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Introduction
0 Lubrication & Maintenance 2 Suspension 3 Differential & Driveline 5 Brakes 6 Clutch 7 Cooling 8A Audio 8B Chime/Buzzer 8E Electronic Control Modules 8F Engine Systems 8G Heated Systems 8H Horn 8I 8J Instrument Cluster 8L Lamps 8M Message Systems 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers/Washers 8W Wiring 9 Engine
Ignition Control
11 Exhaust System 13 Frame & Bumpers 14 Fuel System 19 Steering 21 Transmission and Transfer Case 22 Tires/Wheels 23 Body 24 Heating & Air Conditioning 25 Emissions Control
Component and System Index
Service Manual Comment Forms
(Rear of Manual)
DR
INTRODUCTION
INTRODUCTION
TABLE OF CONTENTS
page
page
VEHICLE SAFETY CERTIFICATION LABEL
FASTENER IDENTIFICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VEHICLE IDENTIFICATION NUMBER
FASTENER USAGE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - FASTENER USAGE
. . . . . . . . . 9
VEHICLE EMISSION CONTROL INFORMATION
THREADED HOLE REPAIR
(VECI) DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BODY CODE PLATE
DESCRIPTION - THREADED HOLE REPAIR . . . . 9
METRIC SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TORQUE REFERENCES
DESCRIPTION
. . . . . . . . . . . . . . . . . . . . . . . . . 11
INTERNATIONAL VEHICLE CONTROL &
DISPLAY SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS . . . 6
VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION
(Fig. 1)
A vehicle safety certification label
is attached to every DaimlerChrysler Corporation vehi- cle. The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle Safety Standards. The label also lists:
† Month and year of vehicle manufacture. † Gross Vehicle Weight Rating (GVWR). The gross front and rear axle weight ratings (GAWR’s) are based on a minimum rim size and maximum cold tire inflation pressure. † Vehicle Identification Number (VIN). † Type of vehicle. † Type of rear wheels. † Bar code. † Month, Day and Hour (MDH) of final assembly. † Paint and Trim codes. † Country of origin. The label is located on the driver-side door shut-
face.
Fig.1VEHICLESAFETYCERTIFICATIONLABEL-
TYPICAL
2
INTRODUCTION
DR
VEHICLE IDENTIFICATION NUMBER DESCRIPTION
VIN CODING/LOCATIONS
The Vehicle Identification Number (VIN) plate is located on the lower windshield fence near the left a-pillar (Fig. 2). The VIN contains 17 characters that provide data concerning the vehicle. Refer to the VIN decoding chart to determine the identification of a vehicle. The VIN is also imprinted on the: † Body Code Plate. † Equipment Identification Plate. † Vehicle Safety Certification Label. † Frame rail. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the VIN. The check digit is used by the manufacturer and govern- ment agencies to verify the authenticity of the vehi-
INTERPRETATION Country of Origin
Make
Vehicle Type
Gross Vehicle Weight Rating
POSITION
Fig.2VINLOCATION
1 - DASH PANEL 2 - VIN CODE PLATE
cle and official documentation. The formula to use the check digit is not released to the general public.
CODE = DESCRIPTION
1 = Manufactured By DaimlerChrysler Corporation 3 = Manufactured By DaimlerChrysler De Mexico
D = Dodge
2 = Incomplete with Side Airbag
3 = Truck with Side Airbag
6 = Incomplete Less Side Airbag
7 = Truck Less Side Airbag
G = 5,001-6000 lbs. H = 6,001-7,000 lbs. J = 7,001-8,000 lbs. K = 8,001-9,000 lbs. L = 9,001-10,000 lbs. M = 10,001-14,000 lbs.
