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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
384 MAINTAINING YOUR VEHICLE
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.
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.
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 Check engine coolant (antifreeze) protection every 12
months (before 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.MAINTAINING YOUR VEHICLE 385
Check the coolant bottle hoses for condition and tight- ness of the connections at both the coolant bottle and radiator. Check the coolant pressure cap and coolant reserve system for proper vacuum sealing. With the engine at normal operating temperature, 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 draincock. If the coolant level in the coolant bottle drops, the system is sealing properly. Coolant Level 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.
386 MAINTAINING YOUR VEHICLE
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.
Adding Coolant When adding coolant, or refilling the system, a minimum solution of 50% recommended HOAT ethylene glycol engine coolant (antifreeze) and distilled water should be used. Use higher concentrations (not to exceed 70%) if temperatures below ⫺34°F (⫺37°C) are anticipated. Use only high purity water such as distilled or deionized water when mixing the water/engine coolant solution. The use of lower quality water will reduce the amount of corrosion protection in the engine cooling system. It is the owner’s responsibility to maintain the NOTE: 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.
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.
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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 Fluids, Lubricants and Genuine Parts for correct fluid type.
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CAUTION!
• Mixing of coolants other than specified engine coolant, may result in engine damage, and de- crease corrosion protection. If a non-HOAT cool- ant is introduced into the cooling system in an emergency, it should be replaced with the speci- fied coolant as soon as possible. • Do not use plain water alone or alcohol base engine coolant (antifreeze) products. Do not use additional rust inhibitors or antirust products, as they may not be compatible with the radiator engine coolant and may plug the radiator. • This vehicle has not been designed for use with Propylene Glycol based coolants. Use of Propy- lene 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.
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.
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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.
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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 Fluids, Lubricants and Genuine Parts for the correct Fluid type.
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.
CAUTION!
WARNING!
Do not allow a petroleum-base fluid to contaminate the brake fluid. Seal damage may result.
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.
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. Clutch Linkage If the clutch pedal linkage begins to squeak or grunt, the clutch pedal pivot bushings should be lubricated. Refer to Fluids, Lubricants and Genuine Parts for the correct lubricant type.
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Rear Axle And 4x4 Front Driving Axle Fluid Level Refer to 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 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.
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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 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 Power Wagon Axles DO NOT REQUIRE any limited slip oil additive (friction modifiers).
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 Fluids, Lubricants and Genuine Parts for correct fluid type. Front Drive Shaft The front drive shaft contains a grease fitting which should be serviced at every oil change (see maintenance schedule A/B). 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 vehicleis on level ground, enough lubricant should be added to bring the level to the bottom of the filler hole. Lubricant Selection G56 (6 – 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 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.
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Fluid Level Check – 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).
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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 (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 it should be between the “HOT” room temperature,
(upper) reference holes when the transmission reaches 180°F (82°C). Remember it is best to check the level at the normal operating temperature.
CAUTION!
Be aware that if the fluid temperature is below 50°F (10°C) it may not register on the dipstick. Do not add fluid until the temperature is elevated enough to produce an accurate reading.
7. Check for leaks. Release 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 Fluids, Lubricants and Genuine Parts for correct fluid type. It is important that the transmission fluid be maintained at the prescribed level using the recom- mended 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 Fluids, Lubricants and Genuine Parts for correct fluid type.
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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 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 fluid leaks. The use of transmission sealers should be avoided, since they may adversely affect seals.
If the transmission is disassembled for any
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In some instances,
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. 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 identi- fied, those for wheel bearings (Letter “G”) and those for chassis (Letter “L”) lubrica- tion. Performance categories within these groups result in dual letter designations for each group. The letter desig- nations 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 con- tainer along with the proper quality level for your application.
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.
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In addition,
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 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 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.
