DEALER SERVICE
An authorized dealer has the qualified service personnel, special tools, and equipment to perform all service operations in an expert manner. Service Manuals are available which include detailed service information for your vehicle. Refer to these Service Manuals before attempting any procedure yourself.
Intentional tampering with emissions control systems may void your warranty and could result in civil penalties being assessed against you.
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WARNING! |
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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 mechanic. |
Change Engine Oil — Gas Engine
The oil change indicator system will remind you that it is time to take your vehicle in for sched- uled maintenance. Refer to “Scheduled Servicing” in this chapter for further informa- tion.
Under no circumstances should oil change intervals exceed 8,000 miles (13,000 km), 12 months or 350 hours of engine run time,
whichever comes first. The 350 hours of engine run or idle time is generally only a concern for fleet customers.
Change Engine Oil — Diesel Engine Refer to the “Scheduled Servicing” for the proper maintenance intervals.
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 require- ments of FCA Material Standard MS-12633.
For best performance and maximum protection under all types of operating conditions, the manufacturer only recommends engine oils that are API CK-4 certified and meet the require- ments of FCA US LLC. Use Mopar or an equiva- lent oil meeting FCA Material Standard
MS-10902. Products meeting Cummins CES 20081 may also be used. The identification of these engine oils are typically located on the back of the oil container.
This symbol means that the oil has been certified by the American Petro- leum Institute (API). The manufac- turer only recommends API Certified engine oils.
This symbol certifies 0W-20, 5W-20, 0W-30, 5W-30 and 10W-30 engine oils.
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CAUTION! |
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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. |
This symbol means that the oil has been certified by the American Petro- leum Institute (API). The manufac- turer only recommends API Certified engine oils.
Oils with a high ash content may produce damaging deposits on cylinder head valves and/or aftertreatment system damage. A maximum sulfated ash content of 1.00 mass % is recommended for all oil used in the engine.
The same oil change interval is to be followed for synthetic oil as for petroleum based oil. Also, synthetic oil must meet the same performance specifications as petroleum oil.
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CAUTION! |
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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. |
Use Mopar SAE 0W-40 engine oil approved to FCA Material Standard MS-12633 such as Pennzoil Ultra equivalent is recommended for all operating temperatures.
The engine oil filler cap also shows the recom- mended engine oil viscosity for your engine. For information on engine oil filler cap location, refer to the “Engine Compartment” illustration in this section.
Lubricants which do not have both the engine oil certification mark and the correct SAE viscosity grade number should not be used.
In ambient temperatures above 0°F (-18°C), we recommend you use SAE 10W-30 engine oil such as Mopar, Shell Rotella and Shell Rimula that meets FCA Material Standard MS-10902 and the API CK-4 engine oil category is required. Products meeting Cummins CES 20081 may
also be used. The identification of these engine oils is typically located on the back of the oil container.
In ambient temperatures below 0°F (-18°C), we recommend you use SAE 5W-40 synthetic engine oil such as Mopar, Shell Rotella and Shell Rimula that meets FCA Material Standard MS-10902 and the API CK-4 engine oil category is required.
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CAUTION! |
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Failure to use SAE 5W-40 synthetic engine oil in ambient temperatures below 0°F (-18°C) could result in severe engine damage. |
Engine oil not designated by the FCA or Cummins Material Standards and API CK-4 should not be used, as engine and exhaust system durability may be compromised. The engine oil filler cap also shows the recom- mended engine oil viscosity for your engine. For information on engine oil filler cap location, refer to “Engine Compartment” in “Servicing And Maintenance” for further information.
You may use synthetic engine oils provided the recommended oil quality requirements are met, and the recommended maintenance intervals for oil and filter changes are followed.
Synthetic engine oils which do not have both the engine oil certification mark and the correct SAE viscosity grade number should not be used.
The manufacturer strongly recommends against the addition 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.
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 an authorized dealer, service station or govern- mental agency for advice on how and where used oil and oil filters can be safely discarded in your area.
The engine oil filter should be replaced with a new filter at every engine oil change.
This manufacturer's engines have a full-flow type disposable 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 ensure most efficient service. Mopar engine oil filters are high quality oil filters and are recommended.
Refer to the “Maintenance Plan” in this section for the proper maintenance intervals.
Be sure to follow the “Severe Duty Conditions” maintenance interval if applicable.
