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4. Place the jack and tools in the storage position holding the jack by the jack turn-screw, slip the jack and tools under the seat so that the bottom slot engages into the fastener on the floor, and then secure to the floor pan using the wing bolt. Reinstall the plastic cover.


590 WHAT TO DO IN EMERGENCIES


Jack And Tools (2500/3500 Series)


Removing The Spare Tire Remove the spare tire before attempting to jack up the truck. Attach the wheel wrench to the jack extension tube. Insert the tube through the access hole between the lower tailgate and the top of the bumper and into the winch mechanism tube. Rotate the wheel wrench handle coun- terclockwise until the spare tire is on the ground with enough cable slack to allow you to pull it out from under the vehicle. When the spare is clear, tilt the retainer at the end of the cable and pull it through the center of the wheel. NOTE: Always stow the spare tire with the valve stem facing the ground.


WHAT TO DO IN EMERGENCIES 591
NOTE: The winch mechanism is designed for use with the jack extension tube only. Use of an air wrench or other power tools is not recommended and can damage the winch. Preparations


1. Park the vehicle on a firm, level surface. Avoid ice or slippery areas.


WARNING!


Do not attempt to change a tire on the side of the vehicle close to moving traffic, pull far enough off the road to avoid the danger of being hit when operating the jack or changing the wheel.


2. Turn on the Hazard Warning flasher. 3. Set the parking brake.


Removing The Spare Tire


1 — Wheel Wrench 2 — Spare Tire It is recommended that you stow the flat or spare to avoid tangling the loose cable.


592 WHAT TO DO IN EMERGENCIES 4. Place the shift lever into PARK. On four-wheel drive vehicles, shift the transfer case to the 4L position. 5. Turn the ignition OFF.


Instructions


WARNING!


6. Block both the front and rear of the wheel diagonally opposite the jacking position. For example, if the right front wheel is being changed, block the left rear wheel.


NOTE: Passengers should not remain in the vehicle when the vehicle is being jacked.


Carefully follow these tire changing warnings to help prevent personal injury or damage to your vehicle: • Always park on a firm, level surface as far from the edge of the roadway as possible before raising the vehicle.


• Turn on the Hazard Warning flasher. • Block the wheel diagonally opposite the wheel to • Set the parking brake firmly and set an automatic transmission in PARK; a manual transmission in REVERSE. • Never start or run the engine with the vehicle on a


be raised.


jack.


(Continued)


WARNING! (Continued)


jack.


• Do not let anyone sit in the vehicle when it is on a • Do not get under the vehicle when it is on a jack. • Only use the jack in the positions indicated and • If working on or near a roadway, be extremely • To assure that spare tires, flat or inflated, are securely stowed, spares must be stowed with the valve stem facing the ground.


for lifting this vehicle during a tire change.


careful of motor traffic.


WHAT TO DO IN EMERGENCIES 593


CAUTION!


Do not attempt to raise the vehicle by jacking on locations other than those indicated in the Jacking Instructions for this vehicle.


1. Remove the spare wheel, jack, and tools from storage. 2. Using the wheel wrench, loosen, but do not remove, the wheel nuts by turning them counterclockwise one turn while the wheel is still on the ground. 3. Placement of the jack:


Jack Warning Label


594 WHAT TO DO IN EMERGENCIES


• 1500 Series Trucks When changing a front wheel, place the scissors jack under the rear portion of the lower control arm as shown below.


4X4 Jacking Location


Operate the jack using the jack drive tube and the wheel wrench. The tube extension may be used but is not required.


4X2 Jacking Location


For 4x2 and 4x4 trucks, when changing a rear wheel, assemble the jack drive tube to the jack and connect the drive tube to the extension tube. Place the jack under the axle between the wheel and the shock bracket with the drive tubes extending to the rear.


Connect the jack tube extension and wheel wrench.


WHAT TO DO IN EMERGENCIES 595


CAUTION!


Before raising the wheel off the ground, make sure that the jack will not damage surrounding truck parts and adjust the jack position as required.


Rear Jacking Location


596 WHAT TO DO IN EMERGENCIES


• 2500/3500 Series Trucks For 2500/3500 4x2 series trucks, when changing a front wheel, place the bottle jack under the frame rail behind the wheel. Locate the jack as far forward as possible on the straight part of the frame.


Operate the jack using the jack drive tube and the wheel wrench. The tube extension, may be used, but is not required. For 2500/3500 4x4 series trucks, when changing the front wheel, assemble the jack drive tube to the jack and connect the drive tube to the extension tube. Place the jack under the axle as close to the tire as possible with the drive tubes extending to the front. Connect the jack tube extension and wheel wrench.


4x2 Jacking Location


WHAT TO DO IN EMERGENCIES 597


4x4 Jacking Location


For 4x2 and 4x4 trucks, when changing a rear wheel, assemble the jack drive tube to the jack and connect the drive tube to the extension tube. Place the jack under the axle between the spring and the shock absorber with the drive tubes extending to the rear.


Rear Jacking Location (All)


Connect the jack tube extension and wheel wrench.


598 WHAT TO DO IN EMERGENCIES


CAUTION!


Before raising the wheel off the ground, make sure that the jack will not damage surrounding truck parts and adjust the jack position as required.


If the bottle jack will not lower by turning the NOTE: dial (thumbwheel) by hand, it may be necessary to use the jack drive tube in order to lower the jack. 4. By rotating the wheel wrench clockwise, raise the vehicle until the wheel just clears the surface.


WARNING!


Raising the vehicle higher than necessary can make the vehicle unstable and cause a collision. It could slip off the jack and hurt someone near it. Raise the vehicle only enough to remove the tire.


5. Remove the wheel nuts and pull the wheel off. On single rear-wheel (SRW) trucks, install the spare wheel and wheel nuts with the cone shaped end of the wheel nuts toward the wheel. On 3500 dual rear-wheel models (DRW) the wheel nuts are a two-piece assembly with a flat face. Lightly tighten the wheel nuts. To avoid the risk of forcing the vehicle off the jack, do not fully tighten the wheel nuts until the vehicle has been lowered. 6. Using the wheel wrench, finish tightening the wheel nuts using a crisscross pattern. The correct wheel nut tightness is 130 ft lbs (177 N·m) torque (1500 Series), 135 ft lbs (183 N·m) torque for 2500/3500 single-rear wheel (SRW) models, and 145 ft lbs (197 N·m) for 3500 dual rear-wheel models. If in doubt about the correct tight- ness, have them checked with a torque wrench by your authorized dealer or at a service station.


WARNING!


A loose tire or jack thrown forward in a collision or hard stop could injure someone in the vehicle. Al- ways stow the jack parts and the extra tire and wheel in the places provided.


7. Install the wheel center cap and remove the wheel blocks. Do not install chrome or aluminum wheel center caps on the spare wheel. This may result in cap damage. 8. Lower the jack to its fully closed position. If the bottle jack will not lower by turning the dial (thumbwheel) by hand, it may be necessary to use the jack drive tube in order to lower the jack. Stow the replaced tire, jack, and tools as previously described. 9. Adjust the tire pressure when possible. NOTE: Do not oil wheel studs. For chrome wheels, do not substitute with chrome plated wheel nuts.


WHAT TO DO IN EMERGENCIES 599


Hub Caps/Wheel Covers — If Equipped The hub caps must be removed before raising the vehicle off the ground. For 2500/3500 single rear-wheel (SRW) models, use the blade on the end of the lug wrench to pry the hub cap off. Insert the blade end into the pry-off notch and carefully pop off the hub cap with a back-and-forth motion. On 3500 models with dual rear wheels (DRW), you must first remove the hub caps. The jack handle driver has a hook at one end that will fit in the pry off notch of the rear hub caps. Position the hook and pull out on the ratchet firmly. The hub cap should pop off. The wheel skins can now be removed. For the front hub cap on 3500
models use the blade on the end of the lug wrench to pry the caps off. The wheel skin can now be removed.


600 WHAT TO DO IN EMERGENCIES


CAUTION!


