Login- Download PDF Manual
-
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!
Cooling System
MAINTAINING YOUR VEHICLE 465
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, refer to Exhaust Gas in the Safety Tips section of this manual.
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.
WARNING!
You or others can be badly burned by hot coolant or steam from your radiator. If you see or hear steam coming from under the hood, don’t open the hood until the radiator has had time to cool. Never try to open a cooling system pressure cap when the radiator is hot.
Engine Coolant Checks Check the engine coolant (antifreeze) protection every 12
months (before the onset of freezing weather, where applicable). If coolant is dirty or rusty in appearance, the system should be drained, flushed and refilled with fresh coolant. Check the front of the A/C condenser for any466 MAINTAINING YOUR VEHICLE
accumulation of bugs, leaves, etc. If dirty, clean by gently spraying water from a garden hose vertically down the face of the condenser. Check the coolant recovery bottle tubing for brittle rub- ber, cracking, tears, cuts and tightness of the connection at the bottle and radiator. Inspect the entire system for leaks. With the engine at normal operating temperature (but not running), check the cooling system pressure cap for proper vacuum sealing by draining a small amount of coolant from the radiator drain cock. If the cap is sealing properly, the engine coolant (antifreeze) will begin to drain from the coolant recovery bottle. DO NOT RE- MOVE THE COOLANT PRESSURE CAP WHEN THE COOLING SYSTEM IS HOT.
Cooling System — Drain, Flush and Refill At the intervals shown on the Maintenance Schedules, the system should be drained, flushed and refilled. If the solution is dirty or contains a considerable amount of sediment, clean and flush with a reliable cooling system cleaner. Follow with a thorough rinsing to remove all deposits and chemicals. Properly dispose of old antifreeze solution. Selection Of Coolant Use only the manufacturer’s recommended coolant; for correct coolant type, refer to “Engine Coolant” under “Fluids, Lubricants and Genuine Parts” in this section.
CAUTION!
† Mixing of coolants other than specified HOAT engine coolants, may result in engine damage and may decrease corrosion protection. If a non-HOAT coolant 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.
MAINTAINING YOUR VEHICLE 467
Adding Coolant Your vehicle has been built with an improved engine coolant that allows extended maintenance intervals. This coolant can be used up to 5 Years or 100,000 miles (160
000 km) before replacement. To prevent reducing this extended maintenance period, it is important that you use the same coolant throughout the life of your vehicle. Please review these recommendations for using Hybrid Organic Additive Technology (HOAT) coolant. When adding coolant: † The manufacturerrecommends using Mopart Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology). † Mix a minimum solution of 50% HOAT engine coolant and distilled water. Use higher concentrations (not to exceed 70%) if temperatures below -34°F (-37°C) are anticipated.
468 MAINTAINING YOUR VEHICLE
† Use only high purity water such as distilled or deion- ized 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.
Please note that it is the owner’s responsibility to main- tain the proper level of protection against freezing ac- cording to the temperatures occurring in the area where the vehicle is operated. NOTE: Mixing coolant types will decrease the life of the engine coolant and will require more frequent coolant changes. Cooling System Pressure Cap The cap must be fully tightened to prevent loss of coolant, and to ensure that coolant will return to the radiator from the coolant recovery bottle.
The cap should be inspected and cleaned if there is any accumulation of foreign material on the sealing surfaces.
WARNING!
† The warning words “DO NOT OPEN HOT” on the cooling system pressure cap are a safety pre- caution. Never add coolant when the engine is overheated. Do not loosen or remove the cap to cool an overheated engine. Heat causes pressure to build up in the cooling system. To prevent scald- ing or injury, do not remove the pressure cap while the system is hot or under pressure. † Do not use a pressure cap other than the one specified for your vehicle. Personal injury or en- gine damage may result.
Disposal of Used Engine Coolant Used ethylene glycol-based engine coolant is a regulated substance requiring proper disposal. Check with your local authorities to determine the disposal rules for your community. To prevent ingestion by animals or children do not store ethylene glycol-based engine coolant in open containers or allow it to remain in puddles on the ground. If ingested by a child, contact a physician immediately. Clean up any ground spills immediately. Coolant Level The coolant bottle provides a quick visual method for determining that the coolant level is adequate. With the engine cold, the level of the coolant in the coolant recovery bottle should be between the ranges indicated on the bottle. The radiator normally remains completely full, so there is no need to remove the radiator cap unless checking for coolant freeze point or replacing coolant. Advise your
MAINTAINING YOUR VEHICLE 469
service attendant of this. As long as the engine operating temperature is satisfactory, the coolant bottle need only be checked once a month. When additional coolant is needed to maintain the proper level, it should be added to the coolant bottle. Do not overfill. Points To Remember NOTE: When the vehicle is stopped after a few miles (a few kilometers) of operation, you may observe vapor coming from the front of the engine compartment. This is normally a result of moisture from rain, snow, or high humidity accumulating on the radiator and being vapor- ized when the thermostat opens, allowing hot coolant to enter the radiator. If an examination of your engine compartment shows no evidence of radiator or hose leaks, the vehicle may be safely driven. The vapor will soon dissipate.
470 MAINTAINING YOUR VEHICLE
† Do not overfill the coolant recovery bottle. † Check coolant freeze point in the radiator and in the coolant recovery bottle. If antifreeze needs to be added, contents of coolant recovery bottle must also be protected against freezing. † If frequent coolant additions are required, or if the level in the coolant recovery bottle does not drop when the engine cools, the cooling system should be pres- sure tested for leaks. † Maintain coolant concentration at 50% HOAT engine coolant (minimum) and distilled water for proper corrosion protection of your engine, which contains aluminum components. † Make sure that the radiator and coolant recovery bottle overflow hoses are not kinked or obstructed.
