants have been removed. When clean fuel is visible, close the drain valve by turning it clockwise, and turn the ignition key to OFF. NOTE: The fuel/water separator drain valve is located on the bottom of the fuel filter housing. If more than a couple ounces/milliliters of fuel have been drained, follow the directions for “Priming If The Engine Has Run Out Of Fuel.”

94 MAINTAINING YOUR VEHICLE

Fuel Filter Replacement NOTE: Using a fuel filter that does not meet the manufacturer’s filtration and water separating require- ments can severely impact fuel system life and reliability.

CAUTION!

Drain the filter into an appropriate container.

• Diesel fuel will damage blacktop paving surfaces. • Do not prefill the fuel filter when installing a new fuel filter. There is a possibility debris could be introduced into the fuel filter during this action. It is best to install the filter dry and allow the in-tank lift pump to prime the fuel system.

1. Remove the left front tire/wheel. 2. Remove the left front wheel splash shield.

3. Clean all debris from around the filter canister and canister head. 4. Disconnect the WIF (Water In Fuel) sensor electrical connector. 5. Open the drain valve two complete revolutions. Drain approximately one cup of fuel into a waste canister. Dispose of the fuel according to environmental regula- tions. 6. Remove the drain hose from the drain valve. 7. Use a oil filter type wrench to loosen filter. Continue removing filter by hand. 8. After fuel filter removal, check and clean the second- ary filter screen. Press the button on the quick-connect fitting. Disconnect fitting from fitting. Unscrew the fitting from the canister head to expose screen. Reverse the steps above to reinstall the filter.

Priming If The Engine Has Run Out Of Fuel

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

WARNING!

CAUTION!

MAINTAINING YOUR VEHICLE 95

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.

1. Add a substantial amount of fuel to the tank, approxi- mately 5 to 10 gal (19L to 38L). 2. Crank the engine for one to two 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” proce- dure.

Do not engage the starter motor for more than 15 sec- onds 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.

WARNING!

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.

96 MAINTAINING YOUR VEHICLE

CAUTION!

Due to lack of lubricants in alcohol or gasoline, the use of these fuels can cause damage to the fuel system.

NOTE: • A maximum blend of 5% biodiesel, meeting ASTM specification D-6751 may be used with your Cum- mins威 diesel engine. Use of biodiesel mixture in excess of 5% can negatively impact the on-engine fuel filter’s ability to separate water from the fuel, resulting in high pressure fuel system corrosion or damage. • Ethanol blends are not recommended or approved for • In addition, commercially available fuel additives are not necessary for the proper operation of your Cum- mins威 diesel engine.

use with your Cummins威 diesel engine.

Intervention Regeneration Strategy – EVIC Message Process Flow The Cummins威 diesel engine meets all EPA Heavy Duty Diesel Engine Emissions Standards, resulting in the low- est emitting diesel engine ever produced. To achieve these emissions standards, your vehicle is equipped with a state-of-the-art engine and exhaust system. The engine and exhaust after-treatment system work together to achieve the EPA Heavy Duty Diesel Engine Emissions Standards. These systems are seam- lessly integrated into your vehicle and managed by the Cummins威 Powertrain Control Module (PCM). The PCM manages engine combustion to allow the exhaust sys- tem’s catalyst to trap and burn Particulate Matter (PM) pollutants, with no input or interaction on your part.

Additionally, the overhead console in your vehicle has the ability to alert you to additional maintenance re- quired on your truck or engine. Refer to the following messages that may be displayed on your Electronic Vehicle Information Center (EVIC):

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.

Perform Service The Cummins威 diesel engine utilizes a Closed Crankcase Ventilation (CCV) system, EGR valve and an EGR cooler. This system filters and recycles gasses produced in the

MAINTAINING YOUR VEHICLE 97

crankcase during the normal combustion process. “Per- form Service” will be displayed on the overhead console of your vehicle if the CCV filter, EGR valve and EGR cooler are due for required maintenance. The CCV filter is located on the top of the engine valve cover. For additional information, see your local authorized dealer. Exhaust System — Regeneration Required Now “Exhaust System — Regeneration Required Now” will be displayed on the overhead console of your vehicle if the exhaust particulate filter reaches 80% of its maximum storage capacity. Under conditions of exclusive short duration and low speed driving cycles, your Cummins威 diesel engine and exhaust after-treatment system may never reach the conditions required to remove the trapped PM. If this occurs, “Exhaust System — Regen- eration Required Now” will be displayed on the over- head console in your vehicle. If this message is displayed, you will hear one chime to assist in alerting you of this condition.