Vehicle Line
Series
Body Style
W = Buses/Incomplete Vehicles with Hydraulic Brakes
A = Ram Pickup 4X2
U = Ram Pickup 4X41 = 1500
2 = 25003 = 3500 Less Dual Rear Wheels 4 = 3500 With Dual Rear Wheels
6 = Conventional Cab
8 = Quad Cab Full Rear Doors
DR VEHICLE IDENTIFICATION NUMBER (Continued)
POSITION
INTERPRETATION
10
11Engine
Check Digit Model Year
Plant Location
INTRODUCTION
CODE = DESCRIPTION
K = 3.7L 6 cyl. MPI Gasoline N = 4.7L 8 cyl. MPI Gasoline D = 5.7L 8 cyl. SMPI Gasoline
6 = 5.9L 6 cyl. Turbo Diesel
C = 5.9L 6 cyl. Turbo Diesel High Output
W = 8.0L 10 cyl. MPI Gasoline
Z = 5.9L 8 cyl. SMPI Gasoline Light Duty
0 through 9 or X
3 = 2003
S = Dodge City
G = Saltillo
J = St. Louis (North)
12 thru 17
Vehicle Build Sequence
VEHICLE EMISSION CONTROL INFORMATION (VECI) DESCRIPTION
All models have a Vehicle Emission Control Infor- mation (VECI) Label. DaimlerChrysler permanently attaches the label in the engine compartment (Fig. 3). The label cannot be removed without defacing label information and destroying label.
The label contains the vehicle’s emission specifica- tions and vacuum hose routings. All hoses must be connected and routed according to the label.
The label also contains an engine vacuum sche- matic. There are unique labels for vehicles built for sale in the state of California and the country of Canada. Canadian labels are written in both the English and French languages.
The VECI label contains the following: † Engine family and displacement † Evaporative family † Emission control system schematic † Certification application † Engine timing specifications (if adjustable) † Idle speeds (if adjustable) † Spark plug and gap
Fig.3VEHICLEEMISSIONSCERTIFICATION
INFORMATIONLABEL
1 - VECI LABEL LOCATION 2 - RADIATOR SUPPORT
4
INTRODUCTION
BODY CODE PLATE DESCRIPTION
DR
The Body Code Plate (Fig. 5) is located on the right front hydroform fender rail just behind the headlight assembly (Fig. 4). There are seven lines of informa- tion on the body code plate. Lines 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 4 in the center of the plate to line 1 at the bottom of the plate.
The last code imprinted on a vehicle code plate will be followed by the imprinted word END. When two vehicle code plates are required, the last available spaces on the first plate will be imprinted with the letters CTD (for continued).
When a second vehicle code plate is necessary, the first four spaces on each row will not be used because of the plate overlap.
Fig.4BODYCODEPLATELOCATION
1 - FENDER 2 - RADIATOR CROSSMEMBER 3 - HYDROFORM FENDER RAIL 4 - RIVOT (2) 5 - BODY CODE PLATE
Fig.5BODYCODEPLATE
1 - PRIMARY PAINT 2 - SECONDARY PAINT 3 - TRANSMISSION CODE 4 - VEHICLE MODEL NUMBER 5 - ENGINE CODE 6 - INTERIOR TRIM CODE 7 - VEHICLE IDENTIFICATION NUMBER 8 - TAILGATE CODE 9 - CARGO BOX CODE 10 - TAILGATE TRIM CODE 11 - BODY-IN-WHITE SEQUENCE 12 - MARKET CODE 13 - SPECIES CODE 14 - PAINT PROCEDURE 15 - VEHICLE ORDER NUMBER
BODY CODE PLATE—LINE 4
DIGITS 1 THROUGH 12
Vehicle Order Number
DIGITS 13, 14, AND 15
Transmission Codes † DGT = 4–speed Automatic (46RE) † DG4 = 4–speed Automatic (45RFE) † DGP = 4–speed Automatic (47RE) † DG8 = 4–speed Automatic (48RE) † DDC = 5–speed Manual (NV3500) † DDP = 5–speed Manual (NV4500) † DEE = 6–speed Manual (NV5600)
DIGITS 16, 17, AND 18
Car Line Shell † DR1 = 1500 4 X 2
† DR6 = 1500 4 X 4
† DR2 = 2500 4 X 2
† DR7 = 2500 4 X 4
† DR3 = 3500 4 X 2
† DR8 = 3500 4 X 4INTRODUCTION
BODY CODE PLATE—LINE 2
DIGIT 1 Open Space
DIGITS 2 AND 3 Species Code. (Used for Manufacturing)
DIGIT 4
Open Space
DIGIT 5
Market Code † B = International † C = Canada † M = Mexico † U = United States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehicle Identification Number (VIN) (Refer to VEHICLE DATA/VEHICLE INFORMA- TION/VEHICLE IDENTIFICATION NUMBER - DESCRIPTION) for proper breakdown of VIN code.