† Keep the front of the radiator clean. If your vehicle is equipped with air conditioning, keep the front of the condenser clean, also. † Do not change the thermostat for Summer or Winter operation. If replacement is ever necessary, install ONLY the correct type thermostat. Other designs may result in unsatisfactory coolant performance, poor gas mileage, and increased emissions.
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.
Ensure 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. Fuel System Connections Electronic Fuel Injection high pressure fuel systems are designed with tubes and special connects, connections and clamps which have unique material characteristics to provide adequate sealing and resist attack by deterio- rated gasoline. You are urged to use only the manufacture’s specified tubes, connections and clamps, or their equivalent in material and specification, in any fuel system servicing.
MAINTAINING YOUR VEHICLE 471
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 and Power Steering Hoses When the vehicle is serviced for scheduled maintenance, inspect surface of hoses and nylon tubing for evidence of heat and mechanical damage. Hard and brittle rubber, cracking, tears, cuts, abrasion, and excessive swelling indicate deterioration of the rubber. Particular attention should be made to examining those hose surfaces nearest to high heat sources, such as the exhaust manifold. Ensure nylon tubing in these areas has not melted or collapsed.
472 MAINTAINING YOUR VEHICLE
Inspect all hose connections such as clamps and cou- plings to make sure they are secure and no leaks are present. NOTE: Often, fluid such as oil, power steering fluid, and brake fluid are used during assembly plant opera- tions to facilitate the assembly of hoses to couplings. Therefore, oil wetness at the hose-coupling area is not necessarily an indication of leakage. Actual dripping of hot fluid when systems are under pressure (during vehicle operation), should be noted before hose is re- placed based on leakage. Inspection of brake hoses should be performed NOTE: whenever the brake system is serviced and every engine oil change. Inspect hydraulic 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 resulting in a possibility of a burst failure.
WARNING!
Worn brake hoses can burst and cause brake failure. You could have an accident. If you see any signs of cracking, scuffing, or worn spots, have the brake hoses replaced immediately.
Brake Master Cylinder — Brake Fluid Level Check The fluid level of the master cylinder should be checked when performing under the hood service, or immedi- ately if the brake system warning 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. For correct fluid type, refer to ”Brake Master Cylinder” under “Fluids, Lubricants and Genuine Parts” in this section.
WARNING!
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.
MAINTAINING YOUR VEHICLE 473
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!
Do not allow a petroleum-base fluid to contaminate the brake fluid. Seal damage may result.
474 MAINTAINING YOUR VEHICLE
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. For the correct lubricant type, refer to “Fluids, Lubricants and Genuine Parts” in this Section. Rear Axle And 4x4 Front Driving Axle Fluid Level For the correct Fluid type, refer to “Fluids, Lubricants and Genuine Parts” in this Section. 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 in (16 mm) below the fill hole on 9 1/4 in manufacturer’s rear axles. For all 2500/3500 Model axles, the fluid level should be 1/4” ± 1/4 in(6.4 mm ± 6.4 mm) below the fill hole on the 9.25 in front and 3/4 in ± 1/4 in (19 mm ± 6.4 mm) on 10.5 in rear axles. The 11.5 in rear axle level should be 1/4
in ± 1/4 in (6.4 mm ± 6.4 mm) below the fill hole. Drain and Refill Follow the Maintenance Schedule for recommended front and rear axle fluid change intervals. Lubricant Selection For the correct fluid type, refer to “Fluids, Lubricants and Genuine Parts” in this Section.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 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. 2500/3500 Model Axles DO NOT REQUIRE any limited slip oil additive (friction modifiers).
MAINTAINING YOUR VEHICLE 475
Transfer Case
Drain And Refill Follow the Maintenance Schedule for recommended transfer case fluid change intervals. Lubricant Selection For the correct Fluid type, refer to “Fluids, Lubricants and Genuine Parts” in this Section. 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.
476 MAINTAINING YOUR VEHICLE
Manual Transmission
Lubricant Selection G238 (6-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 Fluids, Lubricants and Genuine Parts for correct fluid type. This is the only lubricant recommended for use in the Getrag 238 transmission. Lubricant Selection G56 (6-Speed Manual Transmission — If Equipped) Follow the Maintenance Schedule for recommended transmission fluid change intervals. If it is necessary to add or change fluid in this transmission refer to “Fluids, Lubricants and Genuine Parts” for correct fluid type. This is the only lubricant recommended for use in the G56
transmission.Fluid Level Check – All Manual Transmissions This fluid level can be checked by removing the fill plug. If the level of the lubricant is more than 1/4 in(6.4 mm) below the bottom of the filler hole while the vehicle is on level ground, enough lubricant should be added to bring the level to the bottom of the filler hole. Automatic Transmission
Selection Of Lubricant It is important that the proper lubricant is used in the transmission to assure optimum transmission perfor- mance. Use only manufacturer’s recommended transmis- sion fluid; refer to “Fluids, Lubricants and Genuine Parts” in this section for correct fluid type. It is important that the transmission fluid be maintained at the pre- scribed level using the recommended fluid.
CAUTION!
Using a transmission fluid other than the manufac- turer’s recommended fluid may cause deterioration in transmission shift quality and/or torque converter shudder. Using a transmission fluid other than the manufacturer’s recommended fluid will result in more frequent fluid and filter changes. Refer to “Fluids, Lubricants and Genuine Parts” in this sec- tion for correct fluid type.