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WARNING! |
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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. |
The quality of replacement engine air cleaner filters varies considerably. Only high quality filters should be used to ensure most efficient service. Mopar engine air cleaner filters are a high quality filter and are recommended.
Inspect engine air cleaner filter for dirt and or debris, if you find evidence of either dirt or debris you should change your air cleaner filter.
Air Cleaner Filter
Open Air Cleaner Filter Assembly
1 — Air Cleaner Cover 2 — Air Cleaner Filter
Inspect and clean the housing if dirt or debris is present before replacing the air filter element.
Inspect engine air cleaner filter for dirt and or debris, if you find evidence of either dirt or debris you should change your air cleaner filter.
Air Cleaner Filter Cover
1 — Air Cleaner Filter Cover 2 — Screws
Air Cleaner Filter
Inspect and clean the housing if dirt or debris is present before replacing the air filter element.
For best possible performance, your air condi- tioner 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.
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CAUTION! |
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Do not use chemical flushes in your air conditioning system as the chemicals can damage your air conditioning components. Such damage is not covered by the New Vehicle Limited Warranty. |
R-134a Air Conditioning Refrigerant is a hydro- fluorocarbon (HFC) that is an ozone-friendly substance. The manufacturer recommends that air conditioning service be performed by an authorized dealer or other service facilities using recovery and recycling equipment.
Use only manufacturer approved A/C system PAG compressor oil and refrigerants.
R–1234yf Air Conditioning Refrigerant is a hydrofluoroolefin (HFO) that is endorsed by the Environmental Protection Agency and is an ozone-friendly substance with a low global-warming potential. The manufacturer recommends that air conditioning service be performed by an authorized dealer using recovery and recycling equipment.
Use only manufacturer approved A/C system PAG compressor oil, and refrigerants.
Cabin Filter Replacement (A/C Air Filter) Refer to the “Maintenance Plan” for the proper maintenance intervals.
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WARNING! |
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Do not remove the cabin air filter while the vehicle is running, or while the ignition is in the ACC or ON/RUN mode. With the cabin air filter removed and the blower operating, the blower can contact hands and may propel dirt and debris into your eyes, resulting in personal injury. |
The cabin air filter is located in the fresh air inlet behind the glove compartment. Perform the following procedure to replace the filter:
Right Side Of Glove Compartment
Glove Compartment
Filter Cover
Filter Cover Removal
1 — Finger Tabs
Cabin Air Filter
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CAUTION! |
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The cabin air filter is identified with an arrow to indicate airflow direction through the filter. Failure to properly install the filter will result in the need to replace it more often. |
Right Side Of Glove Compartment
Ensure the glove compartment door hinges and glove compartment travel stops are fully engaged.
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Do not attempt to inspect an accessory drive belt with vehicle running.
When working near the radiator cooling fan, disconnect the fan motor lead. The fan is temperature controlled and can start at any time regardless of ignition mode. You could be injured by the moving fan blades.
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 compe- tent mechanic.
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When inspecting accessory drive belts, small cracks that run across ribbed surface of belt from rib to rib, are considered normal. These are not a reason to replace belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also have the belt replaced if it has excessive wear, frayed cords or severe glazing.
Accessory Belt (Serpentine Belt)
Conditions that would require replacement:
Some conditions can be caused by a faulty component such as a belt pulley. Belt pulleys should be carefully inspected for damage and proper alignment.
Belt replacement on some models requires the use of special tools, we recommend having your vehicle serviced at an authorized dealer.
There are two fuel filter assemblies. One is located on the driver's side of the engine. The best access to this water drain valve is from under the hood. The second one is on the under body, located in front of the rear axle above the drive shaft on pick-up models. The Chassis Cab models second filter location is on the frame behind the front axle. The best access to this water drain valve is from under the vehicle.
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Do not drain the fuel/water separator filter when the engine is running.
Diesel fuel will damage blacktop paving surfaces. Drain the filter into an appro- priate container.
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If water is detected in the water separator while the engine is running, or while the ignition switch is in the ON position, the “Water In Fuel Indicator Light” will illuminate and an audible chime will be heard five times. At this point you should stop the engine and drain the water from both of the filters.