BODY CODE PLATE—LINE 1
DIGITS 1 THROUGH 6 Body-in-white assembly sequence.
DIGIT 7
Open Space
DIGIT 8 Tailgate trim code.
DIGIT 9
Open Space
DIGITS 10 THROUGH 12 Cargo box code
DIGIT 13
Open Space
DIGITS 14 THROUGH 16 Tailgate code
DR BODY CODE PLATE (Continued)
DIGIT 19
Price Class † L = Low † H = Highline DIGITS 20 AND 21
Body Type † 41 = Ram Truck Quad Cab, Short Box † 42 = Ram Truck Quad Cab, Long Box † 61 = Ram Truck Standard Cab, Short Box † 62 = Ram Truck Standard Cab, Long Box BODY CODE PLATE—LINE 3DIGITS 1,2, AND 3
Paint Procedure † APA = Monotone † AP9 = Special † APD = Two-tone (Lower break) DIGIT 4Open Space
DIGITS 5 THROUGH 8
Primary Paint (Refer to 23 - BODY/PAINT - SPECIFICATIONS)
for color codes.
DIGIT 9
Open Space
DIGITS 10 THROUGH 13
Secondary Paint
DIGIT 14
Open Space
DIGITS 15 THROUGH 18
Interior Trim CodeDIGIT 19
Open Space
DIGITS 20, 21, AND 22
Engine Code † EKG = 3.7 L 6 cyl. MPI Gasoline † EVA = 4.7 L 8 cyl. MPI Gasoline † EZA = 5.7 L 8 cyl. SMPI Gasoline † EML = 5.9 L 8 cyl. SMPI Gasoline † ETC = 5.9 L 6 cyl. Cummins Turbo Diesel † ETH = 5.9 L 6 cyl. Cummins Turbo Diesel High † EWA = 8.0 L 10 cyl. MPI Gasoline
Output
6
INTRODUCTION
DR
INTERNATIONAL VEHICLE CONTROL & DISPLAY SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS
The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.
FASTENER IDENTIFICATION DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 6) and (Fig. 7).INTERNATIONALSYMBOLS
10
11
12High Beam Fog Lamps Headlamp, Parking Lamps, Panel Lamps Turn Warning Hazard Warning Windshield Washer Windshield Wiper Windshield Wiper and Washer Windscreen Demisting and Defrosting Ventilating Fan Rear Window Defogger Rear Window Wiper
13
14
15
16
17
18
19
20
21
22
23
24Rear Window Washer Fuel Engine Coolant Temperature Battery Charging Condition Engine Oil Seat Belt Brake Failure Parking Brake Front Hood Rear hood (Decklid) Horn Lighter
DR FASTENER IDENTIFICATION (Continued)
INTRODUCTION
Fig.6FASTENERIDENTIFICATION
INTRODUCTION
FASTENER IDENTIFICATION (Continued)
DR
Fig.7FASTENERSTRENGTH
DR
INTRODUCTION
FASTENER USAGE DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY.
Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format.
During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used.
THREADED HOLE REPAIR DESCRIPTION - THREADED HOLE REPAIR
Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommen- dations for application and repair procedures.
METRIC SYSTEM DESCRIPTION
The metric system is based on quantities of one,
ten, one hundred, one thousand and one million.
The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.
CONVERSION FORMULAS AND EQUIVALENT VALUES
MULTIPLY
in-lbs
ft-lbs
Inches Hg (60° F) psi Inches Feet Yards mph
Feet/Sec mph Kilometers/Hr. (Km/h)
BY
x 0.11298
x 1.3558
x 3.377
x 6.895
x 25.4
x 0.3048
x 0.9144
x 1.6093x 0.3048
x 0.4470
x 0.277781 inch = 25 Millimeters 1 Foot = 0.3 Meter 1 Yard = 0.9 Meter 1 Mile = 1.6 Kilometers
TO GET
MULTIPLY
= Newton Meters (N·m) = Newton Meters (N·m) = Kilopascals (kPa) = Kilopascals (kPa) = Millimeters (mm) = Meters (M) = Meters = Kilometers/Hr. (Km/h) = Meters/Sec (M/S) = Meters/Sec (M/S) = Meters/Sec (M/S)
N·m
N·m
kPa kPa mm Km/h
M/S M/S M/S
COMMON METRIC EQUIVALENTS
BY x 8.851
TO GET
= in-lbs
x 0.7376
= ft-lbs
x 0.2961
x 0.145
x 0.03937
x 3.281
x 1.0936
x 0.6214x 3.281
x 2.237
x 3.600= Inches Hg = psi = Inches = Feet = Yards = mph
= Feet/Sec = mph Kilometers/Hr. (Km/h)
1 Cubic Inch = 16 Cubic Centimeters 1 Cubic Foot = 0.03 Cubic Meter 1 Cubic Yard = 0.8 Cubic Meter
Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.) (Fig. 8).