Fluid Level Check If equipped with a dipstick, use the following procedure. If your vehicle has a capped dipstick tube, it is sealed and should not be tampered with. Your authorized dealer has the proper tools to ensure that the fluid level is set properly. The fluid level should be checked when the
MAINTAINING YOUR VEHICLE 477
engine is fully warmed up and the fluid in the transmis- sion is at normal operating temperature. Operation of the transmission with an improper fluid level will greatly reduce the life of the transmission and of the fluid. Check the fluid level whenever the vehicle is serviced. Fluid Level Check – 545RFE/42RLE Check the fluid level while the transmission is at normal operating temperature 82°C (180°F). This occurs after at least 15 mi (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.
478 MAINTAINING YOUR VEHICLE
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 PARK. 5. Remove the dipstick, wipe it clean and reinsert it until seated. 6. Remove the dipstick again and note the fluid level on both sides. The fluid level should be between the “HOT” (upper) reference holes on the dipstick at normal operat- ing temperature. Verify that solid coating of oil is seen on both sides of the dipstick. If the fluid is low, add as required into the dipstick tube. Do not overfill. After adding any quantity of oil through the oil fill tube, wait a minimum of two minutes for the oil to fully drain into the transmission before rechecking the fluid level.
If it is necessary to check the transmission below NOTE: the operating temperature, the fluid level should be between the two “COLD” (lower) holes on the dipstick with the fluid at approximately 70°F (21°C) (room tem- perature). If the fluid level is correctly established at room temperature, it should be between the “HOT” (upper) reference holes when the transmission reaches 180°F (82°C). Remember it is best to check the level at the normal operating temperature.
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. Automatic Transmission Fluid and Filter Change Follow the Maintenance Schedule for recommended transmission fluid and filter change intervals. NOTE: reason, the fluid and filter(s) should be changed. It is important that proper lubricant is used in the transmission. For the correct Fluid type, refer to “Fluids, Lubricants and Genuine Parts” in this Section.
If the transmission is disassembled for any
MAINTAINING YOUR VEHICLE 479
Special Additives Automatic Transmission Fluid (ATF) is an engineered product and its performance may be impaired by supple- mental additives. Therefore, do not add any fluid addi- tives to the transmission. The only exception to this policy is the use of special dyes to aid in detecting fluid leaks. In addition, avoid using transmission sealers as they may adversely affect seals. Front and Rear Wheel Bearings
Front Wheel Bearings Front wheel bearings for all vehicles are sealed-for-life. They do not require greasing or seal replacement. In some instances, these bearings will “purge” excess grease and the bearing will look slightly wet. This is normal. Periodic inspection for excess play is recommended.
can be identified by the Noise Emission Control Label located in the operator’s compartment.
480 MAINTAINING YOUR VEHICLE
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. 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
In addition,
Required Maintenance for Noise Control Systems The following maintenance services must be performed every six months or 6,000 mi (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.
MAINTAINING YOUR VEHICLE 481
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.
482 MAINTAINING YOUR VEHICLE
EXHAUST SYSTEM † Removal or rendering inoperative exhaust system
components including the muffler or tailpipe.
ENGINE COOLING SYSTEM † Removal or rendering inoperative the fan clutch. † Removal of the fan shroud. Noise Emission Warranty The manufacturer warrants that this vehicle as manufac- tured by the manufacturer, was designed, built and equipped to conform at the time it left the manufacturer’s control with all applicable U.S. EPA Noise Control Regu- lations.
This warranty covers this vehicle as designed, built and equipped by the manufacturer, and is not limited to any particular part, component or system of the vehicle manufactured by the manufacturer. Defects in design, assembly or in any part, component or system of the vehicle as manufactured by the manufacturer, which, at the time it left the manufacturer’s control, caused noise emissions to exceed Federal standards, are covered by this warranty for the life of the vehicle.
MAINTAINING YOUR VEHICLE 483
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
12,000
19 00018,000
29 00024,000
39 00030,000
48 00036,000
58 00042,000
68 00048,000
77 0006,000
10 00054,000
87 00060,000
97 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
484 MAINTAINING YOUR VEHICLE
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 affect 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.
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 Mopart 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 Mopart Super Kleen Bug and Tar Remover to remove.
† Use Mopart 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.
MAINTAINING YOUR VEHICLE 485
† 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. † 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
mud or stone shields behind each wheel.
486 MAINTAINING YOUR VEHICLE
† Use Mopart touch up paint on scratches as soon as possible. Your authorized dealer has touch up paint to match the color of your vehicle.
Wheel and Wheel Trim Care 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 and/or excessive brake dust, use Mopart Wheel Cleaner (05066247AB) or equivalent, or select a nonabrasive, non-acidic cleaner. Do not use scouring pads, steel wool, a bristle brush, or metal polishes. Only Mopart or equivalent is recommended. Do not use oven cleaner. Avoid automatic car washes that use acidic solutions or harsh brushes that may damage the wheels’ protective finish.
with a clean, dry towel.
YES Essentialst Fabric Cleaning Procedure – If equipped YES Essentialst seats may be cleaned in the following manner: † Remove as much of the stain as possible by blotting † Blot any remaining stain with a clean, damp towel. † For tough stains, apply Mopart Total Clean or a mild soap solution to a clean, damp cloth and remove stain. Use a fresh, damp towel to remove soap residue. † For grease stains, apply Mopart Multipurpose cleaner to a clean, damp cloth and remove stain. Use a fresh, damp towel to remove soap residue. † Do not use any solvents or protectants on Yes Essen-
tials products.