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CAUTION! |
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If the “Water In Fuel Indicator Light” remains on, DO NOT START the engine before you drain water from the fuel filters to avoid engine damage. |
If the “Water In Fuel Indicator Light” comes on and a single chime is heard while you are driving, or with the ignition switch in the ON position, there may be a problem with your water separator wiring or sensor. See an autho- rized dealer for service.
Upon proper draining of the water from both fuel filters, the “Water In Fuel Indicator Light” will remain illuminated for approximately 10 seconds. If the water was drained while the engine was running, the “Water In Fuel Indicator Light” may remain on for approximately three minutes.
Care should be taken in disposing of used fluids from your vehicle. Used fluids, indiscriminately discarded, can present a problem to the envi- ronment. Contact an authorized dealer, service station, or government agency for advice on recycling programs and for where used fluids and filters can be properly disposed of in your area.
Drain the fuel/water separator filters when the “Water In Fuel Indicator Light” is ON. Within 10 minutes of vehicle shutdown, turn the engine mounted filter drain valve (located on the side of the filter assembly) counterclock- wise 1/4 turn, and turn the under body mounted filter drain valve (located on the bottom of the filter assembly) counterclockwise wise 1 full turn. Then turn the ignition switch to the ON position, and allow any accumulated water to drain. Leave the drain valve open until all water and contaminants have been removed. When clean fuel is visible, close the drain valve following these guidelines:
Over-compression of the seal due to over-tight- ening of the drain will damage the seal, cause a leak, and require the entire sensor to be replaced.
The sensor drain should not be over-tightened during normal service operations to avoid internal damage and future fuel leaks. The drain should be closed and secured without the use of tools.
If more than a couple ounces/milliliters of fuel have been drained, follow the directions for “Priming If The Engine Has Run Out Of Fuel.”
Engine Mounted Fuel Filter Assembly
1 — Drain Valve
feature. Engine will not run if:
Remove used o-ring and discard it.
Do not remove cartridge from bag until you reach this step in order to keep cartridge clean.
Underbody Mounted Fuel Filter Assembly
1 — Drain Valve
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CAUTION! |
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Diesel fuel will damage blacktop paving surfaces. Drain the filter into an appro- priate container.
Do not prefill the fuel filter when installing a new fuel filter. There is a possibility debris could be introduced into the fuel filter during this action. It is best to install the filter dry and allow the in-tank lift pump to prime the fuel system.
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Water In Fuel (WIF) sensor is re-usable. Service kit comes with new o-ring for filter canister and WIF sensor.
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Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death. |
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CAUTION! |
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Do not engage the starter motor for more than 15 seconds at a time. Allow two minutes between the cranking intervals. |
The engine may run rough until the air is forced from all the fuel lines.
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Do not use alcohol or gasoline as a fuel blending agent. They can be unstable under certain conditions and be hazardous or explosive when mixed with diesel fuel. |
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CAUTION! |
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Due to lack of lubricants in alcohol or gasoline, the use of these fuels can cause damage to the fuel system. |
The Cummins diesel engine meets all Environ- mental Protection Agency (EPA) Heavy Duty Diesel Engine Emissions Standards, resulting in one of the lowest emitting diesel engines ever produced.
To achieve these emissions standards, your vehicle is equipped with a state-of-the-art engine and exhaust system. The engine and exhaust after-treatment system work together to achieve the EPA Heavy Duty Diesel Engine Emissions Standards. These systems are seam- lessly integrated into your vehicle and managed by the Cummins Powertrain Control Module (PCM). The PCM manages engine combustion to allow the exhaust system’s catalyst to trap and burn Particulate Matter (PM) pollutants, with no input or interaction on your part.
If the engine is allowed to idle or the truck is driven on low engine speed drive cycles for more than two hours, the system will automati- cally enter an emissions operating mode that will increase the engine idle speed to 900 RPM (1050 RPM for Chassis Cab). While in this mode, which is designed to help maintain the Diesel Particulate Filter, the engine idle speed will return to normal when the brake pedal is applied. A small change in engine tone or a slight change in engine performance while accelerating may also be noticeable at speeds below 20 mph (32 kmh). This operating mode may last for up to an hour of idle time, or around 20 minutes of driving time.
Additionally, your vehicle has the ability to alert you to additional maintenance required on your truck or engine.
Refer to “Instrument Cluster Display” in “Getting To Know Your Instrument Panel” for further information.