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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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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
48,000
77 00042,000
67 00036,000
58 00030,000
48 00024,000
36 00018,000
29 00012,000
19 0006,000
9 60054,000
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 Mopar Car Wash or a mild car wash soap, and rinse the panels completely with clear water. • If insects, tar or other similar deposits have accumu- lated on your vehicle, use Mopar Super Kleen Bug and Tar Remover to remove.
402 MAINTAINING YOUR VEHICLE
• Use Mopar Cleaner Wax to remove road film, stains and to protect your paint finish. Take care never to scratch the paint. • Avoid using abrasive compounds and power buffing that may diminish the gloss or thin out the paint finish.
CAUTION!
Do not use abrasive or strong cleaning materials such as steel wool or scouring powder, which will scratch metal and painted surfaces.
Special Care • If you drive on salted or dusty roads or if you drive near the ocean, hose off the undercarriage at least once a month.
• It is important that the drain holes in the lower edges of the doors, rocker panels and trunk be kept clear and open. • If you detect any stone chips or scratches in the paint, touch them up immediately. The cost of such repairs is considered the responsibility of the owner. • If your vehicle is damaged due to an accident or similar cause which destroys the paint and protective coating, have your vehicle repaired as soon as pos- sible. The cost of such repairs is considered the respon- sibility of the owner. • All wheels and wheel trim, especially aluminum and chrome plated wheels should be cleaned regularly with a mild soap and water to prevent corrosion. To remove heavy soil, use Mopar Wheel Cleaner or 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 automatic car washes that use acidic solutions or harsh brushes that may damage the wheels’ protective finish. • If you carry special cargo such as chemicals, fertilizers, de-icer salt, etc., be sure that such materials are well packaged and sealed. • If a lot of driving is done on gravel roads, consider • Use Mopar 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 Mopar Total Clean to clean fabric upholstery and carpeting. Use Mopar Total Clean to clean vinyl upholstery.
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Mopar Total Clean is specifically recommended for leather upholstery. Your leather upholstery can be best preserved by regular cleaning with a damp soft cloth. Small particles of dirt can act as an abrasive and damage the leather upholstery and should be removed promptly with a damp cloth. Stubborn soils can be removed easily with a soft cloth and Mopar 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.
404 MAINTAINING YOUR VEHICLE
WARNING!
Do not use volatile solvents for cleaning purposes. Many are potentially flammable, and if used in closed areas they may cause respiratory harm.
Glass Surfaces All glass surfaces should be cleaned on a regular basis with Mopar Glass Cleaner or any commercial household- type glass cleaner. Never use an abrasive type cleaner. Use caution when cleaning the inside rear window equipped with electric defrosters or the right rear quarter window equipped with the radio antenna. Do not use scrapers or other sharp instruments 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 can also weaken the fabric. If the belts need cleaning, use a mild soap solution or lukewarm water. Do not remove the belts from the car to wash them.
Replace the belts if they appear frayed or worn or if the buckles do not work properly. Dry with a soft tissue.
INTEGRATED POWER MODULE
Integrated Power Module Location
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An integrated Power Module is located in the engine compartment near the battery. This center contains maxi fuses and mini fuses. A label that identifies each compo- nent is printed on the inside cover. 1. Disconnect the battery negative (-) cable before remov- ing the cover. 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 Integrated Power Module, 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.
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• 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.
NOTE: When reinstalling the IOD fuse, the gages in the Instrument Cluster will do a full sweep, when the ignition key is cycled to RUN. This is a normal condition.
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) . . . . . . . . . . . . . . . . . . . . . H13
Side Marker Bulb . . . . . . . . . . . . . . . . . . . . . . . W5W Park & Turn Signal . . . . . . . . . . . . . . . . . . . 3157NAK Rear License Plate Lamp . . . . . . . . . . . . . . . . . . . 168
Rear Cargo Light. . . . . . . . . . . . . . . . . . . . . . . . . 912
Tail & Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057BULB 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. Open the hood 2. Remove the two (2) bolts from the front of the head- light housing.