INTRODUCTION
10
METRIC SYSTEM (Continued)DR
Fig.8METRICCONVERSIONCHART
DR
INTRODUCTION
11
TORQUE REFERENCES DESCRIPTION
Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica-
tions Chart for torque references not listed in the individual torque charts (Fig. 9).
Fig.9TORQUESPECIFICATIONS
DR
LUBRICATION & MAINTENANCE
0 - 1
LUBRICATION & MAINTENANCE
TABLE OF CONTENTS
page
page
INTERNATIONAL SYMBOLS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS -
DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - ENGINE OIL AND
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION - POWER STEERING FLUID . . 3
DESCRIPTION - ENGINE COOLANT . . . . . . . . 3
DESCRIPTION - TRANSFER CASE - NV241GENII
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION - TRANSFER CASE - NV271
. . 4
DESCRIPTION - TRANSFER CASE - NV243
. . 4
DESCRIPTION - TRANSFER CASE - NV273
. . 4
DESCRIPTION - AXLE . . . . . . . . . . . . . . . . . . . 4INTERNATIONAL SYMBOLS DESCRIPTION
DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations (Fig. 1).
DESCRIPTION - MANUAL TRANSMISSION . . . 4
DESCRIPTION - AUTOMATICTRANSMISSION FLUID . . . . . . . . . . . . . . . . . . 4
OPERATION - AUTOMATIC TRANSMISSION
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FLUID CAPACITIES SPECIFICATIONS
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . 5
MAINTENANCE SCHEDULES
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
JUMP STARTING
STANDARD PROCEDURE - JUMP STARTING . . . 13
HOISTING
STANDARD PROCEDURE - HOISTING . . . . . . . 14
TOWING
STANDARD PROCEDURE - TOWING . . . . . . . . 15
FLUID TYPES
DESCRIPTION
DESCRIPTION - FUEL REQUIREMENTS - DIESEL ENGINE
DESCRIPTION
WARNING: Do not use alcohol or gasoline as a fuel blending agent. They can be unstable under certain conditions and hazardous or explosive when mixed with diesel fuel.
Fig.1INTERNATIONALSYMBOLS
diesel
number
Use good quality diesel fuel from a reputable sup- plier in your Dodge truck. For most year-round ser- vice, fuel meeting ASTM specification D-975 will provide good performance. If the vehicle is exposed to extreme cold (below 0°F/- 18°C), or is required to operate at colder-than-normal conditions for prolonged periods, use climatized No. 2
diesel fuel or dilute the No. 2 diesel fuel with 50% No. 1 diesel fuel. This will provide better protection from fuel gelling or wax-plugging of the fuel filters.LUBRICATION & MAINTENANCE
0 - 2
FLUID TYPES (Continued)Diesel fuel is seldom completely free of water. To prevent fuel system trouble, including fuel line freez- ing in winter, drain the accumulated water from the fuel/water separator using the fuel/water separator drain provided. If you buy good-quality fuel and fol- low the cold-weather advice above, fuel conditioners should not be required in your vehicle. If available in your area, a high cetane “premium” diesel fuel may offer improved cold starting and warm-up perfor- mance.
DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERN- MENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.
When service is required, DaimlerChrysler Corpo- ration recommends that only Mopart brand parts, lubricants and chemicals be used. Mopart provides the servicing DaimlerChrysler Corporation vehicles.
engineered
products
best
for
Only lubricants bearing designations defined by the following organization should be used. † Society of Automotive Engineers (SAE) † American Petroleum Institute (API) † National Lubricating Grease Institute (NLGI)
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Certified. MOPARt that meet or exceed this
provides engine oils, requirement.