• Use a back-and-forth motion to remove the hub cap. Do not use a twisting motion when removing the hub cap, damage to the hub cap finish may occur. • The rear hub caps on the dual rear wheel has two pry-off notches. Make sure that the hook of the jack handle driver is located squarely in the cap notch before attempting to pull off.


You must use the flat end of the lug wrench to pry off the wheel skins. Insert the flat tip completely and using a back-and-forth motion, loosen the wheel skin. Repeat this procedure around the tire until the skin pops off. Replace the wheel skins first using a rubber mallet. When replacing the hub caps, tilt the cap retainer over the lug


nut bolt circle and strike the high side down with a rubber mallet. Be sure that the hub caps and wheel skins are firmly seated around the wheel. Wheel Nuts All wheel nuts should be tightened occasionally to elimi- nate the possibility of wheel studs being sheared or the bolt holes in the wheels becoming elongated. This is especially important during the first few hundred miles/ kilometers of operation to allow the wheel nuts to become properly set. All wheel nuts should first be firmly seated against the wheel. The wheel nuts should then be tightened to recommended torque. Tighten the wheel nuts to final torque in increments. Progress around the bolt circle, tightening the wheel nut opposite to the wheel nut torque is achieved. Recommended torques are shown in the fol- lowing chart.


just previously tightened until


final


Disc Wheels


TypeNut


StudSize M14 x 1.5
M14 x 1.5


Cone Flanged 8-Stud — Dual Rear Wheels Dual wheels are flat-mounted and center-piloted. The lug nuts are a two-piece assembly. When the tires are being rotated or replaced, clean these lug nuts and add two drops of oil at the interface between the hex and the washer.


WHAT TO DO IN EMERGENCIES 601


Hex Size 22 mm 22 mm


TorqueFt Lbs


TorqueNewtonMeters


120-150
130-160


160-200
190-220


Oiling Location


602 WHAT TO DO IN EMERGENCIES Slots in the wheels will assist in properly orienting the inner and outer wheels. Align these slots when assem- bling the wheels for best access to the tire valve on the inner wheel. The tires of both dual wheels must be completely off the ground when tightening, to ensure wheel centering and maximum wheel clamping. Dual wheel models require a special heavy-duty lug nut tightening adapter (included with the vehicle) to cor- rectly tighten the lug nuts. Also, when it is necessary to remove and install dual rear wheels, use a proper vehicle lifting device. NOTE: When installing a spare tire as part of a dual rear wheel end combination, the tire diameter of the two individual tires must be compared. If there is a significant difference, the larger tire should be installed in a front location. The correct direction of rotation for dual tire installations must also be observed.


These dual rear wheels should be tightened as follows:


Tightening Pattern


1. Tighten the wheel nuts in the numbered sequence to a snug fit.


2. Retighten the wheel nuts in the same sequence to the torques listed in the table. Go through the sequence a second time to verify that specific torque has been achieved. Retighten to specifications at 100 miles (160 km) and after 500 miles (800 km). It is recommended that wheel stud nuts be kept torqued to specifications at all times. Torque wheel stud nuts to specifications at each lubrication interval. To Stow The Flat Or Spare


NOTE: Vehicles equipped with aluminum wheels can- not be stored under the vehicle because the wheel retainer will not fit through the wheel pilot hole. Secure the flat tire in the bed of the truck. Have the flat tire repaired or replaced immediately.


WHAT TO DO IN EMERGENCIES 603


WARNING!


A loose tire thrown forward in a collision or hard stop could injure the occupants in the vehicle. Have the deflated (flat) tire repaired or replaced immedi- ately.


Turn the wheel so that the valve stem is down. Slide the wheel retainer through the center of the wheel and position it properly across the wheel opening. For convenience in checking the spare tire inflation, stow with the valve stem toward the rear of the vehicle. Attach the wheel wrench to the extension tube. Rotate the winch mechanism until the wheel is drawn into place against the underside of the vehicle. Continue to rotate until you feel the winch mechanism slip, or click three or four times. It cannot be overtightened. Push against the tire several times to be sure it is firmly in place.


604 WHAT TO DO IN EMERGENCIES HOISTING A conventional floor jack may be used at the jacking locations. Refer to the graphics that show jacking loca- tions. However, a floor jack or frame hoist must never be used on any other parts of the underbody.


CAUTION!


Never use a floor jack directly under the differential housing of a loaded truck or damage to your vehicle may result.


JUMP-STARTING PROCEDURES If your vehicle has a discharged battery it can be jump- started using a set of jumper cables and a battery in another vehicle or by using a portable battery booster pack. Jump-starting can be dangerous if done improperly so please follow the procedures in this section carefully.


NOTE: When using a portable battery booster pack follow the manufacturer’s operating instructions and precautions.


CAUTION!


Do not use a portable battery booster pack or any other booster source with a system voltage greater than 12 Volts or damage to the battery, starter motor, alternator or electrical system may occur.


WARNING!


Do not attempt jump-starting if the battery is frozen. It could rupture or explode and cause personal injury.


Preparations For Jump-Start The battery in your vehicle is located in the front of the engine compartment, behind the left headlight assembly. NOTE: The positive battery post is covered with a protective cap. Lift up on the cap to gain access to the positive battery post.


Positive Battery Post


WHAT TO DO IN EMERGENCIES 605


WARNING!


• Take care to avoid the radiator cooling fan when- ever the hood is raised. It can start anytime the ignition switch is on. You can be injured by moving fan blades. • Remove any metal jewelry such as watch bands or bracelets that might make an inadvertent electrical contact. You could be seriously injured. • Batteries contain sulfuric acid that can burn your skin or eyes and generate hydrogen gas which is flammable and explosive. Keep open flames or sparks away from the battery.


1. Set the parking brake, shift the automatic transmission into PARK and turn the ignition to LOCK. 2. Turn off the heater, radio, and all unnecessary electri- cal accessories.


606 WHAT TO DO IN EMERGENCIES 3. If using another vehicle to jump-start the battery, park the vehicle within the jumper cables reach, set the parking brake and make sure the ignition is OFF.


WARNING!


Do not allow vehicles to touch each other as this could establish a ground connection and personal injury could result.


Jump-Starting Procedure


WARNING!


Failure to follow this procedure could result in per- sonal injury or property damage due to battery ex- plosion.


CAUTION!


Failure to follow these procedures could result in damage to the charging system of the booster vehicle or the discharged vehicle.


1. Connect the positive (+) end of the jumper cable to the positive (+) post of the discharged vehicle. 2. Connect the opposite end of the positive (+) jumper cable to the positive (+) post of the booster battery. 3. Connect the negative end (-) of the jumper cable to the negative (-) post of the booster battery. 4. Connect the opposite end of the negative (-) jumper cable to a good engine ground (exposed metal part of the discharged vehicle’s engine) away from the battery and the fuel injection system.


WARNING!


Do not connect the cable to the negative post (-) of the discharged battery. The resulting electrical spark could cause the battery to explode and could result in personal injury.


5. Start the engine in the vehicle that has the booster battery, let the engine idle a few minutes, and then start the engine in the vehicle with the discharged battery. Once the engine is started, remove the jumper cables in the reverse sequence: 6. Disconnect the negative (-) jumper cable from the engine ground of the vehicle with the discharged battery. 7. Disconnect the negative end (-) of the jumper cable from the negative (-) post of the booster battery.


WHAT TO DO IN EMERGENCIES 607
8. Disconnect the opposite end of the positive (+) jumper cable from the positive (+) post of the booster battery. 9. Disconnect the positive (+) end of the jumper cable from the positive (+) post of the discharged vehicle. If frequent jump-starting is required to start your vehicle you should have the battery and charging system in- spected at your authorized dealer.


CAUTION!


Accessories that can be plugged into the vehicle power outlets draw power from the vehicle’s battery, even when not in use (i.e., cellular phones, etc.). Eventually, if plugged in long enough, the vehicle’s battery will discharge sufficiently to degrade battery life and/or prevent the engine from starting.


