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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.
316 WHAT TO DO IN EMERGENCIES
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, 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.
WARNING!
Stand clear of vehicles when pulling with tow hooks. Tow straps and chains may break, causing serious injury.
CAUTION!
4-Wheel- Drive Vehicles
WHAT TO DO IN EMERGENCIES 317
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.
CAUTION!
To avoid damage to the transfer case while towing, always use one of the following methods.
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.
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).318 WHAT TO DO IN EMERGENCIES
If the vehicle is to be towed 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
m Engine Compartment— 3.7L/4.7L . . . . . . . . . . . 322
m Engine Compartment— 5.7L . . . . . . . . . . . . . . . 323
m Onboard Diagnostic System (OBD II) . . . . . . . . . 324
m Emissions Inspection And MaintenancePrograms
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
m Dealer Service . . . . . . . . . . . . . . . . . . . . . . . . . 326
m Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 327
m Maintenance Procedures . . . . . . . . . . . . . . . . . . 327
N Air Conditioner Maintenance . . . . . . . . . . . . . 327N Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 329
N Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . 333
N Drive Belts — Check Condition AndTensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
N Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . 333
N Engine Air Cleaner Filter . . . . . . . . . . . . . . . . 334
N Engine Fuel Filter . . . . . . . . . . . . . . . . . . . . . 334
N Catalytic Converter . . . . . . . . . . . . . . . . . . . . 335
N Emission-Related Components . . . . . . . . . . . . 336320 MAINTAINING YOUR VEHICLE
N Maintenance Free Battery . . . . . . . . . . . . . . . . 337
N Air Conditioner Maintenance . . . . . . . . . . . . . 338
N Power Steering — Fluid Check . . . . . . . . . . . . 339
N Front Suspension Ball Joints . . . . . . . . . . . . . . 340
N Steering Linkage — Inspection . . . . . . . . . . . . 341
N Half-Shaft Constant Velocity Joints . . . . . . . . . 341
N Body Lubrication . . . . . . . . . . . . . . . . . . . . . 341
N Windshield Wiper Blades . . . . . . . . . . . . . . . . 342
N Windshield Washers . . . . . . . . . . . . . . . . . . . 342
N Exhaust System . . . . . . . . . . . . . . . . . . . . . . 343
N Cooling System . . . . . . . . . . . . . . . . . . . . . . . 344
N Hoses And Vacuum/Vapor Harnesses . . . . . . . 347
N Brake System . . . . . . . . . . . . . . . . . . . . . . . . 348N Clutch Hydraulic System . . . . . . . . . . . . . . . . 349
N Clutch Linkage . . . . . . . . . . . . . . . . . . . . . . . 350
N Propeller Shaft Universal Joints . . . . . . . . . . . 350
N Rear Axle And 4X4 Front Driving AxleFluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . 350
N Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . 351
N Manual Transmission . . . . . . . . . . . . . . . . . . 351
N Automatic Transmission . . . . . . . . . . . . . . . . 352
N Front Wheel Bearings . . . . . . . . . . . . . . . . . . 355
N Selection Of Lubricating Grease . . . . . . . . . . . 356
N Noise Control System Required Maintenance & Warranty For 3500 2-Wheel Drive And 4-Wheel Drive Models Over 10,000 Lbs. (4 535 Kg) Gross Vehicle Weight Rating. . . . . . . . . . . . . . . . . . . 356N Appearance Care And Protection From
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
m Fuse And Relay Center . . . . . . . . . . . . . . . . . . . 365
m Vehicle Storage . . . . . . . . . . . . . . . . . . . . . . . . 365
m Replacement Light Bulbs . . . . . . . . . . . . . . . . . 366
m Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . 366N Headlight (Halogen)/Front Park And Turn
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
N Tail, Stop, Turn And Backup Lights . . . . . . . . . 370
N Center High-Mounted Stoplight With CargoLight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
MAINTAINING YOUR VEHICLE 321
N Cab Top Clearance Lights — If Equipped . . . . 374
N Tailgate ID Lights (Dual Rear Wheels) . . . . . . . 375
N Side Marker Lights (Dual Rear Wheels) . . . . . . 377
N Fog Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 378
. . . . . . . . . . . . . . . . . . . 379m Fluids And Capacities m Recommended Fluids, Lubricants And Genuine
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
N Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
N Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382322 MAINTAINING YOUR VEHICLE
ENGINE COMPARTMENT— 3.7L/4.7L
ENGINE COMPARTMENT— 5.7L
MAINTAINING YOUR VEHICLE 323
324 MAINTAINING YOUR VEHICLE
ONBOARD DIAGNOSTIC SYSTEM (OBD II) Your vehicle is equipped with a sophisticated onboard diagnostic system called OBD II. This system monitors the performance of the emissions, engine, and automatic transmission control systems. When these systems are operating properly, your vehicle will provide excellent performance and fuel economy, as well as engine emis- sions well within current government regulations. If any of these systems require service, the OBD II system will turn on the “Malfunction Indicator Light.” It will also store diagnostic codes and other information to assist your service technician in making repairs. Al- though your vehicle will usually be driveable and not need towing, see your dealer for service as soon as possible.
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.
EMISSIONS INSPECTION AND MAINTENANCE PROGRAMS In some localities, it may be a legal requirement to pass an inspection of your vehicle’s emissions control system. Failure to pass could prevent vehicle registration.
For states which have an I/M (Inspection and Maintenance) requirement, this check verifies the following: the MIL (Malfunction Indicator Lamp) is functioning and is not on when the engine is running, and that the OBD (On Board Diagnostic) system is ready for testing. Normally, the OBD system will be ready. The OBD system may not be ready if your vehicle was recently serviced, if you recently had a dead battery, or a battery replacement. If the OBD system should be determined not ready for the I/M test, your vehicle may fail the test. Your vehicle has a simple ignition key actuated test which you can use prior to going to the test station. To check if your vehicle’s OBD system is ready, you must do the following: 1. Insert your ignition key into the ignition switch.
MAINTAINING YOUR VEHICLE 325
2. Turn the ignition to the ON position, but do not crank or start the engine. 3. If you crank or start the engine, you will have to start this test over. 4. As soon as you turn your key to the ON position, you will see your MIL symbol come on as part of a normal bulb check. 5. Approximately 15 seconds later, one of two things will happen:
a. The MIL light will blink for approximately 5 sec- onds and then remain on until the first engine crank or the key is turned off. This means that your vehicle’s OBD system is not ready and you should not proceed to the I/M station.
326 MAINTAINING YOUR VEHICLE
b. The MIL light will remain fully illuminated until the first engine crank or the key is turned off. This means that your vehicle’s OBD system is ready and you can proceed to the I/M station.
If your OBD system is not ready, you should see your dealer or repair facility. If your vehicle was recently serviced or had a battery failure or replacement, you may need to do nothing more than drive your vehicle as you normally would in order for your OBD system to update. A recheck with the above test routine may then indicate that the system is now ready. Regardless of whether your vehicle’s OBD system is ready or not ready, if the MIL symbol is illuminated during normal vehicle operation, you should have your vehicle serviced before going to the I/M station. The I/M station can fail your vehicle because the MIL symbol is on with the engine running.
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.