98 MAINTAINING YOUR VEHICLE

By simply driving your vehicle at highway speeds for as little as 45 minutes, you can remedy the condition in the particulate filter system and allow your Cummins威 diesel engine and exhaust after-treatment system to remove the trapped PM and restore the system to normal operating condition. Exhaust Filter XX% Full Indicates that the Diesel Particulate Filter (DPF) is ap- proaching full. Exhaust System — Regeneration in Process Indicates that the Diesel Particulate Filter (DPF) is self- cleaning. Maintain your current driving condition until regeneration is completed. Exhaust System — Regeneration Completed Indicates that the Diesel Particulate Filter (DPF) self- cleaning is completed. If this message is displayed, you will hear one chime to assist in alerting you of this condition.

Service Required — See Dealer Now Regeneration has been disabled due to a system malfunc- tion. At this point the engine PCM will register a fault code, the instrument panel will display a MIL light.

CAUTION!

See your authorized dealer, as damage to the exhaust system could occur soon with continued operation.

Exhaust Filter Full — Power Reduced See Dealer The PCM derates the engine in order to limit the likeli- hood of permanent damage to the after-treatment sys- tem. If this condition is not corrected and a dealer service is not performed, extensive exhaust after-treatment dam- age can occur. In order to correct this condition it will be necessary to have your vehicle serviced by your local authorized dealer.

CAUTION!

CAUTION!

MAINTAINING YOUR VEHICLE 99

See your authorized dealer, as damage to the exhaust system could occur soon with continued operation.

Maintenance-Free Batteries The top of the maintenance-free batteries are perma- nently sealed. You will never have to add water, nor is periodic maintenance required. NOTE: Replacement batteries should both be of equal capacity to prevent damage to the vehicle’s charging system.

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 are identified on the battery case. Also, if a “fast charger” is used while the battery is in vehicle, disconnect both vehicle battery cables before connecting the charger to the battery. Do not use a “fast charger” to provide starting voltage.

WARNING!

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

100 MAINTAINING YOUR VEHICLE

Battery Blanket Usage A battery loses 60% of its cranking power as the battery temperature decreases to 0°F (-18°). For the same de- crease in temperature, the engine requires twice as much power to crank at the same RPM. The use of 120 Volt AC powered battery blankets will greatly increase starting capability at low temperatures. Suitable battery blankets are available from your authorized MOPAR威 dealer. 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 Refer to the “Maintenance Schedule” in Section 8 of this manual for the proper maintenance intervals. 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. 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 101

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)

102 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 105,000 miles (168 000 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 103

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.

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

104 MAINTAINING YOUR VEHICLE

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 the engine coolant (antifreeze) freeze point in the radiator and in the coolant recovery bottle. If engine coolant (antifreeze) needs to be added, the contents of the 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. • Make sure that the radiator and coolant recovery bottle overflow hoses are not kinked or obstructed.

MAINTAINING YOUR VEHICLE 105

• 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 operation. If replacement is ever necessary, install ONLY the correct type thermostat. Other designs may result in unsatisfactory cooling performance, poor gas mileage, and increased emissions. Charge Air Cooler — Inter-Cooler The charge air cooler is positioned between the radiator and the air conditioner condenser. Air enters the engine through the air cleaner and passes through the turbo- charger, where it is pressurized. This pressurized air rapidly reaches high temperature. The air is then directed through a hose to the charge air cooler and through another hose to the intake manifold of the engine. The air entering the engine has been cooled by about 50° to 100°F

106 MAINTAINING YOUR VEHICLE

(10° to 38°C). This cooling process enables more efficient burning of fuel resulting in fewer emissions. To guarantee optimum performance of the system, keep the surfaces of the charge air cooler, condenser and radiator clean and free of debris. Periodically check the hoses leading to and from the charge air cooler for cracks or loose clamps resulting in loss of pressure and reduced engine performance. 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 Light” indicates system failure. 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. 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.