608 WHAT TO DO IN EMERGENCIES FREEING A STUCK VEHICLE If the vehicle becomes stuck in snow, sand or mud, it can often be moved by a rocking motion. Move the shift lever rhythmically between DRIVE and REVERSE while ap- plying slight pressure to the accelerator. In general, the least amount of accelerator pedal pressure to maintain the rocking motion without spinning the wheels or racing the engine is most effective.


CAUTION!


Racing the engine or spinning the wheels may lead to transmission overheating and failure. Allow the en- gine to idle with the shift lever in NEUTRAL for at least one minute after every five rocking-motion cycles. This will minimize overheating and reduce the risk of transmission failure during prolonged efforts to free a stuck vehicle.


CAUTION!


• When “rocking” a stuck vehicle by moving be- tween DRIVE and REVERSE, do not spin the wheels faster than 15 mph (24 km/h), or drivetrain damage may result. • Revving the engine or spinning the wheels too fast may lead to transmission overheating and failure. It can also damage the tires. Do not spin the wheels above 30 mph (48 km/h) while in gear (no transmission shifting occurring).


WARNING!


Fast spinning tires can be dangerous. Forces gener- ated by excessive wheel speeds may cause damage, or even failure, of the axle and tires. A tire could explode and injure someone. Do not spin your vehi- cle’s wheels faster than 30 mph (48 km/h) or for longer than 30 seconds continuously without stop- ping when you are stuck and do not let anyone near a spinning wheel, no matter what the speed.


EMERGENCY TOW HOOKS — IF EQUIPPED Your vehicle may be equipped with emergency tow hooks. NOTE: For off-road recovery, it is recommended to use both of the front tow hooks to minimize the risk of damage to the vehicle.


WHAT TO DO IN EMERGENCIES 609


WARNING!


• Chains are not recommended for freeing a stuck vehicle. Chains may break, causing serious injury or death. • Stand clear of vehicles when pulling with tow hooks. Tow straps may become disengaged, caus- ing serious injury.


CAUTION!


Tow hooks are for emergency use only to rescue a vehicle stranded off-road. Do not use tow hooks for tow truck hookup or highway towing. You could damage your vehicle.


610 WHAT TO DO IN EMERGENCIES SHIFT LEVER OVERRIDE If a malfunction occurs and the shift lever cannot be moved out of the PARK position, you can use one of the following procedures to temporarily move the shift lever: Column Shifter — If Equipped


1. Firmly set the parking brake. 2. Turn the ignition switch to the ON/RUN position without starting the engine. 3. Tilt the steering wheel to the full up position 4. Press and maintain firm pressure on the brake pedal. 5. Using a screwdriver or similar tool, press and hold the override tab through the access port (ringed circle) on the bottom of the steering column.


Shift Lever Override Access Port


6. Move the shift lever into the NEUTRAL position. 7. The vehicle may then be started in NEUTRAL.


Center Console Shifter — If Equipped To access the override, carefully remove (using a flat- bladed screwdriver) the override access cover which is located on the right of the shift lever gate. 1. Firmly set the parking brake. 2. Turn the ignition switch to the ON/RUN position without starting the engine. 3. Press and maintain firm pressure on the brake pedal. 4. Using a screwdriver or similar tool, press and hold the override tab through the access port on the center con- sole.


WHAT TO DO IN EMERGENCIES 611


Shift Lever Override Access Cover


5. Move the shift lever into the NEUTRAL position. 6. The vehicle may then be started in NEUTRAL. 7. Reinstall the shift lever override access cover.


612 WHAT TO DO IN EMERGENCIES TOWING A DISABLED VEHICLE This section describes procedures for towing a disabled vehicle using a commercial wrecker service. If the transmission and drivetrain are operable, disabled vehicles may also be towed as described under “Recreational Towing” in the “Starting and Operating” section.


Towing Condition


Wheels OFF the Ground


Flat Tow


NONE


Wheel Lift or


Dolly Tow


Flatbed


Front Rear ALL


2WD Models


4WD Models


If transmission is operable: • Transmission in NEUTRAL • 30 mph (48 km/h)max speed • 15 miles (24 km) max distance


See instructions in “Recreational Towing” under “Starting and Operating” • Transmission in PARK • Transfer Case in NEUTRAL • Tow in forward direction


OK


BEST METHOD


NOT ALLOWED NOT ALLOWED BEST METHOD


Proper towing or lifting equipment is required to prevent damage to your vehicle. Use only tow bars and other equipment designed for the purpose, following equip- ment manufacturer’s instructions. Use of safety chains is mandatory. Attach a tow bar or other towing device to main structural members of the vehicle, not to bumpers or associated brackets. State and local laws applying to vehicles under tow must be observed. If you must use the accessories (wipers, defrosters, etc.) while being towed, the ignition must be in the ON/RUN position, not the ACC position.


WHAT TO DO IN EMERGENCIES 613
If the vehicle’s battery is discharged, see “Shift Lever Override” in “What To Do In Emergencies” for instruc- tions on shifting the automatic transmission out of the PARK position for towing.


CAUTION!


Do not attempt to use sling type equipment when towing. When securing the vehicle to a flat bed truck, do not attach to front or rear suspension components. Damage to your vehicle may result from improper towing.


614 WHAT TO DO IN EMERGENCIES Towing Without The Ignition Key Fob Special care must be taken when the vehicle is towed with the ignition in the LOCK/OFF position. The only approved method of towing without the ignition key is with a flatbed truck. Proper towing equipment is neces- sary to prevent damage to the vehicle. Two-Wheel Drive Models The manufacturer recommends towing your vehicle with all four wheels OFF the ground using a flatbed. If flatbed equipment is not available, and the transmis- sion is operable, the vehicle may be towed (with rear wheels on the ground) with the transmission in NEU- TRAL. Speed must not exceed 30 mph (48 km/h) and the distance must not exceed 15 miles (24 km).


CAUTION!


Towing faster than 30 mph (48 km/h) or farther than 15 miles (24 km) with rear wheels on the ground can cause severe damage to the transmission. Such dam- age is not covered by the New Vehicle Limited Warranty.


If the transmission is not operable, or the vehicle must be towed faster than 30 mph (48 km/h) or farther than 15 miles (24 km), tow with the rear wheels OFF the ground. Acceptable methods are to tow the vehicle on a flatbed, or with the front wheels raised and the rear wheels on a towing dolly, or (when using a suitable steering wheel stabilizer to hold the front wheels in the straight position) with the rear wheels raised and the front wheels on the ground.


Four-Wheel Drive Vehicles The manufacturer recommends towing with all wheels OFF the ground. Acceptable methods are to tow the vehicle on a flatbed or with one end of vehicle raised and the opposite end on a towing dolly. If flatbed equipment is not available, and the transfer case is operable, the vehicle may be towed (in the forward direction, with ALL wheels on the ground), IF the transfer case is in NEUTRAL and the transmission is in PARK. Refer to “Recreational Towing” in “Starting And Operating” for further information.


WHAT TO DO IN EMERGENCIES 615


CAUTION!


• Front or rear wheel lifts should not be used. Internal damage to the transmission or transfer case will occur if a front or rear wheel lift is used when towing. • Failure to follow these towing methods can cause severe damage to the transmission and/or transfer case. Such damage is not covered by the New Vehicle Limited Warranty.