REPLACEMENT PARTS Use of genuine Mopart parts for normal/scheduled maintenance and repairs is highly recommended to in- sure the designed performance. Damage or failures caused by the use of non-Mopar parts for maintenance and repairs will not be covered by the manufacturer’s warranty.
MAINTAINING YOUR VEHICLE 327
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. Air Conditioner Maintenance For best possible performance, your air conditioner should be checked and serviced by an Authorized Dealer at the start of each warm season. This service should include cleaning of the condenser fins and a performance test. Drive belt tension should also be checked at this time.
328 MAINTAINING YOUR VEHICLE
WARNING!
† Use only refrigerants and compressor lubricants approved by the manufacturer for your air condi- tioning system. Some unapproved refrigerants are flammable and can explode, injuring you. Other unapproved refrigerants or lubricants can cause the system to fail, requiring costly repairs. † The air conditioning system contains refrigerant under high pressure. To avoid risk of personal injury or damage to the system, adding refrigerant or any repair requiring lines to be disconnected should be done by an experienced repairman.
Refrigerant Recovery and Recycling R-134a Air Conditioning Refrigerant is a hydrofluorocar- bon (HFC) that is endorsed by the Environmental Pro- tection Agency and is an ozone-saving product. How- ever, the manufacturer recommends that air conditioning service be performed by dealers or other service facilities using recovery and recycling equipment. NOTE: Air Conditioning systems found to be contami- nated with A/C System Sealers, Stop Leak Products, Seal Conditioners, Compressor Oil, or Refrigerants not ap- proved by the manufacturer, voids the warranty for the Air Conditioning system.
Engine Oil
Checking Oil Level To assure proper lubrication of your vehicle’s engine, the engine oil must be maintained at the correct level. The best time to check the engine oil level is about 5 minutes after a fully warmed up engine is shut off or before starting the engine after it has sat overnight. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level readings. Maintain the oil level between the ADD and SAFE markings on the dipstick. Adding one quart of oil when the reading is at the ADD mark will result in a SAFE reading on these engines.
MAINTAINING YOUR VEHICLE 329
330 MAINTAINING YOUR VEHICLE
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: † Day or night temperatures are below 32°F (0°C). † Stop and go driving. † Extensive engine idling. † Driving in dusty conditions † Short trips of less than 10 miles (16.2 km)
speeds during hot weather, above 32°C (90°F)
† More than 50% of your driving is at sustained high † Trailer towing † Heavy Loading † Taxi, Police or delivery service (commercial service) † Off-road or desert operation † If equipped for and operating with E-85 (ethanol)
fuel.
If ANY of these apply to you then change your NOTE: engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first and follow schedule “B” of the 9Maintenance Schedules9 section of this manual. If none of these apply to you, then change your engine oil at every interval shown on schedule 9A9 of the 9Mainte- nance Schedules9 section of this manual.
Dusty Conditions Driving through dust-laden air increases the problems of keeping abrasive materials out of the engine. Under these conditions, special attention should be given to the engine air cleaner, the crankcase inlet air cleaner and the crankcase ventilation system. Make sure that these units are clean at all times. This will tend to reduce to a minimum the amount of abrasive material that may enter the engine. Engine Oil Selection For best performance and maximum protection under all types of operating conditions, the manufacture only recommends engine oils that are API certified and meet the requirements of DaimlerChrysler Material Standard MS-6395. Use Mopar or an equivalent oil meeting the specification MS-6395.
MAINTAINING YOUR VEHICLE 331
Engine Oil Identification (API) Symbol There is a symbol to aid you in selecting the proper engine oil.
This symbol means that the oil has been certified by the American Petroleum Institute (API). The manufacturer only recommends API Certified engine oils that meet of DaimlerChrysler Material Stan- dard MS-6395. Use Mopar or an equivalent oil meeting the specifi- cation MS-6395.
requirements
the
Engine Oil Viscosity Chart The proper SAE viscosity grade of engine oil should be selected based on the following recommendation and be within the operating temperature shown in the recom- mended SAE viscosity chart.
332 MAINTAINING YOUR VEHICLE
3.7L/4.7L/5.7L engines.
† SAE 5W-30 is the preferred oil for Dodge Trucks with † Lubricants which do not have both the engine oil certification mark or current service symbol and the correct viscosity grade number should not be used.
Preferred Viscosity for 3.7L/4.7L/5.7L Engines
Synthetic Engine Oils There are a number of engine oils being promoted as either synthetic or semi-synthetic. If you chose to use such a product, use only those oils that are API Certified and meet the SAE viscosity standard. Follow the service schedule that describes your driving type. Materials Added to Engine Oil The manufacture strongly recommends against the addi- tion of any additives (other than leak detection dyes) to the engine oil. Engine oil is an engineered product and it’s performance may be impaired by supplemental ad- ditives. Disposing of Used Engine Oil And Oil Filters Care should be taken in disposing of used engine oil and oil filters from your vehicle. Used oil and oil filters, indiscriminately discarded, can present a problem to the environment. Contact your dealer, service station, or
governmental agency for advice on how and where used oil and oil filters can be safely discarded in your area. Engine Oil Filter The engine oil filter should be replaced at every engine oil change. Engine Oil Filter Selection The manufacturer’s engines have a full-flow type oil filter. Use a filter of this type for replacement. The quality of replacement filters varies considerably. Only high quality filters should be used to assure most efficient service. Mopar Engine Oil Filters are a high quality oil filter and are recommended. Drive Belts — Check Condition and Tensioner Belt tension is controlled by means of an automatic tensioner. No belt tension adjustments are required. However, belt and belt tensioner condition should be inspected at the specified intervals and replaced if re- quired. See your authorized dealer for service.
MAINTAINING YOUR VEHICLE 333
At the mileage indicated in the maintenance schedule, all belts and tensioner should be checked for condition. Improper belt tension can cause belt slippage and failure. Belts should be inspected for evidence of cuts, cracks, glazing or frayed cords and replaced if there is indication of damage which could result in belt failure. Low gen- erator belt tension can cause battery failure. Also check belt routing to make sure there is no interfer- ence between the belts and other engine components. Spark Plugs Spark plugs must fire properly to assure engine perfor- mance and emission control. New plugs should be in- stalled at the specified mileage. The entire set should be replaced if there is any malfunction due to a faulty spark plug, malfunctioning spark plugs can damage the cata- lytic converter. For proper type of replacement spark plugs, refer to the “Vehicle Emission Control Informa- tion” label in the engine compartment.
334 MAINTAINING YOUR VEHICLE
Engine Air Cleaner Filter Under normal driving conditions, replace the air filter at the intervals shown on Schedule “A”. If, however, you drive the vehicle frequently under dusty or severe con- ditions, the filter element should be inspected periodi- cally and replaced if necessary at the intervals shown on Schedule “B”.
WARNING!
The air induction system (air cleaner, hoses, etc) can provide a measure of protection in the case of engine backfire. Do not remove theair induction system (air cleaner, hoses, etc) unless such removal is necessary for repair or maintenance. Make sure that no one is near the engine compartment before starting the vehicle with the air induction system (air cleaner, hoses, etc) removed. Failure to do so can result in serious personal injury.