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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 vehicle in areas where your exhaust system can contact anything that can burn. |
Diesel Exhaust Fluid (DEF) sometimes known simply by the name of its active component, UREA—is a key component of selective catalytic reduction (SCR) systems, which help diesel vehicles meet stringent emission regulations. DEF is a liquid reducing agent that reacts with engine exhaust in the presence of a catalyst to convert smog-forming nitrogen oxides (NOx) into harmless nitrogen and water vapor.
Refer to “Fluids And Lubricants” in “Technical Specification” for further information.
You can receive assistance in locating DEF in the United States by calling 866-RAM-INFO
(866-726-4636). In Canada call 1–800–465–2001 (English) or 1–800–387–9983 (French)
You can receive assistance in locating DEF by contacting an authorized dealer.
Locks and all body pivot points, including such items as seat tracks, door hinge pivot points and rollers, liftgate, tailgate, decklid, sliding doors and hood hinges, should be lubricated periodically with a lithium based grease, such as Mopar Spray White Lube to ensure 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 Autumn and Spring. Apply a small amount of a high quality lubricant, such as Mopar Lock Cylinder Lubri- cant directly into the lock cylinder.
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 accumulations 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 wind- shield.
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.
Life expectancy of wiper blades varies depending 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.
The wiper blades and wiper arms should be inspected periodically, not just when wiper performance problems are experienced. This inspection should include the following points:
If a wiper blade or wiper arm is damaged, replace the affected wiper arm or blade with a new unit. Do not attempt to repair a wiper arm or blade that is damaged.
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CAUTION! |
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Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. |
Wiper Locking Assembly
Wiper Disengaging
1 — Locking Tab 2 — Wiper
3 — Release Tab
arm and away from the J hook in the end of the wiper arm).
Removing Wiper From Wiper Arm
The best protection against carbon monoxide entry into the vehicle body is a properly main- tained 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 under- side or rear of the vehicle is damaged; have an authorized technician inspect the complete exhaust system and adjacent body areas for broken, damaged, deteriorated, or misposi- tioned parts. Open seams or loose connections could permit exhaust fumes to seep into the passenger compartment. In addition, have the
exhaust system inspected each time the vehicle is raised for lubrication or oil change. Replace as required.
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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” in “Safety” 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 vehicle in areas where your exhaust system can contact anything that can burn.
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CAUTION! |
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The catalytic converter requires the use of unleaded fuel only. Leaded gasoline will destroy the effectiveness of the catalyst as an emissions control device and may seri- ously reduce engine performance and cause serious damage to the engine.
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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 perfor- mance, 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.
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Under normal operating conditions, the cata- lytic converter will not require maintenance. However, it is important to keep the engine properly tuned to ensure proper catalyst opera- tion and prevent possible catalyst damage.
Intentional tampering with emissions control systems can result in civil penalties being assessed against you.
In unusual situations involving grossly malfunc- tioning engine operation, a scorching odor may suggest severe and abnormal catalyst over- heating. 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.
To minimize the possibility of catalytic converter damage:
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You or others can be badly burned by hot engine coolant (antifreeze) 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 open a cooling system pressure cap when the radiator or coolant bottle is hot.
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Keep hands, tools, clothing, and jewelry away from the radiator cooling fan when the hood is raised. The fan starts automati- cally and may start at any time, whether the engine is running or not.
When working near the radiator cooling fan, disconnect the fan motor lead or turn the ignition to the OFF mode. The fan is temperature controlled and can start at any time the ignition is in the ON mode.
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Check the engine coolant (antifreeze) protec- tion 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 (if equipped) or radiator for any accumulation of bugs, leaves, etc. If dirty, clean by gently spraying water from a garden hose vertically down the face of the A/C condenser (if equipped) or the back of the radiator core.
Check the engine cooling system hoses for brittle rubber, cracking, tears, cuts and tight- ness of the connection at the coolant recovery bottle and radiator. Inspect the entire system for leaks.
DO NOT REMOVE THE COOLANT PRESSURE CAP WHEN THE COOLING SYSTEM IS HOT.
Some vehicles require special tools to add coolant properly. Failure to fill these systems properly could lead to severe internal engine damage. If any coolant is needed to be added to the system please contact an authorized dealer.
If the engine coolant (antifreeze) is dirty or contains visible sediment, have an authorized dealer clean and flush with OAT coolant (anti- freeze) (conforming to MS.90032).