Clutch Hydraulic System The clutch hydraulic system is a sealed maintenance-free system. In the event of leakage or other malfunction, the system must be replaced. Transfer Case — If Equipped

Drain And Refill Refer to the “Maintenance Schedule” in Section 8 of this manual for the proper maintenance intervals.

MAINTAINING YOUR VEHICLE 107

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. Manual Transmission — If Equipped

Lubricant Selection Refer to “Fluids, Lubricants, and Genuine Parts” in this section for the correct fluid type. Fluid Level Check The fluid level can be checked by removing the filler plug. If the level of the lubricant is more than 1/4 in (6.4 mm) below the bottom of the filler hole while the vehicle is on level ground, enough lubricant should be added to bring the level to the bottom of the filler hole.

108 MAINTAINING YOUR VEHICLE

Automatic Transmission — If Equipped

Lubricant Selection Refer to “Fluids, Lubricants and Genuine Parts” in this section for the correct fluid type. Fluid Level Check— 68RFE (Ram Truck Only) If your vehicle is equipped with a dipstick, use the following procedure. If your vehicle has a capped dip- stick tube, it is sealed and should not be tampered with. Your authorized dealer has the proper tools to ensure that the fluid level is set properly. The fluid level should be checked when the engine is fully warmed up and the fluid in the transmission is at normal operating tempera- ture. Operation of the transmission with an improper fluid level will greatly reduce the life of the transmission and of the fluid. Check the fluid level whenever the vehicle is serviced.

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 the parking brake and press the brake pedal. 4. Place the shift lever momentarily into each gear posi- tion ending with the shift lever in PARK. 5. Remove the dipstick, wipe it clean and reinsert it until seated. 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 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 oil fill 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 tem- perature). 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 (82°C). Remember it is best to check the level at the normal operating temperature.

MAINTAINING YOUR VEHICLE 109

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 parking brake. 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 position, as long as its seal remains engaged in the dipstick tube.

110 MAINTAINING YOUR VEHICLE

Fluid Level Check — AS68RC (Chassis Cab Only) Check the fluid level while the transmission is at normal operating temperature. This occurs after at least 15 miles (25 km) of driving. At normal operating temperature, the fluid cannot be held comfortably between the fingertips. To properly check the transmission fluid, the following procedure must be used. 1. The vehicle must be on level ground. 2. Operate the engine at idle speed for a minimum of 60 seconds and normal operating temperature. 3. Fully apply the parking brake and press the brake pedal. 4. Place the shift lever momentarily into each gear posi- tion ending with the shift lever in PARK. Make sure the engine is running at idle speed.

5. Remove the dipstick and determine if the fluid is hot or cold. Hot fluid is approximately 160°F to 175°F (70°C to 82°C). This is the normal operating temperature after the vehicle has been driven at least 15 miles (25 km). The fluid cannot be comfortably held between the fingertips. Only use the cold region of the dipstick as a rough reference when doing initial oil level set after transmis- sion rebuild or transmission refill. 6. Wipe the dipstick clean and reinsert it until seated. 7. 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 MOPAR威AS68RC Automatic Transmission Fluid as re- quired into the dipstick tube. Do not overfill. Never use any ATF other than MOPAR威AS68RC Automatic Trans- mission Fluid. 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 to 85°F (20°C to 30°C). If the fluid level is correctly established at room temperature, it should be between the HOT (upper) reference holes when the transmission reaches 160°F to 175°F (70°C to 82°C).

CAUTION!

Be aware that if the fluid level 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 a accurate reading.

MAINTAINING YOUR VEHICLE 111

8. Check for leaks. Release the parking brake. NOTE: To prevent dirt and water from entering the transmission after checking or adding fluid, make sure that the dipstick cap is properly reseated. It is normal for the dipstick cap to spring back slightly from its fully seated position, as long as the seal remains engaged in the dipstick tube. Fluid and Filter Change Refer to the “Maintenance Schedule” in Section 8 for the proper maintenance intervals.

112 MAINTAINING YOUR VEHICLE

Noise Control System Required Maintenance & Warranty All vehicles built over 10,000 lbs. (4 535 kg) Gross Vehicle Weight Rating and manufactured for sale and use in the United States are required to comply with the Federal Government’s Exterior Noise Regulations. These vehicles can be identified by the Noise Emission Control Label located in the operator’s compartment.