Interior Care Use Mopart Total Clean to clean fabric upholstery and carpeting. Use Mopart Total Clean to clean vinyl upholstery. Mopart 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 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.
MAINTAINING YOUR VEHICLE 487
WARNING!
Do not use volatile solvents for cleaning purposes. Many are potentially flammable, and if used in closed areas they may cause respiratory harm.
Cleaning Headlights Your vehicle has plastic headlights that are lighter and less susceptible to stone breakage than glass headlights. Plastic is not as scratch resistant as glass and therefore different lens cleaning procedures must be followed. To minimize the possibility of scratching the lenses and reducing light output, avoid wiping with a dry cloth. To remove road dirt, wash with a mild soap solution fol- lowed by rinsing. Do not use abrasive cleaning components, solvents, steel wool or other aggressive material to clean the lenses.
488 MAINTAINING YOUR VEHICLE
Glass Surfaces All glass surfaces should be cleaned on a regular basis with Mopart Glass Cleaner or any commercial household-type glass cleaner. Never use an abrasive type cleaner. Use caution when cleaning the inside rear win- dow 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 rearview 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.
FUSES (INTEGRATED POWER MODULE) An integrated power module is located in the engine compartment near the battery. This center contains car- tridge fuses and mini fuses. A description of each fuse and component may be stamped on the inside cover, otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart.
Integrated Power Module Location
Cavity Cartridge
Fuse
MAINTAINING YOUR VEHICLE 489
Mini Fuse 20 Amp Yellow 20 Amp Yellow
— 15 Amp Blue 20 Amp Yellow 10 Amp Red — 10 Amp Red
Description
Power Outlet Console
Cabin Compartment Node (CCN) Door Locks — Aisin Transmission Controls (Diesel Only) Power Sunroof
Vistronic Fan/ Wastegate Solenoid — Heated Mirrors
490 MAINTAINING YOUR VEHICLE
Cavity Cartridge
Fuse 30 Amp Pink
10
11
Mini Fuse
5 Amp Orange
20 Amp Yellow
Description
Off Road Module Power Trx-Off Rd Pkg Sen (Gas Engine Only) NOTE: Insert 5 amp fuse in this cavity to enable the TRX capa- bility (If Equipped). Ignition Off Draw (IOD)-Cabin Com- partment Node (CCN)/Radio/Under Hood Lamp/Wireless Control Module (WCM)/Satellite Digi- tal Audio Receiver (SDARS)/Hands Free Module (HFM)/EOM
12
13
14
15
16
17
1819
Cavity Cartridge
Fuse 30 Amp Pink
Mini Fuse
25 Amp Natural
15 Amp Blue 20 Amp Yellow 15 Amp Blue —
Description
Electric Brake
Power-Battery RWAL/ABS Module Feed Park Lights Left
Trailer Park Lights
Park Lights Right
— ABS Pump
Trailer Tow Battery Feed
40 Amp Green 30 Amp Pink
Cavity Cartridge
Fuse
20
21
22
23
24
25
26
20 Amp Blue
Mini Fuse 10 Amp Red 10 Amp Red 2 Amp Gray 10 Amp Red
10 Amp Red 20 Amp Yellow
Description
Occupant Restraints Controller (ORC) 2
Occupant Restraints/ Pass Disable Switch IGN Switch FeedHVAC
AISIN Relay Feed (Diesel Only) Power Mirror/T-Case Brake Brake Switch/Center High Mount Stop Light (CHMSL)/ Aftermarket CHMSL
Cavity Cartridge
Fuse 40 Amp Green
27
28
29
30
31
MAINTAINING YOUR VEHICLE 491
Mini Fuse
10 Amp Red
10 Amp Red 15 Amp Blue
10 Amp Red
Description
Power Seats
Power Run/Start- PCM/Steering Angle Sensor 4X4 Switch/Pass Dr Switch/EC Mirror Power Run/Start- ABS/RWAL/Smart Bar/YAW Sensor/ Universal Exhaust Gas Oxygen (Uego) Sensor Controller PCM (Gas)/TCM (Diesel 58RFE)
492 MAINTAINING YOUR VEHICLE
Cavity Cartridge
Fuse
32
33
34
3536
37
38
Mini Fuse 10 Amp Red
10 Amp Red — 15 Amp Blue
25 Amp Natural 15 Amp Blue
20 Amp Yellow
Description
Power Ignition Run — Adjustable Pedals LED Power-IGN Run — HVAC — Cabin Compartment Node (CCN) Illumi- nation Audio_Amplifier
Variable Gate Turbo (VGT) — Turbo Die- sel Power Outlet IP
Cavity Cartridge
Fuse
39
40
41
4230 Amp Pink
Mini Fuse 10 Amp Red
20 Amp Yellow
—
Description
Seatbelt Tension Reducer/Power IGN Run/Acc Power IGN Run/Acc — Cigar Lighter/Rear Power Point — Diesel PCM (Diesel Only)
CAUTION!
† When installing the Integrated Power Module cover, it is important to ensure the cover is prop- erly positioned and fully latched. Failure to do so may allow water to get into the Integrated Power Module, and possibly result in a electrical system failure. † When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system over- load. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected.
MAINTAINING YOUR VEHICLE 493
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 (IOD) fuse located in the Integrated Power Module, located in the engine compartment. The IOD 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.
494 MAINTAINING YOUR VEHICLE
† Any time you store your vehicle, or keep it out of service (i.e., vacation) for two weeks or more, run the air conditioning system at idle for about five minutes in the fresh air and high blower setting. This will ensure adequate system lubrication to minimize the possibility of compressor damage when the system is started again.