MAINTAINING YOUR VEHICLE


CONTENTS


䡵 Engine Compartment — 3.7L . . . . . . . . . . . . . 620
䡵 Engine Compartment — 4.7L . . . . . . . . . . . . . 621
䡵 Engine Compartment — 5.7L . . . . . . . . . . . . . 622
䡵 Onboard Diagnostic System (OBD II) . . . . . . . 623
▫ Loose Fuel Filler Cap Message . . . . . . . . . . . 623


䡵 Emissions Inspection And Maintenance


Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
䡵 Replacement Parts . . . . . . . . . . . . . . . . . . . . . 625
䡵 Dealer Service . . . . . . . . . . . . . . . . . . . . . . . . 626


䡵 Maintenance Procedures . . . . . . . . . . . . . . . . . 626
▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 627
▫ Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . 629
▫ Engine Air Cleaner Filter . . . . . . . . . . . . . . . 630
▫ Maintenance-Free Battery . . . . . . . . . . . . . . 630
▫ Air Conditioner Maintenance . . . . . . . . . . . . 632
▫ Front Driveshaft Lubrication – 2500/3500


(Four-Wheel Drive) Models (Ram Trucks Only)


. . . . . . . . . . . . . . . . . . . 633
▫ Body Lubrication . . . . . . . . . . . . . . . . . . . . 633


618 MAINTAINING YOUR VEHICLE


▫ Windshield Wiper Blades . . . . . . . . . . . . . . . 634
▫ Adding Washer Fluid . . . . . . . . . . . . . . . . . 634
▫ Exhaust System . . . . . . . . . . . . . . . . . . . . . 635
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . 638
▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . 644
▫ Rear Axle And 4X4 Front Driving Axle Fluid


Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
▫ Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 648
▫ Automatic Transmission . . . . . . . . . . . . . . . 648
▫ Appearance Care And Protection From


Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . 651
䡵 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
▫ Totally Integrated Power Module . . . . . . . . . 658


䡵 Vehicle Storage . . . . . . . . . . . . . . . . . . . . . . . 663
䡵 Replacement Bulbs . . . . . . . . . . . . . . . . . . . . 664
䡵 Bulb Replacement . . . . . . . . . . . . . . . . . . . . . 665


▫ Dual Or Quad Headlamp/Front Park And


Turn Signal — If Equipped . . . . . . . . . . . . . 665
▫ Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . 667
▫ Rear Tail/Stop, Turn Signal And Backup


Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667


▫ Center High-Mounted Stoplamp


(CHMSL) With Cargo Lamp . . . . . . . . . . . . . 669
▫ Cab Top Clearance Lamps — If Equipped . . . 671
▫ Rear Lamp Bar ID Marker (Dual Rear


Wheels) — If Equipped . . . . . . . . . . . . . . . . 672


▫ Side Marker Lamps (Dual Rear Wheels) — If


Equipped . . . . . . . . . . . . . . . . . . . . . . . . . . 673
. . . . . . . . . . . . . . . . . . . . . . 674


䡵 Fluid Capacities


MAINTAINING YOUR VEHICLE 619
䡵 Fluids, Lubricants And Genuine Parts . . . . . . . 676
▫ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 676
▫ Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . 678


620 MAINTAINING YOUR VEHICLE ENGINE COMPARTMENT — 3.7L


1 — Air Cleaner Filter 2 — Automatic Transmission Dipstick (If Equipped) 3 — Engine Oil Dipstick 4 — Brake Fluid Reservoir 5 — Battery 6 — Integrated Power Module (Fuses)


7 — Washer Fluid Reservoir 8 — Power Steering Fluid Reservoir 9 — Engine Oil Fill 10 — Coolant Pressure Cap 11 — Engine Coolant Reservoir


ENGINE COMPARTMENT — 4.7L


MAINTAINING YOUR VEHICLE 621


1 — Air Cleaner Filter 2 — Automatic Transmission Dipstick 3 — Engine Oil Dipstick 4 — Brake Fluid Reservoir 5 — Battery 6 — Integrated Power Module (Fuses)


7 — Washer Fluid Reservoir 8 — Power Steering Fluid Reservoir 9 — Engine Oil Fill 10 — Coolant Pressure Cap 11 — Engine Coolant Reservoir


622 MAINTAINING YOUR VEHICLE ENGINE COMPARTMENT — 5.7L


1 — Air Cleaner Filter 2 — Automatic Transmission Dipstick 3 — Engine Oil Fill 4 — Engine Oil Dipstick 5 — Brake Fluid Reservoir 6 — Battery


7 — Washer Fluid Reservoir 8 — Integrated Power Module (Fuses) 9 — Power Steering Fluid Reservoir 10 — Coolant Pressure Cap 11 — Engine Coolant Reservoir


ONBOARD DIAGNOSTIC SYSTEM (OBD II) Your vehicle is equipped with a sophisticated onboard diagnostic system called OBD II. This system monitors the performance of the emissions, engine, and automatic transmission control systems. When these systems are operating properly, your vehicle will provide excellent performance and fuel economy, as well as engine emis- sions well within current government regulations. If any of these systems require service, the OBD II system will turn on the “Malfunction Indicator Light (MIL).” It will also store diagnostic codes and other information to assist your service technician in making repairs. Al- though your vehicle will usually be drivable and not need towing, see your authorized dealer for service as soon as possible.


MAINTAINING YOUR VEHICLE 623


CAUTION!


• Prolonged driving with the MIL on could cause further damage to the emission control system. It could also affect fuel economy and drivability. The vehicle must be serviced before any emissions tests can be performed. • If the MIL is flashing, while the engine is running, severe catalytic converter damage and power loss will soon occur. Immediate service is required.


Loose Fuel Filler Cap Message


If the vehicle diagnostic system determines that the fuel filler cap is loose, improperly installed, or damaged, a loose gascap indicator will display in the EVIC telltale display area. Refer to “Electronic Vehicle Information Center (EVIC) in “Understanding Your Instrument Panel” for further in- formation. Tighten the fuel filler cap properly and press


624 MAINTAINING YOUR VEHICLE the SELECT button to turn off the message. If the problem continues, the message will appear the next time the vehicle is started. A loose, improperly installed, or damaged fuel filler cap may also turn on the Malfunction Indicator Light (MIL).


EMISSIONS INSPECTION AND MAINTENANCE PROGRAMS In some localities, it may be a legal requirement to pass an inspection of your vehicle’s emissions control system. Failure to pass could prevent vehicle registration.


For states that require an Inspection and Mainte- nance (I/M), this check verifies the “Malfunction Indicator Light (MIL)” is functioning and is not on when the engine is running, and that the OBD II system is ready for testing.


Normally, the OBD II system will be ready. The OBD II system may not be ready if your vehicle was recently serviced, recently had a dead battery or a battery replace- ment. If the OBD II system should be determined not ready for the I/M test, your vehicle may fail the test. Your vehicle has a simple ignition key-actuated test, which you can use prior to going to the test station. To check if your vehicle’s OBD II system is ready, you must do the following: 1. Turn the ignition switch to the ON position, but do not crank or start the engine. 2. If you crank or start the engine, you will have to start this test over. 3. As soon as you turn the ignition switch to the ON position, you will see the MIL symbol come on as part of a normal bulb check.


4. Approximately 15 seconds later, one of two things will happen:


a. The MIL will flash for about 10 seconds and then return to being fully illuminated until you turn OFF the ignition or start the engine. This means that your vehicle’s OBD II system is not ready and you should not proceed to the I/M station. b. The MIL will not flash at all and will remain fully illuminated until you turn OFF the ignition or start the engine. This means that your vehicle’s OBD II system is ready and you can proceed to the I/M station.


If your OBD II system is not ready, you should see your authorized dealer or repair facility. If your vehicle was recently serviced or had a battery failure or replacement, you may need to do nothing more than drive your vehicle as you normally would in order for your OBD II system to update. A recheck with the above test routine may then indicate that the system is now ready.


MAINTAINING YOUR VEHICLE 625
Regardless of whether your vehicle’s OBD II system is ready or not, if the MIL is illuminated during normal vehicle operation you should have your vehicle serviced before going to the I/M station. The I/M station can fail your vehicle because the MIL is on with the engine running.


REPLACEMENT PARTS Use of genuine MOPAR威 parts for normal/scheduled maintenance and repairs is highly recommended to en- sure the designed performance. Damage or failures caused by the use of non-MOPAR威 parts for maintenance and repairs will not be covered by the manufacturer’s warranty.


626 MAINTAINING YOUR VEHICLE DEALER SERVICE Your authorized dealer has the qualified service person- nel, special tools, and equipment to perform all service operations in an expert manner. Service Manuals are available which include detailed service information for your vehicle. Refer to these Service Manuals before attempting any procedure yourself. Intentional tampering with emissions control NOTE: systems may void your warranty and could result in civil penalties being assessed against you.


WARNING!


You can be badly injured working on or around a motor vehicle. Only do service work for which you have the knowledge and the proper equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent me- chanic.