Engine Fuel Filter A plugged fuel filter can cause stalling, limit the speed at which a vehicle can be driven or cause hard starting. Should an excessive amount of dirt accumulate in the fuel tank, frequent filter replacement may be necessary.
Catalytic Converter The catalytic converter requires the use of unleaded fuel only. Leaded gasoline will destroy the effectiveness of the catalyst as an emission control device. Under normal operating conditions, the catalytic con- verter will not require maintenance. However, it is im- portant to keep the engine properly tuned to assure proper catalyst operation and prevent possible catalyst damage.
MAINTAINING YOUR VEHICLE 335
CAUTION!
Damage to the catalytic converter can result if your vehicle is not kept in proper operating condition. In the event of engine malfunction, particularly involv- ing engine misfire or other apparent loss of perfor- mance, have your vehicle serviced promptly. Contin- ued operation of your vehicle with a severe malfunction could cause the converter to overheat, resulting in possible damage to the converter and the vehicle.
NOTE: systems can result against you.
Intentional tampering with emissions control in civil penalties being assessed
336 MAINTAINING YOUR VEHICLE
WARNING!
A hot exhaust system can start a fire if you park over materials that can burn. Such materials might be grass or leaves coming into contact with your ex- haust system. Do not park or operate your vehicle in areas where your exhaust system can contact any- thing that can burn.
In unusual situations involving grossly malfunctioning engine operation, a scorching odor may indicate severe and abnormal catalyst overheating. If this occurs, the vehicle should be stopped, the engine shut off and the vehicle allowed to cool. Thereafter, service, including a tune-up to manufacturer’s specifications, should be ob- tained immediately. To minimize the possibility of catalyst damage:
† Do not shut off the engine or interrupt the ignition when the transmission is in gear and the vehicle is in motion. † Do not try to start engine by pushing or towing the † Do not idle the engine with any spark plug wires disconnected or removed, such as when diagnostic testing, or for prolonged periods during very rough idling or malfunctioning operating conditions.
vehicle.
Emission-Related Components
Positive Crankcase (PCV) Valve Proper operation of the crankcase ventilation system requires that the PCV valve be free of sticking or plug- ging from deposits. Deposits can accumulate in the PCV valve and passages with increasing mileage. Have the PCV valve, hoses, and passages checked for proper operation at the valve is
the intervals specified.
If
plugged or sticking, replace with a new valve— do not attempt to clean the old PCV valve! Check the ventila- tion hoses for indications of damage, weepage or plug- ging with deposits. Replace if necessary. Maintenance Free Battery The top of the maintenance free battery is permanently sealed. You will never have to add water, nor is periodic maintenance required. To determine the battery charge, check the battery test indicator (if equipped) on top of the battery. If the test indicator (if equipped) appears light or yellow, replace the battery.
MAINTAINING YOUR VEHICLE 337
338 MAINTAINING YOUR VEHICLE
WARNING!
Battery fluid is a corrosive acid solution and can burn or even blind you. Don’t allow battery fluid to contact your eyes, skin or clothing. Don’t lean over a battery when attaching clamps. If acid splashes in eyes or on skin, flush the area immediately with large amounts of water. Battery gas is flammable and explosive. Keep flame or sparks away from the battery. Don’t use a booster battery or any other booster source with an output greater than 12 volts. Don’t allow cable clamps to touch each other. Battery posts, terminals and related accessories con- tain lead and lead compounds. Wash hands after handling.
CAUTION!
It is essential when replacing the cables on the battery that the positive cable is attached to the positive post and the negative cable is attached to the negative post. Battery posts are marked (+) positive and negative (-) and identified on the battery case. Also, if a “fast charger” is used while battery is in vehicle, disconnect both vehicle battery cables be- fore connecting the charger to battery. Do not use a “fast charger” to provide starting voltage.
Air Conditioner Maintenance For best possible performance, your air conditioner should be checked and serviced by an Authorized Dealer at the start of each warm season. This service should include cleaning of the condenser fins and a performance test. Drive belt tension should also be checked at this time.
WARNING!
† Use only refrigerants and compressor lubricants approved by the manufacturer for your air condi- tioning system. Some unapproved refrigerants are flammable and can explode, injuring you. Other unapproved refrigerants or lubricants can cause the system to fail, requiring costly repairs. † The air conditioning system contains refrigerant under high pressure. To avoid risk of personal injury or damage to the system, adding refrigerant or any repair requiring lines to be disconnected should be done by an experienced repairman.
MAINTAINING YOUR VEHICLE 339
Refrigerant Recovery and Recycling R-134a Air Conditioning Refrigerant is a hydrofluorocar- bon (HFC) that is endorsed by the Environmental Pro- tection Agency and is an ozone-saving product. How- ever, the manufacturer recommends that air conditioning service be performed by dealers or other service facilities using recovery and recycling equipment. NOTE: Air Conditioning systems found to be contami- nated with A/C System Sealers, Stop Leak Products, Seal Conditioners, Compressor Oil, or Refrigerants not ap- proved by the manufacturer, voids the warranty for the Air Conditioning system. Power Steering — Fluid Check Checking the power steering fluid level at a defined service interval is not required. The fluid should only be checked if a leak is suspected, abnormal noises are
340 MAINTAINING YOUR VEHICLE
apparent, and/or the system is not functioning as antici- pated. Coordinate inspection efforts through a certified DaimlerChrysler Dealership.9
WARNING!
Fluid level should be checked on a level surface and with the engine off to prevent injury from moving parts and to insure accurate fluid level reading. Do not overfill. Use only manufacturers recommended power steering fluid.
If necessary, add fluid to restore to the proper indicated level. With a clean cloth, wipe any spilled fluid from all surfaces. Refer to Recommended Fluids, Lubricants, and Genuine Parts for correct fluid type.
Front Suspension Ball Joints
if the seals on the ball
4 x 2 Models The ball joints and seals should be inspected whenever the vehicle is serviced for other reasons. The ball joints originally supplied with the vehicle are permanently lubricated at the factory and do not require service. However, joints are damaged, the joints should be replaced. Serviceable replacement ball joints are available. Front suspension ball joints should be replaced only by a qualified service technician using tools specially de- signed for this purpose. Damage to the joints and/or suspension components may result if improper replace- ment procedures are used. If seals are damaged the ball joints should be replaced to prevent leakage or contamination of the grease.
Steering Linkage — Inspection Whenever the vehicle is hoisted, all steering linkage joints should be inspected for evidence of damage. If seals are damaged, parts should be replaced to prevent leakage or contamination of the grease. Lubricate the steering linkage regularly according to the “Maintenance Schedule” in this manual. Half-shaft Constant Velocity Joints All four- wheel- drive 1500 models are equipped with four constant velocity joints. Periodic lubrication of these joints is not required. However, the joint boots should be inspected for external leakage or damage periodically. If external leakage or damage is evident, the joint boot and grease should be replaced immediately. Continued op- eration could result in failure of the joint due to water and dirt contamination of the grease. This would require complete replacement of the joint assembly. Refer to the Service Manual for the detailed replacement procedure.