NOTE: When reinstalling the IOD fuse push firmly until fully seated; the gauges in the instrument cluster will do a full sweep when the ignition key is cycled to RUN. This is a normal condition. NOTE: When the vehicle is shipped from the factory, the IOD fuse is in the up, or extracted position. If the radio, interior lamps, keyless entry, or other features do not work with the key OFF, check the position of the fuse (or check to see if the fuse is blown) to ensure that it is fully seated. When the IOD fuse is extracted, the instrument cluster in the odometer window will display 9NO FUSE.”
REPLACEMENT LIGHT BULBS
LIGHT BULBS — Interior Bulb No. Overhead Console Lights . . . . . . . . . . . . . . . TS 212-2
Dome Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7679
NOTE: For lighted switches, see your authorized dealer for replacement instructions. All of the inside bulbs are brass or glass-wedge base. Aluminum base bulbs are not approved.Bulb No. LIGHT BULBS — Exterior Backup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057
Center High Mounted Stop Light . . . . . . . . . . . . . 912
Fog Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 9006LL Headlight (Halogen) . . . . . . . . . . . . . . . . . . . . . . H13
Side Marker, Park & Turn Signal . . . . . . . . . 3157NAK Rear License Plate Light. . . . . . . . . . . . . . . . . . . . 168
Rear Cargo Light. . . . . . . . . . . . . . . . . . . . . . . . . 912LIGHT BULBS — Exterior Bulb No. 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.
MAINTAINING YOUR VEHICLE 495
1. Open the hood 2. Remove the two bolts from the front of the headlight housing.
Front Headlight Housing Bolts
496 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.
MAINTAINING YOUR VEHICLE 497
Headlight Removal
Bulb Removal
Fog Lights
1. Reach under the vehicle, unlock and twist connector counterclockwise 1⁄4 turn and remove connector and bulb from housing.
498 MAINTAINING YOUR VEHICLE
5. Unlock and pull connector straight from the base of the headlight halogen bulb. 6. Twist connector on the side marker/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 side marker/turn signal/park light bulb. Do not touch the headlight halogen bulb. 10. Reverse procedure for installation of bulbs and hous- ing.
2. Pull bulb straight from the connector.
Tail, Stop, Turn and Backup Lights
MAINTAINING YOUR VEHICLE 499
1. Remove the two screws that pass through the bed sheetmetal.
3. Reverse procedure for installation of bulbs and hous- ing.
Removing The Two Screws
500 MAINTAINING YOUR VEHICLE
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.
3. Rotate the bulb socket counterclockwise to remove from the housing.
Pulling Housing From Body
Rotating Bulb Socket From Housing
4. Pull bulb straight out of socket.
MAINTAINING YOUR VEHICLE 501
5. Reverse Procedure to install bulb and housing. Place the two raised blocks past the body.
Pulling Bulb From Socket
Sliding Raised Blocks Past Body
502 MAINTAINING YOUR VEHICLE
Center High-Mounted Stoplight (CHMSL) With Cargo Light
2. Separate the connector holding the housing and wir- ing harness to the body.
1. Remove the two screws holding the housing/lens to the body as shown.
3. Turn desired bulb socket 1⁄4 turn and remove socket and bulb from housing.
4. Pull desired bulb straight from the socket.
Cab Top Clearance Lights — If Equipped
1. Remove the two screws from the top of the light.
MAINTAINING YOUR VEHICLE 503
† Outside Bulbs: Cargo Lights † Inside Bulb: Center High-Mounted Stop Light 5. Reverse procedure for installation of bulbs and hous- ing.
504 MAINTAINING YOUR VEHICLE
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) — If Equipped
1. Remove the two screws and housing and access the bulb sockets from the rear.
MAINTAINING YOUR VEHICLE 505
506 MAINTAINING YOUR VEHICLE
2. Turn socket 1⁄4 turn counterclockwise to access the bulb.
Rear Light Bar ID Marker (Dual Rear Wheel) — If Equipped
1. Loosen the two screws and the housing to gain access to the bulb sockets.
3. Pull bulb straight out from socket. 4. Reverse procedure for installation of bulbs and hous- ing.
2. Turn the socket 1⁄4 turn counterclockwise to access the bulb.
3. Pull the bulb straight out from the socket. 4. Reverse procedure for installation of bulbs and hous- ing. Side Marker Lights (Dual Rear Wheels)
MAINTAINING YOUR VEHICLE 507
2. Pull the entire assembly from the fender. 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.
508 MAINTAINING YOUR VEHICLE
FLUIDS AND CAPACITIES
Fuel (Approximate)
1500 Shortbed Models 1500 Longbed Models 1500 Shortbed Models 2500 Shortbed Models 2500 Longbed Models 3500 Shortbed Models 3500 Longbed Models
U.S.
26 gal 35 gal 34 gal 34 gal 35 gal 34 gal 35 gal
Metric
98 L 132 L 128 L 128 L 132 L 128 L 132 L
Engine Oil (with filter)
3.7L Engine V-6 (SAE 5W-20, API Certified) 4.7L Engine V-8 (SAE 5W-20, API Certified)
5.7L Engine V-8 (SAE 5W-20, API Certified). For trucks operat- ing under a gross combined weight rating less than 14,000 lbs.
5.7L Engine V-8 (SAE 5W-30, API Certified). For 2500/3500
trucks operating under a gross combined weight rating greater
than 14,000 lbs.