Required Maintenance For Noise Control Systems The following maintenance services must be performed every six months or 6,000 miles (9 600 km) whichever comes first, to assure proper operation of the noise control systems. inspection and service should be performed anytime a malfunction is observed

In addition,

or suspected. Proper maintenance of the entire vehicle will help the effectiveness of the noise control systems. Exhaust System Inspect the entire exhaust system for leaks and damaged parts. Devices such as hangers, clamps, and U-bolts should be tight and in good condition. Damaged compo- nents, burned or blown out mufflers, burned or rusted out exhaust pipes should be replaced according to the procedures and specifications outlined in the appropriate service manual. Air Cleaner Assembly Inspect air cleaner housing for proper assembly and fit. Make certain that the air cleaner is properly positioned and that the cover is tight. Check all hoses leading to the air cleaner for tightness. The air filter element must also be clean and serviced according to the instructions out- lined in the Maintenance Schedule section of this manual.

MAINTAINING YOUR VEHICLE 113

Tampering With Noise Control System Prohibited Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorpo- rated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below. • AIR CLEANER − Removal of the air cleaner. − Removal of the air cleaner filter element from the air cleaner housing. − Removal of the air ducting.

114 MAINTAINING YOUR VEHICLE

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

Noise Emission Warranty The manufacturer warrants that this vehicle as manufac- tured by the manufacturer, was designed, built and equipped to conform at the time it left the manufacturer’s

control with all applicable U.S. EPA Noise Control Regu- lations. This warranty covers this vehicle as designed, built and equipped by the manufacturer, and is not limited to any particular part, component or system of the vehicle manufactured by the manufacturer. Defects in design, assembly or in any part, component or system of the vehicle as manufactured by the manufacturer, which, at the time it left the manufacturer’s control, caused noise emissions to exceed Federal standards, are covered by this warranty for the life of the vehicle.

MAINTAINING YOUR VEHICLE 115

Maintenance Log and Service Chart (Diesel Engines) Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest to the mileage at which service was performed. MILES KILOMETERS Exhaust system-inspect Air cleaner assembly-inspect ODOMETER READING PERFORMED BY PERFORMED AT

15,000
24 000

7,500
12 000

22,500
36 000

30,000
48 000

37,500
60 000

45,000
72 000

52,500
84 000

60,000
96 000

67,500
108 000

75,000
120 000

82,500
132 000

90,000
144 000

97,500
126 000

84,000
156 000

105,00
168 000

112,500
181 000

MILES KILOMETERS Exhaust system-inspect Air cleaner assembly-inspect ODOMETER READING PERFORMED BY PERFORMED AT

116 MAINTAINING YOUR VEHICLE

FLUID CAPACITIES

Engine Oil with Filter 6.7L Turbo Diesel Engine Cooling System 6.7L Turbo Diesel Engine (MOPAR威Engine Coolant/ Antifreeze 5 Year/100,000 Mile Formula)

U.S.

12 Quarts

5.7 Gallons

Metric

11.4 Liters

21.4 Liters

FLUIDS, LUBRICANTS AND GENUINE PARTS

MAINTAINING YOUR VEHICLE 117

Engine Component Engine Coolant

Engine Oil (6.7L Turbo Diesel Engine)

Engine Oil Filter (6.7L Turbo Diesel Engine) Engine Fuel Filter (6.7L Turbo Diesel Engine)

Fluid, Lubricant, or Genuine Part MOPAR威 Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) In ambient temperatures below 0°F (-18°C), 5W-40 synthetic engine oil that meets Chrysler Materials Standard MS-10902 and the API CJ-4 engine oil category is required. In ambient temperatures above 0°F (-18°C), 15W-40
engine oil that meets Chrysler Materials Standard MS-10902 and the API CJ-4 engine oil category is required. MOPAR威 Engine Oil Filter (P/N 05083285AA) or equivalent

MOPAR威 Fuel Filter or equivalent. Must meet 7 micron rating. Using a fuel filter that does not meet the manufacturers filtration and water separating requirements can severely impact fuel system life and reli- ability.