MAINTAINING YOUR VEHICLE 341
Body Lubrication Locks and all body pivot points, including such items as seat tracks, doors, tailgate and hood hinges, should be lubricated periodically to assure quiet, easy operation and to protect against rust and wear. Prior to the appli- cation of any lubricant, the parts concerned should be wiped clean to remove dust and grit; after lubricating excess oil and grease should be removed. Particular attention should also be given to hood latching compo- nents to insure proper function. When performing other underhood services, the hood latch, release mechanism and safety catch should be cleaned and lubricated. The external lock cylinders should be lubricated twice a year, preferably in the fall and spring. Apply a small amount of a high quality lubricant such as Mopart Lock Cylinder Lubricant directly into the lock cylinder.
342 MAINTAINING YOUR VEHICLE
Windshield Wiper Blades The rubber edges of the wiper blades and the windshield should be cleaned periodically with a sponge or soft cloth and a mild nonabrasive cleaner. This will remove accu- mulations of salt or road film. Operation of the wipers on dry glass for long periods may cause deterioration of the wiper blades. Always use washer fluid when using the wipers to remove salt or dirt from a dry windshield. Avoid using the wiper blades to remove frost or ice from the windshield. Keep the blade rubber out of contact with petroleum products such as engine oil, gasoline, etc. Windshield Washers The fluid reservoir is located under the hood and should be checked for fluid level at regular intervals. Fill the reservoir with windshield washer solvent only (not ra- diator antifreeze).
To prevent freeze-up of your windshield washer system in cold weather, select a solution or mixture that meets or exceeds the temperature range of your climate. This rating information can be found on most washer fluid containers.
WARNING!
Commercially available windshield washer solvents are flammable. They could ignite and burn you. Care must be exercised when filling or working around the washer solution.
After the engine has warmed, operate the defroster for a few minutes to reduce the possibility of smearing or freezing the fluid on the cold windshield. Mopar All Weather Windshield Washer Solution, used with water as
directed on the container, aids cleaning action, reduces the freezing point to avoid line clogging, and is not harmful to paint or trim. Exhaust System The best protection against carbon monoxide entry into the vehicle body is a properly maintained engine exhaust system. Whenever a change is noticed in the sound of the exhaust system, when exhaust fumes can be detected inside the vehicle, or when the underside or rear of the vehicle is damaged, have a competent mechanic inspect the com- plete exhaust system and adjacent body areas for broken, damaged, deteriorated, or mispositioned parts. Open seams or loose connections could permit exhaust fumes to seep into the passenger compartment. In addition, inspect the exhaust system each time the vehicle is raised for lubrication or oil change. Replace as required.
MAINTAINING YOUR VEHICLE 343
WARNING!
Exhaust gases can injure or kill. They contain carbon monoxide (CO) which is colorless and odorless. Breathing it can make you unconscious and can eventually poison you. To avoid breathing CO, fol- low the preceding safety tips.
Exhaust System Rubber Isolator and Loop-Type Hanger — If Equipped Inspect surfaces whenever the vehicle is hoisted for rubber to metal separation or deep cracks. SLIGHT CRACKING DUE TO WEATHERING DOES NOT AD- VERSELY AFFECT PERFORMANCE. If, however, exces- sively deep localized cracks are present, or any part of the exhaust system abnormally contacts the underbody hard- ware, the isolator and/or hanger should be replaced.
344 MAINTAINING YOUR VEHICLE
Cooling System
Cooling System Maintenance At the intervals shown in the Maintenance Schedules Section of the manual, the system should be drained, flushed and filled. Inspection Coolant protection checks should be made every 12
months (prior to the onset of freezing weather, where applicable). If coolant is dirty or rusty in appearance, the system should be drained, flushed and refilled with fresh coolant as specified. Inspect the entire cooling system for leaks. Check the face of the radiator for any accumulation of bugs, leaves, or other foreign matter. If dirty, clean the radiator core with a garden hose. With the engine OFF, gently spray water from the back of the radiator core.For 3.7L, 4.7L, and 5.7L engines, check the coolant bottle hoses for condition and tightness of the connections at both the coolant bottle and radiator. For 3.7L, 4.7L, 5.7L engines, check the coolant pressure cap and coolant reserve system for proper vacuum sealing. With the engine at normal operating tempera- ture, note the level of the coolant in the coolant bottle. Without removing the pressure cap (with the engine off), drain a small amount of coolant from the radiator drain- cock. If the coolant level in the coolant bottle drops, the system is sealing properly. Coolant Level ( 3.7L, 4.7L, 5.7L Engines) The coolant reserve system provides a quick visual method of determining that the coolant level is adequate. With the engine idling, and warmed to the normal operating temperature, the level of the coolant in the coolant bottle should be between the fluid level marks. Check the coolant level whenever the hood is raised.
The radiator normally remains completely full, so there is no longer a need to remove the coolant pressure cap except for checking coolant freeze point or replacement with new antifreeze coolant.
WARNING!
Never add coolant to the radiator when the engine is overheated. Do not loosen or remove pressure cap to cool an overheated engine! The coolant is under pressure and severe scalding could result.
Drain, Flush And Refill At intervals shown on the Maintenance Schedules, the system should be drained, flushed and refilled. Refer to your dealer or consult a service manual for proper procedures.
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Adding Coolant When adding coolant or refilling system, a 50% solution of ethylene glycol antifreeze coolant in water should be used. Higher concentrations (not to exceed 65%) are required if temperatures below -34 F° (-37 C°) are antici- pated. Use only high purity water such as distilled or deionized water when mixing the water/antifreeze solu- tion. 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 maintain the proper level of protection against freezing according to the temperatures occurring in the area where the vehicle is operated. NOTE: Mixing coolant types will decrease the life of the engine coolant and will require more frequent coolant changes.
346 MAINTAINING YOUR VEHICLE
When additional coolant is needed to maintain the proper level, add the recommended concentration of antifreeze and water to the coolant bottle. Do not overfill. NOTE: Failure to follow the antifreeze concentration and replacement recommendations, or failure to use antifreeze formulated to prevent corrosion of all cooling system metals, may result in radiator plugging, overheat- ing, or cooling system leaks such as in core hole plugs.
WARNING!
Never add coolant to the radiator when the engine is overheated. Do not loosen or remove pressure cap to cool an overheated engine. The coolant is under pressure and severe scalding could result.
Recommended Engine Coolant Refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type.
CAUTION!
Mixing of coolants other than specified (non-HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased cor- rosion protection. If a non-HOAT coolant is intro- duced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible. Do not use plain water alone or alcohol base anti- freeze products. Do not use additional rust inhibitors or antirust products, as they may not be compatible with the radiator coolant and may plug the radiator. This vehicle has not been designed for use with Propylene Glycol based coolants. Use of Propylene Glycol based coolants is not recommended.
Disposal Of Used Engine Coolant Used ethylene glycol based engine coolant is a regulated substance requiring proper disposal. Check with your local authorities to determine the disposal rules for your community. Do not store ethylene glycol-based engine coolant in open containers or allow it to remain in puddles on the ground. Prevent ingestion by animals and children. If ingested by a child, contact a physician immediately. Clean up any ground spills immediately. Coolant Pressure Cap The coolant pressure cap must be fully tightened to prevent the loss of coolant and to insure that the coolant will return to the radiator from the coolant bottle. The pressure cap should be inspected and cleaned if there is any accumulation of foreign material on the sealing surfaces.