Cooling System 3.7L (Mopart Antifreeze/Coolant 5 Year/100,000 Mile Formula)
or equivalent.
4.7L (Mopart Antifreeze/Coolant 5 Year/100,000 Mile Formula)
or equivalent.
5.7L (Mopart Antifreeze/Coolant 5 Year/100,000 Mile Formula)
or equivalent.
MAINTAINING YOUR VEHICLE 509
U.S.
5.0 qts 6.0 qts
7.0 qts
7.0 qts
17 qts
17 qts
18.7 qts
Metric
4.7 L 5.7 L
6.6 L
6.6 L
16 L
16 L
17.7 L
510 MAINTAINING YOUR VEHICLE
FLUIDS, LUBRICANTS AND GENUINE PARTS Engine Component Engine Coolant
Engine Oil (3.7/4.7L Engine) 5.7L Engine Oil (For trucks operat- ing under a gross combined weight rating less than 14,000 lbs/ (6,350 kg.) 5.7L Engine Oil (For 2500/3500
trucks operating under a gross combined weight rating greater than 14,000 lbs/(6,350 kg.) Engine Oil Filter (3.7L Engine)Fluids, Lubricants and Genuine Parts Mopart Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Or- ganic Additive Technology). Use SAE 5W-20, API Certified, meeting material standard MS-6395. Use SAE 5W-20, API Certified, meeting material standard MS-6395.
Use SAE 5W-30, API Certified, meeting material standard MS-6395.
Mopart Engine Oil Filter, P/N 4781452BB or equivalent.
Fluids, Lubricants and Genuine Parts Mopart Engine Oil Filter, P/N 4884899AB or equivalent.
MAINTAINING YOUR VEHICLE 511
Component Engine Oil Filter (4.7L & 5.7L En- gine) Spark Plugs (5.7L Engine) Spark Plugs (4.7L Engine)
REC14MCC4 (Gap 0.043 in [1.09 mm]) Upper Bank — FR8TE2 (Gap 0.039 in [.99 mm]) Lower Bank — FR8T1332
(Gap 0.051 in [1.30 mm]) ZFR6F-11G (Gap 0.043 in [1.09 mm]) 87 Octane 87 Octane Acceptable - 89 Octane RecommendedSpark Plugs (3.7L Engine) Fuel Selection (3.7L/4.7L Engine) Fuel Selection (5.7L Engine) Chassis Component Automatic Transmission Transfer Case NVG 246 Automatic Transfer Case Only Manual Transmission Fluid (G238) Mopart ATF+4, Automatic Transmission Fluid. Mopart ATF+4, Automatic Transmission Fluid. Manual Transmission Fluid (G-56)
Fluids, Lubricants and Genuine Parts. Mopart ATF+4, Automatic Transmission Fluid. Mopart ATF+4, Automatic Transmission Fluid. Mopart PN 05179014AA, NVG 246 Automatic Transmission Fluid or equivalent.
512 MAINTAINING YOUR VEHICLE
Component Clutch Linkage 1500 Model Front Axle (4X4) 1500 Model Rear Axle
2500/3500 Model Front and Rear Axle Brake Master Cylinder
Power Steering Reservoir
Fluids, Lubricants and Genuine Parts. Multipurpose Grease, NLGI Grade 2 E.P. or equivalent. GL-5 SAE 75W-90 (MS-9763) or equivalent. 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 or equivalent. Synthetic, GL-5 SAE, 75W-90 or equivalent. Limited-Slip 10.5/11.5 inch Rear Axles Limited slip additive is not required. Mopart DOT 3 and SAE J1703 should be used or equivalent. If DOT 3
brake fluid is not available, then DOT 4 is acceptable. Use only recom- mended brake fluids. Mopart ATF+4, Automatic Transmission Fluid.MAINTENANCE SCHEDULES
CONTENTS
m Emission Control System Maintenance . . . . . . . . 514
m Maintenance Schedule . . . . . . . . . . . . . . . . . . . 514N Required Maintenance Intervals . . . . . . . . . . . 516
M
514 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 func- tioning 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 anytime 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 SCHEDULE The oil change indicator system will remind you that it is time to take your vehicle in for scheduled maintenance. The “Change Oil” message will flash in the instrument cluster odometer and a single chime will sound, indicat- ing that an oil change is necessary. Based on engine operation conditions the oil change indicator message will illuminate, this means that service is required for your vehicle. Have your vehicle serviced as soon as possible, within the next 500 miles (805 km). NOTE: † The oil change indicator message will not monitor the time since the last oil change. Change your vehicles oil if it has been 6 months since your last oil change even if the oil change indicator message is NOT illumi- nated.
vehicle off-road for an extended period of time.
† Change your engine oil more often if you drive your † Under no circumstances should oil change intervals exceed 6,000 miles (10,000 km) or 6 months, whichever comes first.
Your dealer will reset the oil change indicator message after completing the scheduled oil change. If this sched- uled oil change is performed by someone other than your dealer the message can be reset by referring to the steps described under “Odometer/Trip Odometer” under “In- strument Cluster Description” in Section 4 of this manual. 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
MAINTENANCE SCHEDULES 515
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 reservoir, brake master cylinder, power steering and transmission and add as needed. † Check all lights and other electrical items for correct
as required.
operation.
516 MAINTENANCE SCHEDULES
At Each Oil Change † Change the engine oil filter. † Inspect the brake hoses and lines. † Check the Manual Transmission fluid level.
CAUTION!
Failure to perform the required maintenance items may result in damage to the vehicle.