118 MAINTAINING YOUR VEHICLE

Component Crankcase Ventilation Filter (6.7L Turbo Diesel Engine) Fuel Selection (6.7L Turbo Diesel Engine)

Fluid, Lubricant, or Genuine Part MOPAR威 CCV Filter or equivalent

Use good quality diesel fuel from a reputable supplier in your vehicle. Federal law requires that you must fuel this vehicle with Ultra Low Sulfur Highway Diesel fuel (15 ppm Sulfur maximum) and prohibits the use of Low Sulfur Highway Diesel fuel (500 ppm Sulfur maximum) to avoid damage to the emissions control system. For most year-round service, No. 2 diesel fuel meeting ASTM specification D-975 Grade S15 will provide 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 pro- longed 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. This vehicle is fully com- patible with biodiesel blends up to 5% biodiesel meeting ASTM specifi- cation D-975.

MAINTAINING YOUR VEHICLE 119

Chassis Component Automatic Transmission (6-Speed 68RFE) (Ram Truck Only) Automatic Transmission (6-Speed AS68RC) (Chassis Cab Only) Clutch Linkage Manual Transmission (G-56)

Fluid, Lubricant, or Genuine Part MOPAR威 ATF+4 Automatic Transmission Fluid

MOPAR威 AS68RC Automatic Transmission Fluid

MOPAR威 Multi-Purpose Grease, NLGI Grade 2 E.P. or equivalent MOPAR威 ATF+4 Automatic Transmission Fluid

MAINTENANCE SCHEDULES

CONTENTS

䡵 Maintenance Schedule

. . . . . . . . . . . . . . . . . 122
▫ Oil Change Indicator System . . . . . . . . . . . 123

▫ Perform Service Indicator ▫ Required Maintenance Intervals

. . . . . . . . . . . . . 124
. . . . . . . . . 124

122 MAINTENANCE SCHEDULES

MAINTENANCE SCHEDULE

CAUTION!

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

At Each Stop for Fuel • Check the engine oil level about 30 minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark.

Once a Month • Inspect the batteries, and clean and tighten the termi-

nals as required.

• Check the fluid levels of the coolant reservoir, brake master cylinder, and transmission and transfer case (if equipped), add as needed.

At Each Oil Change • Change the engine oil filter. • Inspect the exhaust system. • Check the automatic transmission fluid level. • Check the manual transmission fluid level. • Check the coolant level, hoses, and clamps. • Lubricate outer tie rod ends. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all re- ceipts.

Oil Change Indicator System

Ram Truck Pick-Up (2500 and 3500 Models) Your vehicle is equipped with an engine oil change indicator system. This system will alert you when it is time to change your engine oil by displaying the words “Oil Change Required” on your Electronic Vehicle Infor- mation Center (EVIC). The engine oil change indicator system is duty cycle based, which means the engine oil change interval may fluctuate depending on your per- sonal driving style. Driving styles such as frequent stop and go type driving or extended idle time can increase the frequency of the engine oil change. This is the result of more frequent regeneration of the exhaust after treat- ment system, which can decrease the life of the engine oil. Failure to change the engine oil per the maintenance schedule can result in internal engine damage.

MAINTENANCE SCHEDULES 123

For information on resetting the Oil Change Indicator message, refer to “Oil Change Required – If Equipped,” under “System Status (EVIC Displays)” in the “Electronic Vehicle Information Center (EVIC)” Section of this manual. When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or six months since the last oil and filter change, replace the engine oil and engine oil filter. Under no circumstances should oil change intervals exceed 7,500 miles (12 000 km) or six months, whichever comes first.

124 MAINTENANCE SCHEDULES

Ram Truck Chassis Cab (3500, 4500, and 5500
Models) Replace the engine oil and oil filter every 7,500 miles (12 000 km) or six months, or sooner if prompted by the oil change indicator system (if equipped). Under no circumstances exceed 7,500 miles (12 000 km) or six months, whichever comes first. Perform Service Indicator Your vehicle will require emissions maintenance at a set interval. To help remind you when this maintenance is due, the Electronic Vehicle Information Center (EVIC)

should oil

intervals

change

will display “Perform Service”. When the “Perform Ser- vice” message is displayed on the EVIC it is necessary to have the emissions maintenance performed. Emissions maintenance includes replacing the Closed Crankcase Ventilation (CCV) filter element, cleaning of the EGR Cooler, and cleaning of the EGR Valve. The procedure for clearing and resetting the ⬙Perform Service⬙ indicator is message Service Information. Required Maintenance Intervals Refer to the Maintenance Schedules on the following pages for the required maintenance intervals.

located in the

appropriate

MAINTENANCE SCHEDULES 125

7,500 Miles (12,000 km) or 6 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be

changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter. Under no circumstances should oil change intervals exceed 7,500 miles (12 000 km) or 6 months, whichever comes first.