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WARNING!
The warning words “DO NOT OPEN HOT” on the radiator pressure cap are a safety precaution. Heat causes pressure to build up in the cooling system. To prevent scalding or injury, do not remove the pres- sure cap.
Hoses And Vacuum/Vapor Harnesses Inspect surfaces of hoses and nylon tubing for evidence of heat and mechanical damage. Hard or soft spots, brittle rubber, cracking, tears, cuts, abrasions, and exces- sive swelling indicate deterioration of the rubber. Pay particular attention to those hoses nearest to high heat sources such as the exhaust manifold. Inspect hose routing to be sure hoses do not come in contact with any heat source or moving component which may cause heat damage or mechanical wear.
348 MAINTAINING YOUR VEHICLE
Insure nylon tubing in these areas has not melted or collapsed. Inspect all hose connections such as clamps and cou- plings to make sure they are secure and no leaks are present. Components should be replaced immediately if there is any evidence of wear or damage that could cause failure. Brake System
Power Disc Brakes (front and rear) Disc brakes do not require adjustment; however, several hard stops during the break-in period are recommended to seat the linings and wear off any foreign material.
Brake Master Cylinder The fluid level of the master cylinder should be checked when performing under the hood service, or immedi- ately if the brake system warning lamp indicates system failure. The brake master cylinder has a translucent plastic reservoir. On the outboard side of the reservoir, there is a “MAX” dot and an “MIN” dot. The fluid level must be kept within these two dots. Do not add fluid above the MAX 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 Recommended Fluids, Lubricants and Genuine Parts for the correct Fluid type.
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WARNING!
CAUTION!
Use of a brake fluid that may have a lower initial boiling point, or is unidentified as to specification, may result in sudden brake failure during hard prolonged braking. You could have an accident.
WARNING!
Overfilling the brake fluid reservoir can result in spilling brake fluid on hot engine parts and the brake fluid catching fire.
Use only brake fluid that has been in a tightly closed container to avoid contamination from foreign matter or moisture.
Do not allow a petroleum-base fluid to contaminate the brake fluid. Seal damage may result.
Brake Hoses Inspection should be performed whenever the brake system is serviced or at intervals specified. Inspect hy- draulic brake hoses for surface cracking, scuffing or worn spots. If there is any evidence of cracking, scuffing, or worn spots, the hose should be replaced immediately! Eventual deterioration of the hose can take place with possible burst failure. 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.
350 MAINTAINING YOUR VEHICLE
Clutch Linkage If the clutch pedal linkage begins to squeak or grunt, the clutch pedal pivot bushings should be lubricated. Refer to Recommended Fluids, Lubricants and Genuine Parts for the correct lubricant type. Propeller Shaft Universal Joints Cross Type (No fittings) — Relubrication of this type of universal joint is not required. The seals should be inspected for external leaks or damage. If external leaks or damage is evident, the universal joint should be replaced. Rear Axle And 4x4 Front Driving Axle Fluid Level Refer to Recommended Fluids, Lubricants and Genuine Parts for the correct Fluid type. For normal service, periodic fluid level checks are not required. When the vehicle is serviced for other reasons the exterior surfaces of the axle assembly should be inspected. If gear oil leakage is suspected inspect the fluid level.
This inspection should be made with the vehicle in a level position. The fluid level should be even with the bottom of the fill hole for the Manufacturer’s C205F HD Front Axles. The fluid level should be 5/8” (16 mm) below on 9 1/4” Manufacturer’s Rear Axles. For all 2500/3500 Model axles, the fluid level should be 1/4” ± 1/4” (6.4 mm ± 6.4 mm) below the fill hole on the 9.25” Front and 3/4”± 1/4” (19 mm ± 6.4 mm) on 10.5” Rear axles. The 11.5” Rear Axle level should be 1/4” ± 1/4” (6.4 mm ± 6.4 mm) below the fill hole. Drain and Refill Vehicles operated in normal service do not have regularly scheduled oil changes. If fluid has become contaminated with water or to provide the correct viscosity grade, drain and refill. Lubricant Selection Refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type.
NOTE: The presence of water in the gear lubricant will result in corrosion and possible failure of differential components. Operation of the vehicle in water, as may be encountered in some off-highway types of service, will require draining and refilling the axle to avoid damage. Limited-Slip Differentials in 1500 Model vehicles re- quire that 4 oz. (118 ml) Mopart limited slip additive be added to the gear lubricant. Refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type. The Mopart limited slip additive should be added to the gear lubricant whenever a fluid change is made. Ram 2500/3500 Model Axles DO NOT REQUIRE any limited slip oil additive (friction modifiers).
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Transfer Case
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. Lubricant Selection Refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type. Manual Transmission
Fluid Level Check This fluid level can be checked by removing the filler plug. If the level of the lubricant is more than 1/4” (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.352 MAINTAINING YOUR VEHICLE
Lubricant Selection NV-3500 (5-Speed Manual Transmission — If Equipped) This transmission is filled with manual transmission fluid at the factory. This fluid does not require periodic changing. If it is necessary to add or change fluid in this transmission refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type. This is the only lubricant recommended for use in the NV-3500 transmis- sion. Lubricant Selection NV-4500 (5-Speed Manual Transmission — If Equipped) This transmission does not require periodic changing. If it becomes necessary to add or change the fluid in this transmission, refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type.
Automatic Transmission
Fluid Level Check The fluid level should be checked when the engine is fully warmed up and the fluid in the transmission is at normal operating temperature. Operation of the trans- mission 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. Fluid Level Check – 45RFE/545RFE Check the fluid level while the transmission is at normal operating temperature 82°C (180°F). This occurs after at least 15 miles (25 km) of driving. At normal operating temperature the fluid cannot be held comfortably be- tween the fingertips.
To check the automatic transmission fluid level properly, 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 gear selector momentarily in each gear position ending with the lever in P (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
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required into the dipstick tube. Do not overfill. After adding any quantity of oil through the oil fill tube, wait a minimum of two (2) 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.
354 MAINTAINING YOUR VEHICLE
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.
Selection Of Lubricant Refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type. It is important that the transmission fluid be maintained at the prescribed level using the recommended fluid.
CAUTION!
Using a transmission fluid other than the manufac- turers recommended fluid may cause deterioration in transmission shift quality and/or torque converter shudder. Using a transmission fluid other than the manufacturers recommended fluid will result in more frequent fluid and filter changes. Refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type.
Automatic Transmission Fluid and Filter Change To obtain best performance and long life for automatic transmissions, the manufacturer recommends that they be given regular maintenance service by an Authorized Dodge Dealer or Service Center. It is important that proper lubricant is used in the transmission. Refer to Recommended Fluids, Lubricants and Genuine Parts for correct fluid type. The fluid and filter(s) should be changed as specified in the Maintenance Schedule (Section 8). NOTE: reason, the fluid and filter(s) should be changed. Special Additives The manufacturer strongly recommends against the ad- dition of any additives to the transmission. Exception to this policy is the use of special dyes to aid in detecting
If the transmission is disassembled for any
MAINTAINING YOUR VEHICLE 355
In some instances,
fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals. Front Wheel Bearings Front wheel bearings for all Dodge Ram Trucks are sealed-for-life. They do not require greasing or seal replacement. these bearings will “purge” excess grease and the bearing will look slightly wet. This is normal. Periodic inspection for excess play is recommended. Rear Wheel Bearings — Manufacturer’s Axles These bearings are normally considered permanently lubricated. Cleaning and repacking is required only when axle shafts are removed or in case of extreme water or dust contamination.