Required Maintenance Intervals
** Vehicles built with the 4.7L engine are NOTE: equipped with sixteen spark plugs, one set is located on the top of the engine under the coils and the second set is located on the side of the engine. The spark plugs located under the coils are a standard plug and must be changed every 30,000 miles (50 000 km) The spark plugs located on the side of the engine are a premium plug and must be changed every 102,000 miles (170 000 km).
Maintenance Items Change the engine oil and engine oil filter. Rotate Tires. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Lube Front Drive Shaft Fitting (2500/3500, 4x4 only). If using your vehicle for any of the following: Dusty or off-road conditions. Inspect the engine air cleaner filter, replace if necessary. Inspect the brake linings, replace if necessary. Inspect the front & rear axle fluid, change if using your vehicle for police, taxi, fleet, off-road or frequent trailer towing. Inspect the CV Joints. Perform the first inspection at 12,000 miles (20 000 km) or 12 months.
MAINTENANCE SCHEDULES 517
Perform Maintenance Every (Where time and mileage
are listed, follow the interval that occurs first.) Miles 6,000
6,00010 000
10 000Kilometers
or Months
6,000
6,000
12,000
12,000
18,000
24,000
10 000
10 000
20 000
20 000
30 000
40 000
12
12
18
24
M
518 MAINTENANCE SCHEDULES
Maintenance Items Inspect Exhaust System. Perform the first inspection at 12,000 miles (20 000 km) or 12 months. Inspect the front suspension, tie rod ends and boot seals, replace if necessary. Replace the engine air cleaner filter. Inspect the transfer case fluid. Replace the top row of spark plugs on 4.7L engines. ** Replace the spark plugs on 3.7L and 5.7L engines. Change the automatic transmission fluid & filter if using your vehicle for any of the following: police, taxi, fleet or frequent trailer towing. Change the transfer case fluid if using your vehicle for any of the following: police, taxi, fleet, off-road or fre- quent trailer towing.
Perform Maintenance Every (Where time and mileage
are listed, follow the interval that occurs first.) Miles
Kilometers
or Months
24,000
24,000
30,000
30,000
30,000
30,00060,000
60,000
40 000
40 000
50 000
50 000
50 000
50 000100 000
100 000
24
24
30
30
30
3060
60
MAINTENANCE SCHEDULES 519
Perform Maintenance Every (Where time and mileage
are listed, follow the interval that occurs first.) Miles
Kilometers
or Months
60,000
100 000
90,000
102,000
102,000
102,000
120,000
120,000150 000
170 000
170 000
170 000
200 000
200 00060
90
60
102
102
120
120Maintenance Items Change the manual transmission fluid if using your vehicle for any of the following: trailer towing, snow plowing, heavy loading, taxi, police, delivery service (commercial service), off-road, desert operation or more then 50% of your driving is at sustained high speeds during hot weather, above 90F° (32C°). Inspect and replace PCV valve if necessary. † Flush and replace the engine coolant. Replace the ignition cables on 4.7L engines. Replace the side row of spark plugs on 4.7L engines. ** Change the automatic transmission fluid & filter. Replace Accessory Drive Belt(s). † This maintenance is recommended by the manufacturer to the owner, but is not required to maintain emissions warranty.
520 MAINTENANCE SCHEDULES
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.
IF YOU NEED CONSUMER ASSISTANCE
CONTENTS
m Suggestions For Obtaining Service For Your
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523
N Prepare For The Appointment . . . . . . . . . . . . 523
N Prepare A List . . . . . . . . . . . . . . . . . . . . . . . . 523
N Be Reasonable With Requests . . . . . . . . . . . . . 523
m If You Need Assistance . . . . . . . . . . . . . . . . . . . 523
N Chrysler LLC Customer Center . . . . . . . . . . . 524
N Chrysler Canada Inc. Customer Center . . . . . . 525
N In Mexico Contact . . . . . . . . . . . . . . . . . . . . . 525N Customer Assistance For The Hearing Or
N Service Contract
Speech Impaired (TDD/TTY) . . . . . . . . . . . . . 525
. . . . . . . . . . . . . . . . . . . . . . 525
m Warranty Information (U.S. Vehicles Only) . . . . . 526
m MOPARtParts . . . . . . . . . . . . . . . . . . . . . . . . . 526
m Reporting Safety Defects . . . . . . . . . . . . . . . . . . 526N In The 50 United States And
Washington, D.C.
. . . . . . . . . . . . . . . . . . . . . 526
N In Canada . . . . . . . . . . . . . . . . . . . . . . . . . . 527
m Publication Order Forms . . . . . . . . . . . . . . . . . . 527522 IF YOU NEED CONSUMER ASSISTANCE
m Department Of Transportation Uniform Tire
Quality Grades . . . . . . . . . . . . . . . . . . . . . . . . 528
N Treadwear . . . . . . . . . . . . . . . . . . . . . . . . . . 529N Traction Grades . . . . . . . . . . . . . . . . . . . . . . 529
N Temperature Grades . . . . . . . . . . . . . . . . . . . 529SUGGESTIONS FOR OBTAINING SERVICE FOR YOUR VEHICLE
Prepare For The Appointment If you’re having warranty work done, be sure to have the right papers with you. Take your warranty folder. All work to be performed may not be covered by the warranty. Discuss additional charges with the service manager. Keep a maintenance log of your vehicle’s service history. This can often provide a clue to the current problem. Prepare A List Make a written list of your vehicle’s problems or the specific work you want done. If you’ve had an accident or work done that is not on your maintenance log, let the service advisor know.