SAE VISCOSITY
An SAE viscosity grade is used to specify the vis- cosity of engine oil. Use only engine oils with multi- ple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indi- cates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your par- ticular temperature range and variation (Fig. 2).
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CON- SERVING is located on the label of an engine oil con- tainer.
DR
Fig.2TEMPERATURE/ENGINEOILVISCOSITY
CONTAINER IDENTIFICATION
Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the front label of engine oil plastic bottles and the top of engine oil cans (Fig. 3).
This symbol means that the oil has been certified by the American Petroleum Institute (API). Diamler- Chrysler only recommend API Certified engine oils. Use Mopart engine oil or equivalent.
Fig.3APISYMBOL
GEAR LUBRICANTS
SAE ratings also apply to multigrade gear lubri- cants. In addition, API classification defines the lubricants usage. Such as API GL-5 and SAE 75W- 90.
LUBRICANTS AND GREASES
Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 4) on the label. At the bottom of the NLGI symbol is the usage and quality identification letters. Wheel bearing lubricant is identified by the letter “G”. Chassis lubricant is identified by the letter “L”. The letter following the usage letter indicates the quality of the lubricant. The following symbols indicate the highest quality.
DR FLUID TYPES (Continued)
LUBRICATION & MAINTENANCE
0 - 3
ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT.
CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection.
Fig.4NLGISYMBOL
1 - WHEEL BEARINGS 2 - CHASSIS LUBRICATION 3 - CHASSIS AND WHEEL BEARINGS
SPECIALIZED LUBRICANTS AND OILS
Some maintenance or
repair procedures may require the use of specialized lubricants or oils. Con- sult the appropriate sections in this manual for the correct application of these lubricants.
DESCRIPTION - POWER STEERING FLUID
Mopart ATF +4, Automatic Transmission Fluid is required in the power steering system. Substitute fluids can induce power steering system failure.
Mopart ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change.
DESCRIPTION - ENGINE COOLANT
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWAL- LOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMIT- ING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN
The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air.
Mopart
Antifreeze/Coolant,
The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Year/100,000 Mile Formula (MS-9769), or the equiva- lent ethylene glycol base coolant with organic corro- sion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solu- tion.
MoparT
Antifreeze/Coolant,
CAUTION: Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection.
COOLANT PERFORMANCE
The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mix- tures follows:
Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for pur- pose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol-The
corrosion inhibiting additives in ethylene-glycol need the pres- ence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plas- tic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F).
50/50 Ethylene-Glycol and Water-Is the recom- mended mixture, it provides protection against freez- ing to -37°C (-34°F). The antifreeze concentration
LUBRICATION & MAINTENANCE
0 - 4
FLUID TYPES (Continued)must always be a minimum of 44 percent, year- round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protec- tion against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher per- centage of antifreeze can cause the engine to over- heat because specific heat of antifreeze is lower than that of water.
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethyl- ene-glycol.
COOLANT SELECTION AND ADDITIVES
NOTE: Refer to the vehicle’s coolant bottle to iden- tify HOAT or Non-HOAT coolant. Non-HOAT coolant is green in color.
The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopart Antifreeze/Coolant, Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution.
-37°C (-35°F). If
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
DESCRIPTION - TRANSFER CASE - NV241
GENIIRecommended lubricant
for the NV241 GENII transfer case is Mopart ATF +4, Automatic Trans- mission Fluid.
DESCRIPTION - TRANSFER CASE - NV271
Recommended lubricant for the NV271 transfer case is Mopart ATF +4, Automatic Transmission Fluid.
DESCRIPTION - TRANSFER CASE - NV243
Recommended lubricant for the NV243 transfer case
is Mopart ATF +4, Automatic Transmission Fluid.
DESCRIPTION - TRANSFER CASE - NV273
Recommended lubricant for the NV273 transfer case
is Mopart ATF +4, Automatic Transmission Fluid.
DR
DESCRIPTION - AXLE
NOTE: DaimlerChrysler recommends using MoparT lubricants or lubricants of equal quality.