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Front Headlight Housing Bolts
408 MAINTAINING YOUR VEHICLE
3. Remove the plug from the inner fender well and remove the nut through the access hole.
Inner Fender Plug
Rear Headlight Housing Nut Access
4. Pull the housing out from the fender to allow room to disconnect the electrical connectors.
NOTE: For easier removal, pull the headlight assembly straight forward, applying the greatest amount of force to the outer edge of the headlight assembly.
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Headlight Removal
Bulb Removal
5. Unlock and pull connector straight from the base of the headlight halogen bulb.
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6. Twist connector on turn signal/park light bulb 1⁄4 turn and remove connector and bulb from housing. 7. Remove housing from vehicle with headlight halogen bulb in housing. 8. Twist the headlight halogen bulb 1⁄4 turn and remove headlight bulb from the housing. 9. Replace headlight or turn signal bulb. Do not touch the headlight halogen bulb. 10. Reverse procedure for installation of bulbs and hous- ing.
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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3. Push the red lock slide in on the connector and remove the housing from the vehicle. 4. Remove the four (4) screws from the bulb strip in the housing.
412 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.
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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.
Fog Lights
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1. Reach under the vehicle, unlock and twist connector counterclockwise 1⁄4 turn and remove connector and bulb from housing.
416 MAINTAINING YOUR VEHICLE
2. Pull bulb straight from the connector.
3. Reverse procedure for installation of bulbs and hous- ing.
FLUIDS AND CAPACITIES
Fuel
5.7L, 89 Octane
2500 Shortbed Models 2500 Longbed Models
Engine Oil (with filter)
5.7L Engine V-8, SAE 5W-20, API Certified
Cooling System 5.7L (Mopar威 Antifreeze/Coolant 5 Year/100,000 Mile
Formula)
U.S.
34 gal. 35 gal.
7.0 qts.
18.7 qts.
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Metric
128L 132L
6.6L
17.7L
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FLUIDS, LUBRICANTS AND GENUINE PARTS Engine Component Engine Coolant
Engine Oil
Engine Oil Filter Spark Plugs
Fuel Selection (5.7L)
Fluids, Lubricants and Genuine Parts Mopar威 Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Or- ganic Additive Technology) P/N 5011764AB or equivalent. Use SAE 5W-20, API Certified, meeting material standard MS-6395. Refer to oil viscosity chart for alternative grade. Mopar威 Engine Oil Filter, P/N 5281090 or equivalent. Refer to the Vehicle Emission Control Information label in the engine com- partment. 89 Octane Mid-Grade, (R+M)/2 Method Preferred (87 Octane Acceptable)
MAINTAINING YOUR VEHICLE 419
Chassis Component Automatic Transmission Transfer Case Manual Transmission Fluid (G-56) Front Driveshaft Grease Fitting. Clutch Linkage Front and Rear Axle
Brake Master Cylinder
Power Steering Reservoir
Fluids, Lubricants and Genuine Parts. Mopar威 ATF+4, Automatic Transmission Fluid Mopar威 ATF+4, Automatic Transmission Fluid Mopar威 ATF+4, Automatic Transmission Fluid Use Mopar威 type MS-6560 (lithium based grease), or equivalent. Multipurpose Grease, NLGI Grade 2 E.P. Synthetic, GL-5 SAE, 75W-90. Limited-Slip 10.5 inch Rear Axle DOES NOT REQUIRE a limited slip additive. Mopar威 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. Mopar威 ATF+4, Automatic Transmission Fluid
MAINTENANCE SCHEDULES
CONTENTS
䡵 Emission Control System Maintenance . . . . . . . . 422
䡵 Maintenance Schedules . . . . . . . . . . . . . . . . . . . 422▫ Schedule “B” . . . . . . . . . . . . . . . . . . . . . . . . 425
▫ Schedule “A” . . . . . . . . . . . . . . . . . . . . . . . . 437M
422 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 ⬙Maintenance Schedules⬙ section of this manual. If ANY of these apply to you then flush and NOTE: replace your engine coolant every 102,000 miles (170 000
km) or 60 months, whichever comes first and follow schedule “B” of the ⬙Maintenance Schedules⬙ section of this manual. NOTE: Most vehicles are operated under the conditions listed for Schedule ⬙B⬙.MAINTENANCE SCHEDULES 423
Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Sched- ule ⬙B⬙. 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.