IF YOU NEED CONSUMER ASSISTANCE 523
Be Reasonable With Requests If you list a number of items and you must have your vehicle by the end of the day, discuss the situation with the service advisor and list the items in order of priority. At many authorized dealers, you may obtain a rental vehicle at a minimal daily charge. If you need a rental, it is advisable to make these arrangements when you call for an appointment.
IF YOU NEED ASSISTANCE The manufacturer and its authorized dealers are vitally interested in your satisfaction. We want you to be happy with our products and services. Warranty service must be done by an authorized dealer. We strongly recommend that you take the vehicle to an authorized selling dealer. They know you and the vehicle best, and are most concerned that you get prompt and
524 IF YOU NEED CONSUMER ASSISTANCE
high quality service. The manufacturer’s authorized deal- ers have the facilities, factory-trained technicians, special tools, and the latest information to ensure the vehicle is fixed correctly and in a timely manner. This is why you should always talk to an authorized dealer’s service manager first. Most matters can be re- solved with this process. † If for some reason you are still not satisfied, talk to the general manager or owner of the authorized dealer- ship. They want to know if you need assistance. † If an authorized dealership is unable to resolve the concern, you may contact the Manufacturer’s Cus- tomer Center.
Any communication to the Manufacturer’s Customer Center should include the following information: † Owner’s name and address † Owner’s telephone number (home and office) † Authorized dealership name † Vehicle Identification Number (VIN) † Vehicle delivery date and mileage Chrysler LLC Customer Center P.O. Box 21–8004
Auburn Hills, MI 48321–8004
Phone: (800) 992-1997Chrysler Canada Inc. Customer Center P.O. Box 1621
Windsor, Ontario N9A 4H6
Phone: (800) 465–2001
In Mexico contact: Av. Prolongacion Paseo de la Reforma, 1240
Sante Fe C.P. 05109
Mexico, D. F. In Mexico City: 5081-4568
Outside Mexico City: 1-800-505-1300
Customer Assistance For The Hearing Or Speech Impaired (TDD/TTY) To assist customers who have hearing difficulties, the manufacturer has installed special TDD (Telecommuni- cation Devices for the Deaf) equipment at its Customer Center. Any hearing or speech impaired customer, who has access to a TDD or a conventional teletypewriter (TTY) in the United States, can communicate with the manufacturer by dialing 1–800–380–CHRY.IF YOU NEED CONSUMER ASSISTANCE 525
Service Contract You may have purchased a service contract for an vehicle to help protect you from the high cost of unexpected repairs after the manufacturer’s New Vehicle Limited Warranty expires. The manufacturer stands behind only the manufac- turer’s Service Contracts. If you purchased a manufacturer’s Service Contract, you will receive Plan Provisions and an Owner Identification Card in the mail within three weeks of the vehicle delivery date. If you have any questions about the service contract, call the manufacturer’s Service Contract National Customer Hotline at 1-800-521-9922. The manufacturer will not stand behind any service contract that is not the manufacturer’s Service Contract. It is not responsible for any service contract other than the manufac- turer’s Service Contract. If you purchased a service contract that is not a manufacturer’s Service Contract, and you require service after the manufacturer’s New Vehicle Lim- ited Warranty expires, please refer to the contract docu- ments, and contact the person listed in those documents.
526 IF YOU NEED CONSUMER ASSISTANCE
We appreciate that you have made a major investment when you purchased the vehicle. An authorized dealer has also made a major investment in facilities, tools, and training to assure that you are absolutely delighted with the ownership experience. You’ll be pleased with their sincere efforts to resolve any warranty issues or related concerns.
WARNING!
Engine exhaust, some of its constituents, and certain vehicle components contain, or emit, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids contained in vehicles and certain prod- ucts of component wear contain, or emit, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
WARRANTY INFORMATION (U.S. Vehicles Only) See the Warranty Information Booklet for the terms and provisions of Chrysler LLC warranties applicable to this vehicle.
MOPART PARTS Mopart fluids, lubricants, parts, and accessories are available from an authorized dealer. They will help keep the vehicle operating at its best.
REPORTING SAFETY DEFECTS
In The 50 United States And Washington, D.C. If you believe that your vehicle has a defect that could cause a crash or cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying the manufacturer. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in
a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your authorized dealer, and the manufacturer. To contact NHTSA, you may either call the Auto Safety Hotline toll free at 1–888–327–4236 (TTY: 1–800–424– 9153), or go to http://www.safercar.gov; or write to: Administra- tor, NHTSA, 400 Seventh Street, SW., Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from http://www.safercar.gov. In Canada If you believe that your vehicle has a safety defect, you should contact the Customer Service Department imme- diately. Canadian customers who wish to report a safety defect to the Canadian government should write to: Transport Canada, Motor Vehicle Defect Investigations and Recalls, 2780 Sheffield Road, Ottawa, Ontario K1B 3V9.
IF YOU NEED CONSUMER ASSISTANCE 527
PUBLICATION ORDER FORMS To order the following manuals, you may use either the website or the phone numbers listed below. Visa, Mas- tercard, American Express, and Discover orders are ac- cepted. If you prefer mailing your payment, please call for an order form. NOTE: A street address is required when ordering manuals (no P.O. Boxes). † Service Manuals
These comprehensive Service Manuals provide the information that students and professional technicians need in diagnosing/troubleshooting, problem solving, maintaining, servicing, and repairing Chrysler LLC vehicles. A complete working knowledge of the ve- hicle, system, and/or components is written in straightforward language with illustrations, diagrams, and charts.
528 IF YOU NEED CONSUMER ASSISTANCE
† Diagnostic Procedure Manuals