MAINTENANCE PROCEDURES The pages that follow contain the required maintenance services determined by the engineers who designed your vehicle. Besides those maintenance items specified in the fixed maintenance schedule, there are other components which may require servicing or replacement in the future.


CAUTION!


• Failure to properly maintain your vehicle or per- form repairs and service when necessary could result in more costly repairs, damage to other components or negatively impact vehicle perfor- mance. Immediately have potential malfunctions examined by an authorized Chrysler Group LLC dealership or qualified repair center.


(Continued)


CAUTION! (Continued)


• Your vehicle has been built with improved fluids that protect the performance and durability of your vehicle and also allow extended maintenance intervals. Do not use chemical flushes in these components as the chemicals can damage your engine, transmission, power steering or air condi- tioning. Such damage is not covered by the New Vehicle Limited Warranty. If a flush is needed because of component malfunction, use only the specified fluid for the flushing procedure.


Engine Oil


Checking Oil Level To assure proper lubrication of your vehicle’s engine, the engine oil must be maintained at the correct level. Check the oil level at regular intervals, such as every fuel stop.


MAINTAINING YOUR VEHICLE 627
The best time to check the engine oil level is about five minutes after a fully warmed up engine is shut off. Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level readings. Always maintain the oil level within the SAFE zone on the dipstick. Adding one quart of oil when the reading is at the bottom of the SAFE zone will result in a reading at the top of the safe zone on these engines.


CAUTION!


Overfilling or underfilling the crankcase will cause oil aeration or loss of oil pressure. This could damage your engine.


Change Engine Oil The oil change indicator system will remind you that it is time to take your vehicle in for scheduled maintenance. Refer to “Maintenance Schedule” for further information.


628 MAINTAINING YOUR VEHICLE NOTE: Under no circumstances should oil change intervals exceed 8,000 miles (13 000 km) or six months, whichever occurs first.


Engine Oil Selection For best performance and maximum protection under all types of operating conditions, the manufacturer only recommends engine oils that are API Certified and meet the requirements of Chrysler Material Standard MS-6395. American Petroleum Institute (API) Engine Oil Identification Symbol


This symbol means that the oil has been certified by the American Petroleum Institute (API). The manufacturer only recommends API Certified engine oils.


CAUTION!


Do not use chemical flushes in your engine oil as the chemicals can damage your engine. Such damage is not covered by the New Vehicle Limited Warranty.


Engine Oil Viscosity (SAE Grade) SAE 5W-20 engine oil is recommended for all operating temperatures. This engine oil improves low temperature starting and vehicle fuel economy. The engine oil filler cap also shows the recommended engine oil viscosity for your engine. For information on engine oil filler cap location, refer to “Engine Compartment” in “Maintaining Your Vehicle” for further information. NOTE: Vehicles equipped with a 5.7L engine must use SAE 5W-20 oil. Failure to do so may result in improper operation of the Multi-Displacement System (MDS). Re- fer to “Multi-Displacement System” in “Starting and Operating” for further information.


Lubricants which do not have both the engine oil certi- fication mark and the correct SAE viscosity grade num- ber should not be used. NOTE: For 2500/3500 trucks with a 5.7L engine oper- ating under a gross combined weight rating of 14,000 lbs (6 350 kg) or greater, SAE 5W-30 engine oil is recom- mended for all operating temperatures. Synthetic Engine Oils You may use synthetic engine oils if the recommended oil quality requirements are met and the recommended maintenance intervals for oil and filter changes are followed. Materials Added To Engine Oil The manufacturer strongly recommends against the ad- dition of any additives (other than leak detection dyes) to the engine oil. Engine oil is an engineered product and its performance may be impaired by supplemental additives.


MAINTAINING YOUR VEHICLE 629


Disposing Of Used Engine Oil And Oil Filters Care should be taken in disposing of used engine oil and oil filters from your vehicle. Used oil and oil filters, indiscriminately discarded, can present a problem to the environment. Contact your authorized dealer, service station or governmental agency for advice on how and where used oil and oil filters can be safely discarded in your area. Engine Oil Filter The engine oil filter should be replaced with a new filter at every engine oil change. Engine Oil Filter Selection The manufacturer’s engines have a full-flow type oil filter. Use a filter of this type for replacement. The quality of replacement filters varies considerably. Only high- quality filters should be used to assure most efficient service. MOPAR威 engine oil filters are a high-quality oil filter and are recommended.


630 MAINTAINING YOUR VEHICLE Engine Air Cleaner Filter Refer to the “Maintenance Schedule” for the proper maintenance intervals.


WARNING!


The air induction system (air cleaner, hoses, etc.) can provide a measure of protection in the case of engine backfire. Do not remove the air induction system (air cleaner, hoses, etc.) unless such removal is necessary for repair or maintenance. Make sure that no one is near the engine compartment before starting the vehicle with the air induction system (air cleaner, hoses, etc.) removed. Failure to do so can result in serious personal injury.


Engine Air Cleaner Filter Selection The quality of replacement engine air cleaner filters varies considerably. Only high quality filters should be


used to assure most efficient service. MOPAR威 engine air cleaner filters are a high quality filter and are recommended. Maintenance-Free Battery Your vehicle is equipped with a maintenance-free battery. You will never have to add water, nor is periodic main- tenance required.


WARNING!


• Battery fluid is a corrosive acid solution and can burn or even blind you. Do not allow battery fluid to contact your eyes, skin, or clothing. Do not lean over a battery when attaching clamps. If acid splashes in eyes or on skin, flush the area imme- diately with large amounts of water. Refer to “Jump-Starting Procedures” in “What To Do In Emergencies” for further information.


(Continued)


WARNING! (Continued)


• Battery gas is flammable and explosive. Keep flame or sparks away from the battery. Do not use a booster battery or any other booster source with an output greater than 12 Volts. Do not allow cable clamps to touch each other. • Battery posts, terminals, and related accessories contain lead and lead compounds. Wash hands after handling.


MAINTAINING YOUR VEHICLE 631


CAUTION!


• It is essential when replacing the cables on the battery that the positive cable is attached to the positive post and the negative cable is attached to the negative post. Battery posts are marked posi- tive (+) and negative (-) and are identified on the battery case. Cable clamps should be tight on the terminal posts and free of corrosion. • If a “fast charger” is used while the battery is in the vehicle, disconnect both vehicle battery cables before connecting the charger to the battery. Do not use a “fast charger” to provide starting voltage. 7


632 MAINTAINING YOUR VEHICLE Air Conditioner Maintenance For best possible performance, your air conditioner should be checked and serviced by an authorized dealer at the start of each warm season. This service should include cleaning of the condenser fins and a performance test. Drive belt tension should also be checked at this time.


CAUTION!


Do not use chemical flushes in your air conditioning system as the chemicals can damage your air condi- tioning components. Such damage is not covered by the New Vehicle Limited Warranty.


WARNING!


• Use only refrigerants and compressor lubricants approved by the manufacturer for your air condi- tioning system. Some unapproved refrigerants are flammable and can explode, injuring you. Other unapproved refrigerants or lubricants can cause the system to fail, requiring costly repairs. Refer to Warranty Information Book, located on the DVD, for further warranty information. • The air conditioning system contains refrigerant under high pressure. To avoid risk of personal injury or damage to the system, adding refrigerant or any repair requiring lines to be disconnected should be done by an experienced repairman.


NOTE: Use only manufacturer approved A/C System Sealers, Stop Leak Products, Seal Conditioners, Compres- sor Oil, or Refrigerants.