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424 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.
end links.
At Each Oil Change • Change the engine oil filter. • Lubricate the front driveshaft grease fitting and tie rod • 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. • Lubricate Front Drive Shaft Fitting.
sion components.
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. • Heavy Loading. • Taxi, police, or delivery service (commercial service).
speeds during hot weather, above 90° F C (32°).
• Off-road or desert operation. • If equipped for and operating with E-85 (ethanol)
SCHEDULE “B” 425
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 ⬙Maintenance Schedules⬙ section of this manual. If ANY of these apply to you then flush and NOTE: replace your engine coolant every 102,000 miles (170 000
km) or 60 months, whichever comes first and follow schedule “B” of the ⬙Maintenance Schedules⬙ section of this manual. If none of these apply to you, then change your engine oil at every interval shown on schedule ⬙A⬙ of the ⬙Mainte- nance Schedules⬙ section of this manual.M
426 SCHEDULE “B”
Miles (Kilometers) Change engine oil and engine oil filter, or at 3
months, whichever comes first. Lubricate Front Drive Shaft Fitting. Rotate tires. Check spare tire for proper pressure and correct stowage. Lubricate tie rod end links. Change rear axle fluid. Change front axle fluid. Inspect brake linings. Inspect engine air cleaner filter, replace if neces- sary.3,000
(5 000)6,000
(10 000)9,000
(15 000)12,000
(20 000)15,000
(25 000)Miles (Kilometers) Change engine oil and engine oil filter, or at 3
months, whichever comes first. Lubricate Front Drive Shaft Fitting. Rotate tires. Check spare tire for proper pressure and correct stowage. Lubricate tie rod end links. Change rear axle fluid. Change front axle fluid. Check transfer case fluid level. Inspect brake linings. Inspect engine air cleaner filter, replace if neces- sary. Replace spark plugs. Inspect PCV valve, replace as necessary.**SCHEDULE “B” 427
18,000
(30 000)21,000
(35 000)24,000
(40 000)27,000
(45 000)30,000
(50 000)M
428 SCHEDULE “B”
Miles (Kilometers) Change engine oil and engine oil filter, or at 3
months, whichever comes first. Lubricate Front Drive Shaft Fitting. Rotate tires. Check spare tire for proper pressure and correct stowage. Lubricate tie rod end links. Change rear axle fluid. Change front axle fluid. Inspect brake linings. Inspect engine air cleaner filter, replace if neces- sary.33,000
(55 000)36,000
(60 000)39,000
(65 000)42,000
(70 000)45,000
(75 000)Miles (Kilometers) Change engine oil and engine oil filter, or at 3
months, whichever comes first. Lubricate Front Drive Shaft Fitting. Flush and replace engine coolant at 60 months, or 102, 000 miles (170 000 km) whichever comes first. Rotate tires. Check spare tire for proper pressure and correct stowage. Lubricate tie rod end links. Drain and refill transfer case fluid. Change rear axle fluid. Change front axle fluid. Change 6-spd manual transmission (G-56) fluid.SCHEDULE “B” 429
48,000
(80 000)51,000
(85 000)54,000
(90 000)57,000
(95 000)60,000
(100 000)430 SCHEDULE “B”
Miles (Kilometers) Inspect brake linings. Inspect engine air cleaner filter, replace if neces- sary. Replace spark plugs. Replace ignition cables. Inspect PCV valve, replace as necessary.** Drain and refill automatic tranmission fluid and change main sump filter (545RFE only).