FRONTAXLE
† C205F - Mopart Gear Lubricant 75W-90
† 9 1/4 AA - Mopart Synthetic Gear Lubricant75W-90
REARAXLE
† 9 1/4 - Mopart Synthetic Gear Lubricant 75W-140
† 10 1/2 AA - Mopart Synthetic Gear Lubricant † 11 1/2 AA - Mopart Synthetic Gear Lubricant75W-90
75W-90
NOTE: Trac-LokT differentials require Limited Slip Additive in the lubricant. Trac-Rite™ differentials DO NOT require Limited Slip Additive.
DESCRIPTION - MANUAL TRANSMISSION
NOTE: DaimlerChrysler recommends using MoparT lubricants or lubricants of equal quality.
† NV3500 - Mopart Manual Transmission Lubricant † NV4500 - Mopart Synthetic 75W85 Manual † NV5600 - Mopart Manual Transmission Lubri-
Transmission Lubricant
cant
DESCRIPTION - AUTOMATIC TRANSMISSION FLUID
NOTE: Refer to Service Procedures in this group for fluid level checking procedures.
Mopart ATF +4, Automatic Transmission Fluid is the recommended fluid for DaimlerChrysler auto- matic transmissions.
Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid.
Mopart ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change.
DR FLUID TYPES (Continued) FLUID ADDITIVES
DaimlerChrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks.
Various “special” additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been sup- ported to the satisfaction of DaimlerChrysler and these additives must not be used. The use of trans- mission “sealers” should also be avoided, since they may adversely affect the integrity of transmission seals.
OPERATION - AUTOMATIC TRANSMISSION FLUID
The automatic transmission fluid is selected based upon several qualities. The fluid must provide a high level of protection for the internal components by providing a lubricating film between adjacent metal components. The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range. If the viscosity stays con- stant through the temperature range of operation, transmission operation and shift feel will remain con- sistent. Transmission fluid must also be a good con- ductor of heat. The fluid must absorb heat from the internal transmission components and transfer that heat to the transmission case.
FLUID CAPACITIES
SPECIFICATIONS
FLUID CAPACITIES
2DESCRIPTION
SPECIFICATION
FUEL TANK
Short Box (Lt. Duty)
Long Box (Lt. Duty)
98 L (26 gal.)*
132 L (35 gal.)*
ENGINE OIL WITH FILTER
3.7L
4.7L
5.7L
5.9L
8.0L
4.7 L (5.0 qts.)
5.6 L (6.0 qts.)
6.6 L (7.0 qts.)
4.7 L (5.0 qts.)
6.6 L (7.0 qts.)
5.9L DIESEL
10.4 L (11.0 qts.)
LUBRICATION & MAINTENANCE
0 - 5
2DESCRIPTION
SPECIFICATION
COOLING SYSTEM
3.7L
4.7L
5.7L
5.9L
8.0L
5.9L Diesel Engine
15.4 L (16.2 qts.)**
15.4 L (16.2 qts.)**
15.4L (16.2 qts.)**
15.5 L (16.3 qts.)**
24L (24.3 qts.)**
28L (29.5 qts.)**
POWER STEERING
Power steering fluid capacities are dependent on engine/ chassis options as well as steering gear/cooler options. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these capacities may vary. Refer to 19, Steering for proper fill and bleed procedures.
AUTOMATIC TRANSMISSION
Service Fill - 46RE
O-haul - 46RE
Service Fill - 45RFE/
545RFE
3.8 L (4.0 qts.)
9-9.5L (19-20 pts.) L 4X2 - 5.2 L (11.0 pts.)
4X4 - 6.2 L (13.0 pts.) 14-16 L (29-33 pts.) L
O-haul - 45RFE/545RFE L Dry fill capacity Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC/FLUID -
STANDARD PROCEDURE) MANUAL TRANSMISSION
NV3500 4X2
NV3500 4X4NV4500
NV56002.3 L (4.8 pts.) 2.0 L (4.2 pts.) 3.8 L (8.0 pts.) 4.5 L (9.5 pts.)