Refrigerant Recovery And Recycling R-134a Air Conditioning Refrigerant is a hydrofluoro- carbon (HFC) that is endorsed by the Environmental Protection Agency (EPA) and is an ozone-saving product. However, the manufacturer recommends that air condi- tioning service be performed by authorized dealers or other service facilities using recovery and recycling equipment. Front Driveshaft Lubrication – 2500/3500
(Four-Wheel Drive) Models (Ram Trucks Only) Lubricate the front driveshaft grease fitting at each oil change. Refer to the “Maintenance Schedule” for the proper maintenance intervals. Use MOPAR威 Type MS- 6560 (lithium-based grease), or equivalent. Body Lubrication Locks and all body pivot points, including such items as seat tracks, door hinge pivot points and rollers, liftgate,


MAINTAINING YOUR VEHICLE 633
tailgate, sliding doors and hood hinges, should be lubri- cated periodically with a lithium based grease, such as MOPAR威 Spray White Lube or equivalent, to assure quiet, easy operation and to protect against rust and wear. Prior to the application of any lubricant, the parts concerned should be wiped clean to remove dust and grit. After lubricating, excess oil and grease should be removed. Particular attention should also be given to hood latching components to ensure proper function. When performing other underhood services, the hood latch, release mechanism and safety catch should be cleaned and lubricated. The external lock cylinders should be lubricated twice a year, preferably in the Fall and Spring. Apply a small amount of a high quality lubricant, such as MOPAR威 Lock Cylinder Lubricant or equivalent directly into the lock cylinder.


634 MAINTAINING YOUR VEHICLE Windshield Wiper Blades Clean the rubber edges of the wiper blades and the windshield periodically with a sponge or soft cloth and a mild nonabrasive cleaner. This will remove accumula- tions of salt or road film. Operation of the wipers on dry glass for long periods may cause deterioration of the wiper blades. Always use washer fluid when using the wipers to remove salt or dirt from a dry windshield. Avoid using the wiper blades to remove frost or ice from the windshield. Keep the blade rubber out of contact with petroleum products such as engine oil, gasoline, etc. NOTE: Life expectancy of wiper blades varies depend- ing on geographical area and frequency of use. Poor performance of blades may be present with chattering, marks, water lines or wet spots. If any of these conditions are present, clean the wiper blades or replace as necessary.


Adding Washer Fluid The fluid reservoir is located under the hood and should be checked for fluid level at regular intervals. Fill the reservoir with windshield washer solvent only (not ra- diator antifreeze). When refilling the washer fluid reser- voir, take some washer fluid and apply it to a cloth or towel and wipe the wiper blades clean. This will help blade performance. To prevent freeze-up of your windshield washer system in cold weather, select a solution or mixture that meets or exceeds the temperature range of your climate. This rating information can be found on most washer fluid containers.


WARNING!


Commercially available windshield washer solvents are flammable. They could ignite and burn you. Care must be exercised when filling or working around the washer solution.


After the engine has warmed up, operate the defroster for a few minutes to reduce the possibility of smearing or freezing the fluid on the cold windshield. Windshield washer solution used with water as directed on the container, aids cleaning action, reduces the freezing point to avoid line clogging, and is not harmful to paint or trim.


MAINTAINING YOUR VEHICLE 635


Exhaust System The best protection against carbon monoxide entry into the vehicle body is a properly maintained engine exhaust system. If you notice a change in the sound of the exhaust system; or if the exhaust fumes can be detected inside the vehicle; or when the underside or rear of the vehicle is damaged; have an authorized technician inspect the complete ex- haust system and adjacent body areas for broken, dam- aged, deteriorated, or mispositioned parts. Open seams or loose connections could permit exhaust fumes to seep into the passenger compartment. In addition, inspect the exhaust system each time the vehicle is raised for lubri- cation or oil change. Replace as required.


636 MAINTAINING YOUR VEHICLE


WARNING!


• Exhaust gases can injure or kill. They contain carbon monoxide (CO), which is colorless and odorless. Breathing it can make you unconscious and can eventually poison you. To avoid breathing CO, refer to “Safety Tips/Exhaust Gas” in “Things To Know Before Starting Your Vehicle” for further information. • A hot exhaust system can start a fire if you park over materials that can burn. Such materials might be grass or leaves coming into contact with your exhaust system. Do not park or operate your ve- hicle in areas where your exhaust system can contact anything that can burn.


CAUTION!


• The catalytic converter requires the use of un- leaded fuel only. Leaded gasoline will destroy the effectiveness of the catalyst as an emissions con- trol device and may seriously reduce engine per- formance and cause serious damage to the engine. • Damage to the catalytic converter can result if your vehicle is not kept in proper operating condition. In the event of engine malfunction, particularly involving engine misfire or other apparent loss of performance, have your vehicle serviced promptly. Continued operation of your vehicle with a severe malfunction could cause the converter to overheat, resulting in possible damage to the converter and vehicle.


Intentional tampering with emissions control in civil penalties being assessed


Under normal operating conditions, the catalytic con- verter will not require maintenance. However, it is im- portant to keep the engine properly tuned to assure proper catalyst operation and prevent possible catalyst damage. NOTE: systems can result against you. In unusual situations involving grossly malfunctioning engine operation, a scorching odor may suggest severe and abnormal catalyst overheating. If this occurs, stop the vehicle, turn off the engine and allow it to cool. Service, including a tune-up to manufacturer’s specifica- tions, should be obtained immediately.


MAINTAINING YOUR VEHICLE 637
To minimize the possibility of catalytic converter dam- age: • Do not shut off the engine or interrupt the ignition, when the transmission is in gear and the vehicle is in motion. • Do not try to start the engine by pushing or towing the • Do not idle the engine with any spark plug wires disconnected or removed, such as when diagnostic testing, or for prolonged periods during very rough idle or malfunctioning operating conditions.


vehicle.


638 MAINTAINING YOUR VEHICLE Cooling System


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, do not open the hood until the radiator has had time to cool. Never try to open a cooling system pressure cap when the radiator is hot.


Engine Coolant Checks Check the engine coolant (antifreeze) protection every 12 months (before the onset of freezing weather, where applicable). If the engine coolant (antifreeze) is dirty or rusty in appearance, the system should be drained, flushed and refilled with fresh coolant. Check the front of the A/C condenser for any accumulation of bugs, leaves, etc. If dirty, clean by gently spraying water from a garden hose vertically down the face of the condenser.


Check the coolant recovery bottle tubing for brittle rub- ber, cracking, tears, cuts and tightness of the connection at the bottle and radiator. Inspect the entire system for leaks. With the engine at normal operating temperature (but not running), check the cooling system pressure cap for proper vacuum sealing by draining a small amount of engine coolant (antifreeze) from the radiator drain cock. If the cap is sealing properly, the engine coolant (anti- freeze) will begin to drain from the coolant recovery bottle. DO NOT REMOVE THE COOLANT PRESSURE CAP WHEN THE COOLING SYSTEM IS HOT. Cooling System – Drain, Flush, And Refill If the engine coolant (antifreeze) is dirty or contains a considerable amount of sediment, clean and flush with a reliable cooling system cleaner. Follow with a thorough rinsing to remove all deposits and chemicals. Properly dispose of old engine coolant (antifreeze) solution.


Refer to the “Maintenance Schedule” for the proper maintenance intervals. Selection Of Coolant Use only the manufacturer’s recommended engine cool- ant (antifreeze). Refer to “Fluids, Lubricants, and Genu- ine Parts” in “Maintaining Your Vehicle” for further information.


CAUTION!


• Mixing of engine coolant (antifreeze) other than specified HOAT engine coolant (antifreeze), may result in engine damage and may decrease corro- sion protection. If a non-HOAT engine coolant (antifreeze) is introduced into the cooling system in an emergency, it should be replaced with the specified engine coolant (antifreeze) as soon as possible.


(Continued)


MAINTAINING YOUR VEHICLE 639


CAUTION! (Continued)


• Do not use water alone or alcohol-based engine coolant (antifreeze) products. Do not use addi- tional rust inhibitors or antirust products, as they may not be compatible with the engine coolant (antifreeze) and may plug the radiator. • This vehicle has not been designed for use with Propylene Glycol based engine coolant (anti- freeze). Use of Propylene Glycol based engine coolant (antifreeze) is not recommended.


Adding Coolant Your vehicle has been built with an improved engine coolant (antifreeze) that allows extended maintenance intervals. This engine coolant (antifreeze) can be used up to five years or 104,000 miles (169 000 km) before replace- ment. To prevent reducing this extended maintenance period, it is important that you use the same engine coolant (antifreeze) throughout the life of your vehicle.