48,000
(80 000)51,000
(85 000)54,000
(90 000)57,000
(95 000)60,000
(100 000)Miles (Kilometers) Change engine oil and engine oil filter, or at 3
months, whichever comes first. Lubricate Front Drive Shaft Fitting. Rotate tires. Check spare tire for proper pressure and correct stowage. Lubricate tie rod end links. Inspect engine air cleaner filter. Change rear axle fluid. Change front axle fluid. Inspect brake linings. Inspect auto tension drive belt and replace if re- quired.63,000
(105 000)66,000
(110 000)69,000
(115 000)72,000
(120 000)75,000
(125 000)SCHEDULE “B” 431
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432 SCHEDULE “B”
Miles (Kilometers) Change engine oil and engine oil filter, or at 3
months, whichever comes first. Lubricate Front Drive Shaft Fitting. Rotate tires. Check spare tire for proper pressure and correct stowage. Lubricate tie rod end links. Change rear axle fluid. Change front axle fluid. Check transfer case fluid level. Inspect brake linings. Inspect engine air cleaner filter, replace if neces- sary.78,000
(130 000)81,000
(135 000)84,000
(140 000)87,000
(145 000)90,000
(150 000)Miles (Kilometers) Replace spark plugs. Inspect PCV valve, replace as necessary.** Inspect auto tension drive belt and replace if re- quired.
78,000
(130 000)81,000
(135 000)84,000
(140 000)87,000
(145 000)90,000
(150 000)SCHEDULE “B” 433
434 SCHEDULE “B”
Miles (Kilometers) Change engine oil and engine oil filter, or at 3 months, whichever comes first. Lubricate Front Drive Shaft Fitting. Rotate tires. Check spare tire for proper pressure and correct stowage. Lubricate tie rod end links. Flush and replace engine coolant, if not replaced at 60
months. Inspect brake linings.93,000
(155 000)96,000
(160 000)99,000
(165 000)102,000
(170 000)Miles (Kilometers) Change engine oil and engine oil filter, or at 3
months, whichever comes first. Lubricate Front Drive Shaft Fitting. Rotate tires. Check spare tire for proper pressure and cor- rect stowage. Lubricate tie rod end links. Drain and refill transfer case fluid. Change rear axle fluid. Change front axle fluid. Change 6-spd manual transmission (G-56) fluid. Inspect brake linings. Inspect engine air cleaner filter, replace if necessary. Replace spark plugs.105,000
(175 000)108,000
(180 000)111,000
(185 000)114,000
(190 000)117,000
(195 000)120,000
(200 000)SCHEDULE “B” 435
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436 SCHEDULE “B”
105,000
(175 000)Miles (Kilometers) Replace ignition cables. Inspect PCV valve, replace as necessary.** Inspect auto tension drive belt and replace if required. Drain and refill automatic tranmission fluid and change main sump and spin-on cooler return filter (if equipped) [545RFE only]. Flush and replace engine coolant at 120
months, if not replaced at 102,000 miles (170
000 km). * This applies only if the vehicle is used for frequent trailer towing, snowplowing, fleet vehicle or commercial service. **This maintenance is recommend, but not required.108,000
(180 000)111,000
(185 000)114,000
(190 000)117,000
(195 000)120,000
(200 000)Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all re- ceipts.
Schedule “A” Miles (Kilometers) [Months] Change engine oil and engine oil filter. Lubricate Front Prop Shaft fitting. Rotate tires. Check spare tire for proper pressure and correct stowage. Check transfer case fluid level. Lubricate tie rod end links. Inspect brake linings. Inspect engine air cleaner filter, replace if neces- sary. Replace spark plugs.
SCHEDULE “A” 437
6,000
(10 000)12,000
(20 000)18,000
(30 000)24,000
(40 000)30,000
(50 000)[6]
[12]
[18]
[24]
[30]
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