TRANSFER CASE
NV241 GENII
NV243
NV271
NV273
1.6 L (3.4 pts.)
1.6 L (3.4 pts.)
1.89 L (4.0 pts.)
1.89 L (4.0 pts.)
FRONT AXLE ± .03 L (1 oz)
C205F 9 1/4 AA
1.66 L (3.5 pts.) 2.25 L (4.75 pts.)
REAR AXLE ± .03 L (1 oz)
9 1/4
10 1/2 AA 11 1/2 AA
2.32 L (4.9 pts.)*** 2.25 L (4.75 pts.) 3.62 L (7.65 pts)
*** With Trac-Lok add 118 ml (4 oz.) of Limited Slip Additive.
** Includes 0.9L (1.0 qts.) for coolant reservoir.
*Nominal refill capacities are shown. A variation may be observed from vehicle to vehicle due to manufacturing
tolerance and refill procedure.
0 - 6
LUBRICATION & MAINTENANCE
DR
MAINTENANCE SCHEDULES DESCRIPTION
Maintenance Schedule Information not included in this section, is located in the appropriate Owner’s Manual.
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 0° C (32° F).† Stop and go driving. † Extensive engine idling. † Driving in dusty conditions. † Short trips of less than 16 km (10 miles). † More than 50% of your driving is at sustained high speeds during hot weather, above 32° C (90° F). † Trailer towing. † Taxi, police, or delivery service (commercial ser- vice).† Off-road or desert operation. † If equipped for and operating with E-85
(ethanol) fuel.NOTE: Most vehicles are operated under the condi- tions listed for Schedule (B(.
Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Schedule 9B9.
Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval that occurs first.
CAUTION: Failure to perform the required mainte- nance items may result in damage to the vehicle.
AtEachStopforFuel
† 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 accuracy 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.
OnceaMonth
or damage.
terminals as required.
† Check tire pressure and look for unusual wear † Inspect the battery and clean and tighten the † Check the fluid levels of coolant reservoir, brake master cylinder, power steering and transmission and add as needed. † Check all lights and all other electrical items for
correct operation.
AtEachOilChange
pension components.
† Change the engine oil filter. † Inspect the exhaust system. † Inspect the brake hoses. † Inspect the CV joints (if equipped) and front sus- † Check the automatic transmission fluid level. † Check the manual transmission fluid level. † Check the coolant level, hoses, and clamps. † Rotate the tires at each oil change interval shown on Schedule “A” 10 000 km (6,000 miles) or every other interval shown on Schedule “B” 10 000
km (6,000 miles).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 0° C (32° F).† Stop and go driving. † Extensive engine idling. † Driving in dusty conditions. † Short trips of less than 16 km (10 miles). † More than 50% of your driving is at sustained high speeds during hot weather, above 32° C (90° F). † Trailer towing. † Taxi, police, or delivery service (commercial ser- vice).† Off-road or desert operation. † If equipped for and operating with E-85
(ethanol) fuel.DR MAINTENANCE SCHEDULES (Continued)
LUBRICATION & MAINTENANCE
0 - 7
Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if necessary.Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if necessary. Replace spark plugs. Inspect PCV valve, replace as necessary. Drain and refill automatic tranmission fluid, change filter and adjust bands (46RE/47RE/ 48RE).‡ Drain and refill automatic tranmission fluid and change main sump filter (45RFE/ 545RFE only).‡Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if necessary.3,000
(5 000)6,000
(10 000)
9,000
(14 000)
21,000
(34 000)18,000
(29 000)24,000
(38 000)12,000
(19 000)15,000
(24 000)27,000
(43 000)30,000
(48 000)X*
33,000
(53 000)39, 000
(62 000)36,000
(58 000)42,000
(67 000)45,000
(72 000)LUBRICATION & MAINTENANCE
0 - 8
MAINTENANCE SCHEDULES (Continued)Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Drain and refill transfer case fluid. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if necessary. Replace spark plugs. Replace ignition cables (5.7L/5.9L/8.0L). Inspect PCV valve, replace as necessary. Drain and refill automatic tranmission fluid, change filter and adjust bands (46RE/47RE/ 48RE). Drain and refill automatic tranmission fluid and change main sump filter (45RFE/ 545RFE only).Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Inspect engine air cleaner filter. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L/5.9L/8.0L).51,000
(82 000)54,000
(86 000)57,000
(91 000)48,000
(77 000)DR
60,000
(96 000)X*
63,000
66,000
69,000
72,000
75,000
(101 000)