Refer to the “Maintenance Plan” in this section for the proper maintenance intervals.
Refer to “Fluids And Lubricants” in “Technical Specifications” for further information.
Your vehicle has been built with an improved engine coolant (OAT coolant conforming to MS.90032) that allows extended maintenance intervals. This engine coolant (antifreeze) can be used up to ten years or 150,000 miles (240,000 km) before replacement. To prevent reducing this extended maintenance period, it is important that you use the same engine coolant (OAT coolant conforming to MS.90032) throughout the life of your vehicle.
Please review these recommendations for using Organic Additive Technology (OAT) engine coolant (antifreeze) that meets the requirements of FCA Material Standard MS.90032. When adding engine coolant (antifreeze):
The cap must be fully tightened to prevent loss of engine coolant (antifreeze), and to ensure that engine coolant (antifreeze) will return to the radiator from the coolant expansion bottle/ recovery tank if so equipped. The cap should be inspected and cleaned if there is any accumulation of foreign material on the sealing surfaces.
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Do not open hot engine cooling system. 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 engine damage may result.
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Used ethylene glycol-based coolant (antifreeze) is a regulated substance requiring proper disposal. Check with your local authorities to determine the disposal rules for your commu- nity. To prevent ingestion by animals or chil- dren, do not store ethylene glycol-based coolant 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.
The level of the coolant in the pressurized coolant bottle should be between the “MIN” and “MAX” range on the bottle when the engine is cold.
The radiator normally remains completely full, so there is no need to remove the cap unless checking for coolant freeze point or replacing engine coolant (antifreeze). Advise your service attendant of this. As long as the engine oper- ating 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.
When the vehicle is stopped after a few miles/ kilometers of operation, you may observe vapor coming from the front of the engine compart- ment. This is normally a result of moisture from rain, snow, or high humidity accumulating on the radiator and being vaporized when the ther- mostat opens, allowing hot engine coolant (anti- freeze) 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.
The charge air cooler is positioned below the radiator and the air conditioner condenser. Air enters the engine through the air cleaner and passes through the turbocharger, where it is pressurized. This pressurized air rapidly reaches high temperature. The air is then directed through a hose to the charge air cooler and through another hose to the intake mani- fold of the engine. The air entering the engine has been cooled by about 50° to 100°F (10° to 38°C). This cooling process enables more effi- cient burning of fuel resulting in fewer emis- sions.
To guarantee optimum performance of the system, keep the surfaces of the charge air cooler, condenser and radiator clean and free of debris. Periodically check the hoses leading to and from the charge air cooler for cracks or loose clamps resulting in loss of pressure and reduced engine performance.
In order to ensure brake system performance, all brake system components should be inspected periodically. Refer to the “Mainte- nance Plan” in this section for the proper main- tenance intervals.
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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. |
Fluid Level Check — Brake Master Cylinder 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.
If necessary, add fluid to bring level within the designated marks on the side of the reservoir of the brake master cylinder. Be sure to clean the top of the master cylinder area before removing cap.
With disc brakes the fluid level can be expected to fall as the brake linings wear. However, an unexpected drop in fluid level may be caused by a leak and a system check should be conducted.
Refer to “Fluids And Lubricants” in “Technical Specifications” for further information.
Selection Of Lubricant
It is important to use the proper transmission fluid to ensure optimum transmission perfor- mance and life. Use only the manufacturer’s specified transmission fluid. Refer to “Fluids And Lubricants” in “Technical Specifications”. It is important to maintain the transmission fluid at the correct level using the recommended fluid. No chemical flushes should be used in any transmission; only the approved lubricant should be used.
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CAUTION! |
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Using a transmission fluid other than the manufacturer’s recommended fluid may cause deterioration in transmission shift quality and/or torque converter shudder, and (for six-speed transmissions) will require more frequent fluid and filter changes. Refer to “Fluids And Lubricants” in “Technical Specifications” for fluid specifications. |
The manufacturer strongly recommends against using any special additives in the trans- mission. Automatic Transmission Fluid (ATF) is an engineered product and its performance may be impaired by supplemental additives. Therefore, do not add any fluid additives to the transmission. The only exception to this policy is the use of special dyes for diagnosing fluid leaks in six-speed transmissions. Avoid using transmission sealers as they may adversely affect seals.