356 MAINTAINING YOUR VEHICLE
Selection of Lubricating Grease The National Lubricating Grease Institute (NLGI) has developed a symbol (Certification Mark) to aid the vehicle owner in the proper selection of grease for the lubrication of wheel bearings and chassis components. This symbol (an example is shown below) is located on the grease container and identifies the application and quality of the grease.
There are two groups iden- tified, those for wheel bear- ings (Letter “G”) and those for chassis (Letter “L”) lu- brication. Performance cat- egories within these groups result in dual letter designa- tions for each group. The letter designations shown in the example are the highest quality level available and when combined as shown can
be used for both wheel bearing and chassis lubrication. Use only those greases that have the NLGI symbol on the container along with the proper quality level for your application. Noise Control System Required Maintenance & Warranty For 3500 2-Wheel Drive and 4-Wheel Drive models over 10,000 lbs. (4 535 kg) Gross Vehicle Weight Rating. 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.
MAINTAINING YOUR VEHICLE 357
or suspected. Proper maintenance of the entire vehicle will help the effectiveness of the noise control systems. Air Cleaner Assembly Inspect air cleaner housing for proper assembly and fit. Make certain that the air cleaner is properly positioned and the cover is tight. Check all hoses leading to the cleaner for tightness. The gasket between the air cleaner housing and throttle body must be intact and in good condition. The engine air cleaner filter must also be clean and serviced according to the instructions outlined in the appropriate maintenance schedule. 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
Required Maintenance for Noise Control Systems The following maintenance services must be performed every 6 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,
358 MAINTAINING YOUR VEHICLE
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. † Inverting the air cleaner lid. † Removal of the air ducting. 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 manufacturers 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 manufacturers control, caused noise emissions to exceed Federal standards, are covered by this warranty for the life of the vehicle.
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6,000
9 60030,000
48 00012,000
19 00024,000
36 00018,000
29 000Noise 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
36,000
58 00048,000
77 00042,000
67 000360 MAINTAINING YOUR VEHICLE
Noise Systems Maintenance Chart and Service Log Insert Month, Day, Year under column mileage closest to the mileage at which service was performed.
54,000
87 00060,000
96 00066,000
106 00072,000
116 00078,000
126 00084,000
135 00090,000
145 00096,000
154 000MILES KILOMETERS Exhaust system- inspect Air cleaner assembly-inspect ODOMETER READING PERFORMED BY PERFORMED AT
Appearance Care and Protection from Corrosion
Protection of Body and Paint from Corrosion Vehicle body care requirements vary according to geo- graphic locations and usage. Chemicals that make roads passable in snow and ice, and those that are sprayed on trees and road surfaces during other seasons, are highly corrosive to the metal in your vehicle. Outside parking, which exposes your vehicle to airborne contaminants, road surfaces on which the vehicle is operated, extreme hot or cold weather and other extreme conditions will have an adverse effect on paint, metal trim, and under- body protection. The following maintenance recommendations will enable you to obtain maximum benefit from the corrosion resistance built into your vehicle. What Causes Corrosion? Corrosion is the result of deterioration or removal of paint and protective coatings from your vehicle.
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The most common causes are: † Road salt, dirt and moisture accumulation. † Stone and gravel impact. † Insects, tree sap and tar. † Salt in the air near seacoast localities. † Atmospheric fallout/industrial pollutants. Washing † Wash your vehicle regularly. Always wash your ve- hicle in the shade using a mild car wash soap, and rinse the panels completely with clear water. † If insects, tar or other similar deposits have accumu- † Use Mopart auto polish to remove road film and stains and to polish your vehicle. Take care never to scratch the paint.
lated on your vehicle, wash it as soon as possible.
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† Avoid using abrasive compounds and power buffing that may diminish the gloss or thin out the paint finish.
CAUTION!
Do not use abrasive or strong cleaning materials such as steel wool or scouring powder, which will scratch metal and painted surfaces.
Special Care † If you drive on salted or dusty roads or if you drive near the ocean, hose off the undercarriage at least once a month. † It is important that the drain holes in the lower edges of the doors, rocker panels and tailgate be kept clear and open.
† If you detect any stone chips or scratches in the paint, touch them up immediately. The cost of such repairs is considered the responsibility of the owner. † If your vehicle is damaged due to an accident or similar cause which destroys the paint and protective coating have your vehicle repaired as soon as possible. The cost of such repairs is considered the responsibil- ity of the owner. † All wheels and wheel trim, especially aluminum and chrome plated wheels should be cleaned regularly with mild soap and water to prevent corrosion. To remove heavy soil, select a nonabrasive, non-acidic cleaner. Do not use scouring pads, steel wool, a bristle brush or metal polishes. Only Mopar cleaners are recommended. Do not use oven cleaner. Avoid auto- matic car washes that use acidic solutions or harsh brushes that may damage the wheels’ protective fin- ish.
† If you carry special cargo such as chemicals, fertilizers, de-icer salt, etc., be sure that such materials are well packaged and sealed. † If a lot of driving is done on gravel roads, consider † Use Mopart touch up paint on scratches as soon as possible. Your dealer has touch up paint to match the color of your vehicle.
mud or stone shields behind each wheel.
Interior Care Use Mopart Fabric Cleaner to clean fabric upholstery and carpeting. Use Mopart Vinyl Cleaner to clean vinyl upholstery and trim. Mopart Total Clean is specifically recommended for leather upholstery.
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Your leather upholstery can be best preserved by regular cleaning with a damp soft cloth. Small particles of dirt can act as an abrasive and damage the leather upholstery and should be removed promptly with a damp cloth. Stubborn soils can be removed easily with a soft cloth and Mopart Total Clean. Care should be taken to avoid soaking your leather upholstery with any liquid. Please do not use polishes, oils, cleaning fluids, solvents, deter- gents, or ammonia based cleaners to clean your leather upholstery. Application of a leather conditioner is not required to maintain the original condition.
WARNING!
Do not use volatile solvents for cleaning purposes. Many are potentially flammable, and if used in closed areas they may cause respiratory harm.
364 MAINTAINING YOUR VEHICLE
Glass Surfaces All glass surfaces should be cleaned on a regular basis with any commercial household-type glass cleaner. Never use an abrasive type cleaner. Use caution when cleaning inside rear windows equipped with electric defrosters or windshields equipped with a windshield wiper de-icer. Do not use scrapers or other sharp instru- ments which may scratch the elements. When cleaning the rear view mirror, spray cleaner on the towel or rag that you are using. Do not spray cleaner directly on the mirror. Cleaning Plastic Instrument Cluster Lenses The lenses in front of the instruments in this vehicle are molded in clear plastic. When cleaning the lenses, care must be taken to avoid scratching the plastic.