❏ Rotate tires. ❏ Lubricate front drive shaft fitting (4x4). ❏ Lubricate outer tie rod ends.

Odometer Reading

Repair Order #

Date

Dealer Code

Signature Authorized Chrysler Dealer

126 MAINTENANCE SCHEDULES

15,000 Miles (24,000 km) or 12 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be

changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter. Under no circumstances should oil change intervals exceed 7,500 miles (12 000 km) or 6 months, whichever comes first.

❏ Rotate tires. ❏ Lubricate front drive shaft fitting (4x4). ❏ Lubricate outer tie rod ends. ❏ Change front axle fluid (Ram Truck/Chassis Cab 4x4). ❏ Change rear axle fluid (Ram Truck Only). ❏ Replace fuel filter element.

Odometer Reading

Repair Order #

Date

Dealer Code

Signature Authorized Chrysler Dealer

MAINTENANCE SCHEDULES 127

22,500 Miles (36,000 km) or 18 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be

changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter. Under no circumstances should oil change intervals exceed 7,500 miles (12 000 km) or 6 months, whichever comes first.

❏ Rotate tires. ❏ Lubricate front drive shaft fitting (4x4). ❏ Lubricate outer tie rod ends. ❏ Inspect the front suspension, tie rod ends, and boot seals, replace if necessary. ❏ Inspect brake linings. ❏ Inspect and adjust parking brake if necessary. ❏ Inspect drive belt, replace if necessary.

Odometer Reading

Repair Order #

Date

Dealer Code

Signature Authorized Chrysler Dealer

128 MAINTENANCE SCHEDULES

30,000 Miles (48,000 km) or 24 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be

changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter. Under no circumstances should oil change intervals exceed 7,500 miles (12 000 km) or 6 months, whichever comes first.

❏ Rotate tires. ❏ Lubricate front drive shaft fitting (4x4). ❏ Lubricate outer tie rod ends. ❏ Change front axle fluid (Ram Truck/Chassis Cab 4x4). ❏ Change rear axle fluid (Ram Truck Only). ❏ Change automatic transmission fluid (Chassis Cab Only). ❏ Replace fuel filter element.

Odometer Reading

Repair Order #

Date

Dealer Code

Signature Authorized Chrysler Dealer

MAINTENANCE SCHEDULES 129

37,500 Miles (60,000 km) or 30 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be

changed. If not prompted by the Engine Oil Indicator System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter. Under no circumstances should oil change intervals exceed 7,500 miles (12 000 km) or 6 months, whichever comes first.

❏ Rotate tires. ❏ Lubricate front drive shaft fitting (4x4). ❏ Lubricate outer tie rod ends.

Odometer Reading

Repair Order #

Date

Dealer Code

Signature Authorized Chrysler Dealer

130 MAINTENANCE SCHEDULES

45,000 Miles (72,000 km) or 36 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be changed. If not prompted by the Engine Oil Indicator

System within 7,500 miles (12 000 km) or 6 months since the last oil and filter change, change the engine oil and engine oil filter. Under no circumstances should oil change intervals exceed 7,500 miles (12 000 km) or 6 months, whichever comes first.

❏ Rotate tires. ❏ Lubricate front drive shaft fitting (4x4). ❏ Lubricate outer tie rod ends. ❏ Inspect the front suspension, tie rod ends, and boot seals, replace if necessary. ❏ Inspect brake linings. ❏ Inspect and adjust parking brake if necessary. ❏ Change front axle fluid (Ram Truck/Chassis Cab 4x4). ❏ Change rear axle fluid (Ram Truck Only). ❏ Inspect drive belt, replace as necessary. ❏ Replace fuel filter element.

Odometer Reading

Repair Order #

Date

Dealer Code

Signature Authorized Chrysler Dealer

MAINTENANCE SCHEDULES 131

52,500 Miles (84,000 km) or 42 Months Maintenance Service Schedule ❏ When prompted by the Engine Oil Indicator System, the engine oil and filter must be