(106 000)
(110 000)
(115 000)
(120 000)
DR MAINTENANCE SCHEDULES (Continued)
LUBRICATION & MAINTENANCE
0 - 9
Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if necessary. Replace spark plugs. Inspect PCV valve, replace as necessary. Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L/5.9L/8.0L). Drain and refill automatic tranmission fluid, change filter and adjust bands (46RE/47RE/ 48RE). Drain and refill automatic tranmission fluid and change main sump and spin-on cooler return filter (if equipped) [45RFE/545RFE only].Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Flush and replace engine coolant. Flush and replace Power Steering Fluid. Inspect brake linings.78,000
81,000
84,000
87,000
90,000
(125 000)
(130 000)
(134 000)
(139 000)
(144 000)
X* X‡
93,000
96,000
99,000
(149 000)
(154 000)
(158 000)
100,000
(160 000)102,000
(163 000)LUBRICATION & MAINTENANCE
0 - 10
MAINTENANCE SCHEDULES (Continued)DR
Miles (Kilometers) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Drain and refill transfer case fluid. Change rear axle fluid. Change front axle fluid (4X4). Inspect brake linings. Inspect engine air cleaner filter, replace if necessary. Replace spark plugs. Replace ignition cables (5.7L/5.9L/8.0L). Inspect PCV valve, replace as necessary. Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L/5.9L/8.0L). Drain and refill automatic tranmission fluid, change filter and adjust bands (46RE/ 47RE/48RE). Drain and refill automatic tranmission fluid and change main sump filter (45RFE/ 545RFE only).
105,000
(168 000)108,000
(173 000)111,000
(178 000)114,000
(182 000)117,000
(187 000)120,000
(192 000)X‡
X*
X‡
* This maintenance is recommended by the manu- facture to the owner but is not required to maintain the emissions warranty.
‡ This maintenance is not required if previously
replaced.
Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.
DR MAINTENANCE SCHEDULES (Continued) Schedule “A”
LUBRICATION & MAINTENANCE
0 - 11
Miles (Kilometers) [Months] Change engine oil and engine oil filter. Check transfer case fluid level. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Inspect brake linings. Replace engine air cleaner filter. Replace spark plugs.6,000
(10 000)
12,000
(19 000)18,000
(29 000)24,000
(38 000)30,000
(48 000)[6]
[12]
[24]
[18]
Miles (Kilometers) [Months] Change engine oil and engine oil filter. Check transfer case fluid level. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Flush and replace engine coolant at 60 months, regardless of mileage. Inspect brake linings. Replace engine air cleaner filter. Replace spark plugs. Inspect PCV valve, replace as necessary. Replace ignition cables (5.7L/5.9L/8.0L).
36,000
(58 000)42,000
(67 000)48,000
(77 000)54,000
(84 000)60,000
(96 000)[36]
[42]
[48]
[54]
[60]
X*
[30]
66,000
(106 000)
[66]
LUBRICATION & MAINTENANCE
0 - 12
MAINTENANCE SCHEDULES (Continued)DR
Miles (Kilometers) [Months] Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500
(4X4) models only. Drain and refill transfer case fluid. Flush and replace engine coolant, if not done at 60 mos. Flush and replace Power Steering Fluid. Inspect brake linings. Replace engine air cleaner filter. Replace spark plugs. Replace ignition cables (5.7L/5.9L/ 8.0L). Inspect PCV valve, replace as necessary. Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L/5.9L/ 8.0L). Drain and refill automatic tranmission fluid, change filter and adjust bands (46RE/47RE/48RE). Drain and refill automatic tranmission fluid and change main sump filter and spin-on cooler return filter (if equipped) [45RFE/545RFE only].72,000
78,000
84,000
90,000
96,000
(115 000)
(125 000)
(134 000)
(144 000)
(154 000)
100,000
(160 000)[78]
[84]
[72]
[96]
[90]
X*
Miles (Kilometers) [Months] Change engine oil and engine oil filter. Check transfer case fluid level. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Inspect brake linings. Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L/5.9L/8.0L). Replace engine air cleaner filter. Replace spark plugs.
102,000
(163 000)108,000
(173 000)114,000
(182 000)120,000
(192 000)[102]
[108]
[114]
[120]
X‡
X‡
* This maintenance is recommended by the manu- facture to the owner but is not required to maintain the emissions warranty.
‡ This maintenance is not required if previously
replaced.
Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.
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 right equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent mechanic.