1. Clean with a wet soft rag. A mild soap solution may be used, but do not use high alcohol content or abrasive cleaners. If soap is used, wipe clean with a clean damp rag. 2. Dry with a soft tissue. Seat Belt Maintenance Do not bleach, dye or clean the belts with chemical solvents or abrasive cleaners. This will weaken the fabric. Sun damage will also weaken the fabric. If the belts need cleaning, use a mild soap solution or lukewarm water. Do not remove the belts from the car to wash them. Replace the belts if they appear frayed or worn or if the buckles do not work properly.
FUSE AND RELAY CENTER
Your vehicle is equipped with a fuse and relay center located in the engine compartment near the battery. Located on the underside of the cover is a label that identifies each component. 1. Disconnect the battery negative (-) cable before remov- ing the cover.
MAINTAINING YOUR VEHICLE 365
2. Use specified fuses only. 3. Always properly reinstall the cover.
VEHICLE STORAGE If you are storing your vehicle for more than 21 days, we recommend that you take the following steps to mini- mize the drain on your vehicle’s battery: † Disconnect the Ignition-Off Draw fuse (I.O.D.) fuse located in the Fuse and Relay Center, located in the engine compartment. The I.O.D. cavity includes a snap-in retainer that allows the fuse to be discon- nected, without removing it from the fuse block. † The electronic shift transfer case should be placed in the 4HI mode and kept in this position to minimize the battery drain. † As an alternative to the above steps you may, discon-
nect the negative cables from both batteries.
366 MAINTAINING YOUR VEHICLE
REPLACEMENT LIGHT BULBS
LIGHT BULBS — Inside Bulb No. Overhead Console Lights . . . . . . . . . . . . . . . TS 212-2
Dome Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7679
All of the inside bulbs are brass or glass wedge base. Aluminum base bulbs are not approved.LIGHT BULBS — Outside Bulb No. Back-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057
Center High Mounted Stop Lamp . . . . . . . . . . . . . 912
Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 9006LL Headlamp (Halogen) . . . . . . . . . . . . . . . . . . . 9007QL Park & Turn Signal . . . . . . . . . . . . . . . . . . . 3157NAK Rear License Plate Lamp . . . . . . . . . . . . . . . . . . . 168
Rear Cargo Light. . . . . . . . . . . . . . . . . . . . . . . . . 912
Tail & Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057
Cab Clearance Lights . . . . . . . . . . . . . . . . . . . . . . 168
Dual Rear Wheel Sidemarker Light . . . . . . . . . . . . 168
Dual Rear Wheel Tailgate ID Lights (3) . . . . . . . . . 168BULB REPLACEMENT
Headlight (Halogen)/Front Park and Turn Lights
CAUTION!
This is a halogen bulb. Avoid touching the glass with your fingers. Reduced bulb life will result.
1. Remove the expanding fastener from the headlight welt.
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368 MAINTAINING YOUR VEHICLE
2. Remove the three (3) bolts from the headlight housing. NOTE: The lower bolt on the driver side headlight also retains the ambient temperature sensor between the headlight assembly and the frame.
MAINTAINING YOUR VEHICLE 369
3. Pull the housing out from the fender to allow room to disconnect the electrical connectors.
4. Unlock and pull connector straight from the base of the headlight halogen bulb. 5. Twist connector on turn signal/park light bulb 1⁄4 turn and remove connector and bulb from housing. 6. Remove housing from vehicle with headlight halogen bulb in housing.
370 MAINTAINING YOUR VEHICLE
7. Twist collar on headlight halogen bulb 1⁄4 turn and remove headlight bulb from the housing. 8. Replace headlight or turn signal bulb. Do not touch the headlight halogen bulb. 9. Reverse procedure for installation of bulbs and hous- ing. 10. Tighten the outboard fastener first. Tail, Stop, Turn and Backup Lights
1. Remove the two (2) screws that pass through the bed sheetmetal.
2. Pull the housing straight out from the body, with a quick motion, to separate the housing from the body. If not pulled straight, locators may be damaged.
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4. Remove the four (4) screws from the bulb strip in the housing.
3. Push the red lock slide in on the connector and remove the housing from the vehicle.
372 MAINTAINING YOUR VEHICLE
5. Pull the appropriate bulb straight from the bulb strip.
7. While holding the taillight firmly in place, fasten the top screw first. Center High-Mounted Stoplight With Cargo Light
1. Remove the two (2) screws holding the housing/lens to the body as shown.
† Top Bulb: Park/Turn/Hazard † Center Bulb: Stop/Park/Sidemarker † Bottom Bulb: Backup Lights 6. Reverse procedure for installation of bulbs and hous- ing.
2. Separate the connector holding the housing and wir- ing harness to the body.
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3. Turn desired bulb socket 1⁄4 turn and remove socket and bulb from housing. 4. Pull desired bulb straight from the socket.
† Outside Bulbs: Cargo Lamps † Inside Bulb: Center High Mount Stop Lamp 5. Reverse procedure for installation of bulbs and hous- ing.
374 MAINTAINING YOUR VEHICLE
Cab Top Clearance Lights — If Equipped
1. Remove the two screws from the top of the light.
2. Rotate the socket 1⁄4 turn and pull it from the light assembly.
3. Pull the bulb straight from it’s socket and replace.
Tailgate ID Lights (Dual Rear Wheels)
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1. Remove the two screws and housing and access the bulb sockets from the rear.
376 MAINTAINING YOUR VEHICLE
2. Turn socket 1⁄4 turn counterclockwise to access the bulb.
3. Pull bulb straight out from socket. 4. Reverse procedure for installation of bulbs and hous- ing.
Side Marker Lights (Dual Rear Wheels)
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3. Turn socket 1⁄4 turn counterclockwise and remove from assembly to access the bulb. 4. Pull bulb straight out from socket. 5. Reverse procedure for installation of bulbs and hous- ing.
1. Push rearward on the side marker light assembly. 2. Pull the entire assembly from the fender.
378 MAINTAINING YOUR VEHICLE
Fog Lights
1. Reach under the vehicle, unlock and twist connector counterclockwise 1⁄4 turn and remove connector and bulb from housing.
2. Pull bulb straight from the connector.
3. Reverse procedure for installation of bulbs and hous- ing.
FLUIDS AND CAPACITIES
Fuel
3.7L/4.7L, 87 Octane
5.7L, 89 Octane
1500 Shortbed Models 1500 Longbed Models 2500 Shortbed Models 2500 Longbed Models 3500 Shortbed Models 3500 Longbed Models
Engine Oil (with filter)
3.7L Engine V-6, SAE 5W-30, API Certified 4.7L Engine V-8, SAE 5W-30, API Certified 5.7L Engine V-8, SAE 5W-30, API Certified
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U.S.
Metric
26 gal. 35 gal. 34 gal. 35 gal. 34 gal. 35 gal.
5.0 qts. 6.0 qts. 7.0 qts.
98L 132L 128L 132L 128L 132L
4.7L 5.7L 6.6L
380 MAINTAINING YOUR VEHICLE
Cooling System 3.7L (Mopart Antifreeze/Coolant 5 Year/100,000 Mile
Formula)
4.7L (Mopart Antifreeze/Coolant 5 Year/100,000 Mile
Formula)
5.7L (Mopart Antifreeze/Coolant 5 Year/100,000 Mile
Formula)
U.S.