640 MAINTAINING YOUR VEHICLE Please review these recommendations for using Hybrid Organic Additive Technology (HOAT) engine coolant (antifreeze). When adding engine coolant (antifreeze): • The manufacturer


recommends using MOPAR威 Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. • 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. • Use only high purity water such as distilled or deion- ized water when mixing the water/engine coolant (antifreeze) solution. The use of lower quality water will reduce the amount of corrosion protection in the engine cooling system.


Please note that it is the owner’s responsibility to main- tain the proper level of protection against freezing ac- cording to the temperatures occurring in the area where the vehicle is operated. NOTE: Mixing engine coolant (antifreeze) types will decrease the life of the engine coolant (antifreeze) and will require more frequent coolant changes. Cooling System Pressure Cap The cap must be fully tightened to prevent loss of engine coolant (antifreeze), and to ensure that the engine coolant (antifreeze) will return to the radiator from the coolant recovery bottle. The cap should be inspected and cleaned if there is any accumulation of foreign material on the sealing surfaces.


WARNING!


• The warning words “DO NOT OPEN HOT” on the cooling system pressure cap are a safety pre- caution. Never add engine coolant (antifreeze) when the engine is overheated. Do not loosen or remove the cap to cool an overheated engine. Heat causes pressure to build up in the cooling system. To prevent scalding or injury, do not remove the pressure cap while the system is hot or under pressure. • Do not use a pressure cap other than the one specified for your vehicle. Personal injury or en- gine damage may result.


MAINTAINING YOUR VEHICLE 641


Disposal Of Used Coolant Used ethylene glycol-based engine coolant (antifreeze) is a regulated substance requiring proper disposal. Check with your local authorities to determine the disposal rules for your community. To prevent ingestion by ani- mals or children do not store ethylene glycol-based engine coolant (antifreeze) in open containers or allow it to remain in puddles on the ground. If ingested by a child or pet, seek emergency assistance immediately. Clean up any ground spills immediately. Checking Coolant Level – 3.7L, 4.7L, And 5.7L Engines With the engine OFF and cold, the level of the engine coolant should be between the MIN and MAX range on the dipstick.


642 MAINTAINING YOUR VEHICLE To check the coolant level: 1. Open the coolant reservoir.


2. Lift and remove the plastic dipstick from the reservoir neck.


3. Check the coolant level on the dipstick.


The radiator normally remains completely full, so there is no need to remove the radiator cap unless checking for engine coolant (antifreeze) freeze point or replacing en- gine coolant (antifreeze). Advise your service attendant of this. As long as the engine operating temperature is satisfactory, the coolant bottle need only be checked once a month. When additional engine coolant (antifreeze) is needed to maintain the proper level, it should be added to the coolant bottle. Do not overfill. Points To Remember NOTE: When the vehicle is stopped after a few miles (a few kilometers) of operation, you may observe vapor coming from the front of the engine compartment. This is normally a result of moisture from rain, snow, or high humidity accumulating on the radiator and being vapor- ized when the thermostat opens, allowing hot coolant to enter the radiator.


MAINTAINING YOUR VEHICLE 643
If an examination of your engine compartment shows no evidence of radiator or hose leaks, the vehicle may be safely driven. The vapor will soon dissipate. • Do not overfill the coolant recovery bottle. • Check engine coolant (antifreeze) freeze point in the radiator and in the coolant recovery bottle. If engine coolant (antifreeze) needs to be added, contents of coolant recovery bottle must also be protected against freezing. • If frequent engine coolant (antifreeze) additions are required, or if the level in the coolant recovery bottle does not drop when the engine cools, the cooling system should be pressure tested for leaks. • Maintain engine coolant (antifreeze) concentration at 50% HOAT engine coolant (antifreeze) (minimum) and distilled water for proper corrosion protection of your engine, which contains aluminum components.


644 MAINTAINING YOUR VEHICLE


• 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 engine coolant (antifreeze) performance, poor gas mileage, and increased emissions.


Brake System In order to assure brake system performance, all brake system components should be inspected periodically. Refer to the “Maintenance Schedule” for the proper maintenance intervals.


WARNING!


Riding the brakes can lead to brake failure and possibly a collision. Driving with your foot resting or riding on the brake pedal can result in abnormally high brake temperatures, excessive lining wear, and possible brake damage. You would not have your full braking capacity in an emergency.


Brake Fluid Level Check The fluid level of the master cylinder should be checked when performing under the hood service or immediately 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. Use only the manufacturer’s recommended brake fluid. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information.


MAINTAINING YOUR VEHICLE 645


WARNING!


• Use only manufacturer’s recommended brake fluid. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information. Using the wrong type of brake fluid can severely damage your brake system and/or impair its performance. The proper type of brake fluid for your vehicle is also identified on the original factory installed hydraulic master cylin- der reservoir.


(Continued)


646 MAINTAINING YOUR VEHICLE


WARNING! (Continued)


• To avoid contamination from foreign matter or moisture, use only new brake fluid or fluid that has been in a tightly closed container. Keep the master cylinder reservoir cap secured at all times. Brake fluid in a open container absorbs moisture from the air resulting in a lower boiling point. This may cause it to boil unexpectedly during hard or prolonged braking, resulting in sudden brake failure. This could result in a collision. • Overfilling the brake fluid reservoir can result in spilling brake fluid on hot engine parts, causing the brake fluid to catch fire. Brake fluid can also damage painted and vinyl surfaces, care should be taken to avoid its contact with these surfaces.


WARNING! (Continued)


• Do not allow petroleum based fluid to contami- nate the brake fluid. Brake seal components could be damaged, causing partial or complete brake failure. This could result in a collision.


Rear Axle And 4x4 Front Driving Axle Fluid Level 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. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further informa- tion. This inspection should be made with the vehicle in a level position.


(Continued)


For 1500 Model axles, the fluid level should be even with the bottom of the fill hole (within 1/4 in (6.4 mm) of edge of hole) for the FDU215 HD front axle and C235FE rear axle. For all 2500/3500 Model axles, the fluid level should be 1/4 in ± 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 Refer to the “Maintenance Schedule” for the proper maintenance intervals. Lubricant Selection Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information.


MAINTAINING YOUR VEHICLE 647
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 1500 Model rear axles equipped with a Limited Slip Differential require that 5 oz. (148 ml) MOPAR威 Limited Slip Additive or equivalent be added to the gear lubri- cant. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information. The MOPAR威 Limited Slip Additive or equivalent 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).


648 MAINTAINING YOUR VEHICLE Transfer Case


Drain And Refill Refer to the “Maintenance Schedule” for the proper maintenance intervals. Lubricant Selection Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information. 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.


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 the manufacturer’s recommended trans- mission fluid. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further informa- tion. It is important that the transmission fluid be main- tained at the prescribed level using the recommended fluid.


CAUTION!


• Do not use chemical flushes in your transmission as the chemicals can damage your transmission components. Such damage is not covered by the New Vehicle Limited Warranty.


(Continued)


CAUTION! (Continued)


• Using a transmission fluid other than the manu- facturer’s recommended fluid may cause deterio- ration in transmission shift quality and/or torque converter shudder. Using a transmission fluid other than the manufacturer’s recommended fluid will fluid and filter changes. Refer to “Fluids, Lubricants, and Genu- ine Parts” in “Maintaining Your Vehicle” for fur- ther information.


require more frequent


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.


MAINTAINING YOUR VEHICLE 649


Fluid Level Check The fluid level should be checked when the engine is fully warmed up and the fluid in the transmission is at normal operating temperature. Operation of the trans- mission with an improper fluid level will greatly reduce the life of the transmission and of the fluid. Check the fluid level whenever the vehicle is serviced. Check the fluid level while the transmission is at normal operating temperature 82°C (180°F). This occurs after at least 15 miles (25 km) of driving. At normal operating temperature the fluid cannot be held comfortably be- tween the fingertips. To check the automatic transmission fluid level properly, the following procedure must be used: 1. Operate the engine at idle speed and normal operating temperature. 2. The vehicle must be on level ground.