17 qts.
17 qts.
18.7 qts.
Metric
16L
16L
17.7L
MAINTAINING YOUR VEHICLE 381
RECOMMENDED FLUIDS, LUBRICANTS AND GENUINE PARTS Engine Component Engine Coolant
Engine Oil
Engine Oil Filter Spark Plugs
Fuel Selection (all except 5.7L) Fuel Selection (5.7L)
Fluids, Lubricants and Genuine Parts Mopart Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Or- ganic Additive Technology) P/N 5011764AB or equivalent. Use SAE 5W-30, API Certified, meeting material standard MS-6395. Refer to oil viscosity chart for alternative grade. Mopart Engine Oil Filter, P/N 5281090 or equivalent. Refer to the Vehicle Emission Control Information label in the engine com- partment. 87 Octane, (R+M)/2 Method 89 Octane, (R+M)/2 Method, Mid-Grade Preferred (87 Octane acceptable)
382 MAINTAINING YOUR VEHICLE
Chassis Component Automatic Transmission Transfer Case Manual Transmission Fluid NV 3500 Mopart “Manual Transmission Fluid” P/N 4874464. Manual Transmission Fluid NV 4500 75W-85 Synthetic, API grade GL4, Mopart P/N 4874459. Clutch Linkage 1500 Model Front Axle (4X4) 1500 Model Rear Axle
Fluids, Lubricants and Genuine Parts. Mopart ATF+4, Automatic Transmission Fluid Mopart ATF+4, Automatic Transmission Fluid
Multipurpose Grease, NLGI Grade 2 E.P. GL-5 SAE 75W-90
Mopart Synthetic Gear Lubricant SAE 75W-140 (MS-8985). Limited-Slip Rear Axles on 1500 Models Require the addition of 118 ml (4 oz.) Mopart limited slip additive. Synthetic, GL-5 SAE, 75W-90. Limited-Slip 10.5/11.5 inch Rear Axles DO NOT REQUIRE a limited slip additive. Mopart DOT 3 and SAE J1703 should be used. If DOT 3 brake fluid is not available, then DOT 4 is acceptable. Use only recommended brake fluids. Mopart ATF+4, Automatic Transmission Fluid2500/3500 Model Front and Rear Axle Brake Master Cylinder
Power Steering Reservoir
MAINTENANCE SCHEDULES
CONTENTS
m Emission Control System Maintenance . . . . . . . . 384
m Maintenance Schedules . . . . . . . . . . . . . . . . . . . 384N Schedule “B” . . . . . . . . . . . . . . . . . . . . . . . . 387
N Schedule “A” . . . . . . . . . . . . . . . . . . . . . . . . 397M
384 MAINTENANCE SCHEDULES
EMISSION CONTROL SYSTEM MAINTENANCE The “Scheduled” maintenance services, listed in bold type in this section (Section 8) must be done at the times or mileages specified to assure the continued proper functioning of the emission control system. These, and all other maintenance services included in this manual, should be done to provide best vehicle performance and reliability. More frequent maintenance may be needed for vehicles in severe operating conditions such as dusty areas and very short trip driving. Inspection and service also should be done any time a malfunction is suspected. NOTE: Maintenance, replacement, or repair of the emis- sion control devices and systems on your vehicle may be performed by any automotive repair establishment or individual using any automotive part which has been certified pursuant to U.S. EPA or, in the State of Califor- nia, California Air Resources Board regulations.
MAINTENANCE SCHEDULES There are two maintenance schedules that show the required service for your vehicle. First is Schedule “B”. It is for vehicles that are operated under the conditions that are listed below and at the beginning of the schedule. † Day or night temperatures are below 32° F (0° C). † Stop and go driving. † Extensive engine idling. † Driving in dusty conditions. † Short trips of less than 10 miles (16 km). † More than 50% of your driving is at sustained high † Trailer towing. † Snowplowing.
speeds during hot weather, above 90° F C (32°).
† Heavy Loading. † Taxi, police, or delivery service (commercial service). † Off-road or desert operation. † If equipped for and operating with E-85 (ethanol)
fuel.
If ANY of these apply to you then change your NOTE: engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first and follow schedule “B” of the 9Maintenance Schedules9 section of this manual. NOTE: Most vehicles are operated under the conditions listed for Schedule 9B9. Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Sched- ule 9B9.
MAINTENANCE SCHEDULES 385
Use the schedule that best describes your driving condi- tions. Where time and mileage are listed, follow the interval that occurs first. NOTE: Under no circumstances should oil change in- tervals exceed 6000 miles (10 000 km) or 6 months whichever comes first.
CAUTION!
Failure to perform the required maintenance items may result in damage to the vehicle.
M
386 MAINTENANCE SCHEDULES
At Each Stop for Fuel † Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while the vehicle is on level ground will improve the accu- racy of the oil level reading. Add oil only when the level is at or below the ADD or MIN mark. † Check the windshield washer solvent and add if
required.
damage.
Once a Month † Check tire pressure and look for unusual wear or † Inspect the battery and clean and tighten the terminals † Check the fluid levels of coolant bottle, brake master
as required.
cylinder, and transmission and add as needed.
† Check all lights and all other electrical items for correct
operation.
sion components.
At Each Oil Change † Change the engine oil filter. † Inspect the exhaust system. † Inspect the brake hoses. † Inspect the CV joints (if equipped) and front suspen- † Check the automatic transmission fluid level. † Check the manual transmission fluid level. † Check the coolant level, hoses, and clamps. Tire Rotation † Rotate the tires at 6,000 miles (10 000 km).
Schedule “B” Follow schedule “B” if you usually operate your vehicle under one or more of the following conditions. † Day or night temperatures are below 32° F (0° C). † Stop and go driving. † Extensive engine idling. † Driving in dusty conditions. † Short trips of less than 10 miles (16 km). † More than 50% of your driving is at sustained high † Trailer towing. † Snowplowing.
speeds during hot weather, above 90° F C (32°).
SCHEDULE “B” 387
† Heavy Loading. † Taxi, police, or delivery service (commercial service). † Off-road or desert operation. † If equipped for and operating with E-85 (ethanol)
fuel.
If ANY of these apply to you then change your NOTE: engine oil every 3,000 miles (5 000 km) or 3 months, whichever comes first and follow schedule “B” of the 9Maintenance Schedules9 section of this manual. If none of these apply to you, then change your engine oil at every interval shown on schedule 9A9 of the 9Mainte- nance Schedules9 section of this manual.
388 SCHEDULE “B”
Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) mod- els only. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if neces- sary.
3,000
(5 000)6,000
(10 000)9,000
(14 000)12,000
(19 000)15,000
(24 000)SCHEDULE “B” 389
Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) mod- els only. Change rear axle fluid. Change front axle fluid (4X4). Check transfer case fluid level (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if neces- sary. Replace spark plugs. Inspect PCV valve, replace as necessary. Drain and refill automatic tranmission fluid and change main sump filter (45RFE/545RFE only).
21,000
(34 000)18,000
(29 000)27,000
(43 000)24,000
(38 000)30,000
(48 000)X*
390 SCHEDULE “B”
Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) mod- els only. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if neces- sary.