650 MAINTAINING YOUR VEHICLE 3. Fully apply the parking brake and press the brake pedal. 4. Place the shift lever momentarily into each gear posi- tion ending with the 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 Refer to the “Maintenance Schedule” for the proper maintenance intervals. NOTE: reason, the fluid and filter(s) should be changed. It is important that proper lubricant is used in the transmission. Refer to “Fluids, Lubricants, and Genuine Parts” in “Maintaining Your Vehicle” for further information. Appearance Care And Protection From Corrosion


If the transmission is disassembled for any


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


MAINTAINING YOUR VEHICLE 651
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.


652 MAINTAINING YOUR VEHICLE


• Insects, tree sap and tar. • Salt in the air near seacoast localities. • Atmospheric fallout/industrial pollutants. Washing • Wash your vehicle regularly. Always wash your ve- hicle in the shade using MOPAR威 Car Wash or equiva- lent, or a mild car wash soap and rinse the panels completely with clear water. • If insects, tar or other similar deposits have accumu- lated on your vehicle, use MOPAR威 Super Kleen Bug and Tar Remover or equivalent to remove. • Use a high quality cleaner wax, such as MOPAR威 Cleaner Wax or equivalent 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. • Use of power washers exceeding 1,200 psi (8 274 kPa) can result in damage or removal of paint and decals.


Special Care • If you drive on salted or dusty roads or if you drive near the ocean, hose off the undercarriage at least once a month.


• It is important that the drain holes in the lower edges of the doors, rocker panels and trunk be kept clear and open. • If you detect any stone chips or scratches in the paint, touch them up immediately. The cost of such repairs is considered the responsibility of the owner. • If your vehicle is damaged due to a collision or similar cause which destroys the paint and protective coating, have your vehicle repaired as soon as possible. The cost of such repairs is considered the responsibility 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.


MAINTAINING YOUR VEHICLE 653


• Use MOPAR威 Touch Up Paint or equivalent 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 MOPAR威 Wheel Cleaner or equivalent or select a non-abrasive, non-acidic cleaner.


654 MAINTAINING YOUR VEHICLE


CAUTION!


Do not use scouring pads, steel wool, a bristle brush, or metal polishes. Do not use oven cleaner. These products may damage the wheel’s protective finish. Avoid automatic car washes that use acidic solutions or harsh brushes that may damage the wheel’s pro- tective finish. Only MOPAR威 Wheel Cleaner or equivalent is recommended.


Stain Repel Fabric Cleaning Procedure – If Equipped Stain Repel seats may be cleaned in the following man- ner: • Remove as much of the stain as possible by blotting • Blot any remaining stain with a clean, damp towel.


with a clean, dry towel.


• For tough stains, apply MOPAR威 Total Clean or equivalent, 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 MOPAR威 Multi-Purpose Cleaner or equivalent to a clean, damp cloth and remove stain. Use a fresh, damp towel to remove soap residue. • Do not use any harsh solvents or any other form of


protectants on Stain Repel products.


Interior Care Use MOPAR威 Total Clean or equivalent to clean fabric upholstery and carpeting. Use MOPAR威 Total Clean or equivalent to clean vinyl upholstery. MOPAR威 Total Clean or equivalent is specifically recom- mended for leather upholstery.


Your leather upholstery can be best preserved by regular cleaning with a damp soft cloth. Small particles of dirt can act as an abrasive and damage the leather upholstery and should be removed promptly with a damp cloth. Stubborn soils can be removed easily with a soft cloth and MOPAR威 Total Clean or equivalent. Care should be taken to avoid soaking your leather upholstery with any liquid. Please do not use polishes, oils, cleaning fluids, solvents, detergents, or ammonia-based cleaners to clean your leather upholstery. Application of a leather condi- tioner is not required to maintain the original condition.


WARNING!


Do not use volatile solvents for cleaning purposes. Many are potentially flammable, and if used in closed areas they may cause respiratory harm.


MAINTAINING YOUR VEHICLE 655


Cleaning Headlights Your vehicle is equipped with plastic headlights and fog lights (if equipped) 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. Glass Surfaces All glass surfaces should be cleaned on a regular basis with MOPAR威 Glass Cleaner or any commercial household-type glass cleaner. Never use an abrasive type


656 MAINTAINING YOUR VEHICLE 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 cloth.


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. Dry with a soft cloth. Replace the belts if they appear frayed or worn or if the buckles do not work properly. Spray-On Bedliner – If Equipped During ownership, the shine and luster of the Spray-On Bedliner can fade from oxidation, road dirt, heavy-duty hauling and hard water stains. Weathering and UV exposure will lead to fading, dulling, and loss of gloss over time.


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To help maintain the appearance of your Spray-On Bedliner, the manufacturer recommends you periodically rinse all loose dirt from your truck bed and clean your twice per year using the MOPAR威 truck at Spray-On Bedliner Conditioner available at your local authorized dealer. To Help Maintain The Appearance Of Your Spray-On Bedliner, Follow The Steps Below: 1. Rinse your truck bed out with water to remove any loose dirt and debris. 2. Mix a mild soap or detergent with water with a soft cloth or brush. 3. Rinse bedliner with water.


MAINTAINING YOUR VEHICLE 657
4. Once dry, apply a small amount of MOPAR威 Spray-On Bedliner Conditioner to a moist towel or sponge and wipe over the entire surface of the truck bedliner.


WARNING!


Do not use silicon-based protection products to clean your bedliner. Silicon-based products can become slippery and may result in personal injury.


Spray-On Bedliners are chemically-resistant to many different types of chemicals (including gasoline, oil, hydraulic fluids) for short periods of time. If a spill occurs on your Spray-On Bedliner, rinse the truck out as soon as possible to avoid permanent damage.


it


658 MAINTAINING YOUR VEHICLE Repairing The Spray-On Bedliner While extremely tough, is possible to damage a Spray-On Bedliner. One common condition is when loading a heavy pallet and dragging that pallet across the floor of the bed. If a nail or sharp point is exposed under the weight of the pallet a scratch or tear is possible. While not covered by your new vehicle warranty, a cosmetic fix to cover the metal exposed by the scratch is required. To repair a tear or gouge, follow the directions provided in the MOPAR威 Quick Repair Kit.


FUSES


Totally Integrated Power Module The Totally Integrated Power Module is located in the engine compartment near the battery. This center con- tains cartridge 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.


Cavity


J01


J02


Totally Integrated Power Module Cartridge


Description


Fuse


Mini Fuse


40 Amp Green 30 Amp


Pink


Trailer Tow


Electric Brake


MAINTAINING YOUR VEHICLE 659


Cavity


J03


J04


J05


J06


J07


J08


J10


Mini Fuse


Cartridge


Fuse


30 Amp


Pink


25 Amp Natural 25 Amp Natural 40 Amp Green


30 Amp


Pink


40 Amp Green 30 Amp


Pink


Description


Cavity


Cartridge


Fuse


Mini Fuse


Diesel Powertrain Control Module – If Equipped Driver Door Node


Passenger Door Node Antilock Brakes Pump/Stability Control System Antilock Brakes Valve/Stability Control System Power Seat


Sway Bar Module – If Equipped


J11


J12


J13


J14


J15


J17


J18


30 Amp


Pink


30 Amp


Pink


60 Amp Yellow 20 Amp


Blue


40 Amp Green 40 Amp Green 20 Amp


Blue


Description


Transfer Case Module Rear Defroster


Main Ignition Off Draw (IOD) Fuse Trailer Tow Lamps/Park Lamps Front Blower


Starter Motor Solenoid Powertrain Control Module Transmis- sion Range


660 MAINTAINING YOUR VEHICLE


Cartridge


Fuse


60 Amp Yellow


30 Amp


Pink


20 Amp


Blue


25 Amp Natural


Cavity


J19


J20


J21


J22


M1


M5


M6


Mini Fuse


Description


Cavity


Cartridge


Fuse


Rad Fan Motor HI/ Rad Fan Motor Low Front Wiper Ground/Low/High Washer Control


M7


M8


M9


Sunroof Module


M10

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