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CAUTION! |
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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. |
The fluid level is preset at the factory and does not require adjustment under normal operating conditions. Routine fluid level checks are not required, therefore the transmission has no dipstick. An authorized dealer can check your transmission fluid level using special service tools.
If you notice fluid leakage or transmission malfunction, visit an authorized dealer immedi- ately to have the transmission fluid level checked. Operating the vehicle with an improper fluid level can cause severe transmis- sion damage.
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CAUTION! |
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If a transmission fluid leak occurs, visit an authorized dealer immediately. Severe transmission damage may occur. An authorized dealer has the proper tools to adjust the fluid level accurately. |
Fluid Level Check — Six-Speed Transmission It is best to check the fluid level when the trans- mission is at normal operating temperature
(158-176°F / 70-80°C). This normally occurs
after at least 15 miles (25 km) of driving. At normal operating temperature the fluid cannot be held comfortably between the fingertips. You can read the transmission sump temperature in the instrument cluster screen refer to “Instru- ment Cluster Display” in “Getting To Know Your Instrument Panel” for further information.
Use the following procedure to check the trans- mission fluid level properly:
the normal operating temperature. If the transmission is not functioning properly, or the vehicle cannot be driven, see the NOTE and CAUTION below about checking the fluid level at colder temperatures.
If it is necessary to check the transmission below the operating temperature, the fluid level should be between the two “COLD” (lower) holes on the dipstick with the fluid at 60-70°F /
16-21°C. Only use the COLD region of the dipstick as a rough reference when setting the fluid level after a transmission service or fluid change. Re-check the fluid level, and adjust as required, once the transmission reaches normal operating temperature.
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CAUTION! |
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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. Run the engine at idle, in PARK, to warm the fluid. |
If it is necessary to check the transmission below the operating temperature, the fluid level should be between the two COLD (lower) holes on the dipstick with the fluid at 68-86°F /
20-30°C. Only use the COLD region of the dipstick as a rough reference when setting the fluid level after a transmission service or fluid change. Re-check the fluid level, and adjust as required, once the transmission reaches normal operating temperature.
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CAUTION! |
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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. Run the engine at idle, in PARK, to warm the fluid. |
Under normal operating conditions, the fluid installed at the factory will provide satisfactory lubrication for the life of the vehicle.
Routine fluid and filter changes are not required. However, change the fluid and filter if the fluid becomes contaminated (with water, etc.), or if the transmission is disassembled for any reason.
Refer to the “Maintenance Plan” for the proper maintenance intervals.
In addition, change the fluid and filters if the fluid becomes contaminated (with water, etc.), or if the transmission is disassembled for any reason.
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 And Lubricants” in “Technical Specifications” for further information. This inspection should be made with the vehicle in a level position.
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, 11.5 in rear axle, and 12.0 in rear axle.
Refer to the “Maintenance Plan” for the proper maintenance intervals.
Refer to “Fluids And Lubricants” in “Technical Specifications” for further information.
The presence of water in the gear lubricant will result in corrosion and possible failure of differ- ential 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 DO REQUIRE limited slip oil additive (friction modifiers).
Slight noise and mild shuddering may be evident while turning a vehicle with limited slip differential on concrete or dry pavement. These conditions should be considered normal opera- tion of the limited slip differential.
Selection Of Lubricant
Use only the manufacturer's recommended fluid. Refer to “Fluids And Lubricants” in “Tech- nical Specifications” for further information.
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.
Refer to the “Maintenance Plan” in this section for the proper maintenance intervals.
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 Govern- ment's Exterior Noise Regulations. These vehi- cles can be identified by the Noise Emission Control Label located in the operator's compart- ment.
The following maintenance services must be performed every six months or 7,500 miles (12,000 km) whichever comes first, to ensure proper operation of the noise control systems. In addition, 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.
Inspect the entire exhaust system for leaks and damaged parts. Devices such as hangers, clamps, and U-bolts should be tight and in good condition. Damaged components, burned or blown out mufflers, burned or rusted out exhaust pipes should be replaced according to the procedures and specifications outlined in
the appropriate service manual. Air Cleaner Assembly
Inspect air cleaner housing for proper assembly and fit. Make certain that the air cleaner is prop- erly positioned and that the cover is tight. Check all hoses leading to the air cleaner for tightness.
The air filter element must also be clean and serviced according to the instructions outlined in the Scheduled Maintenance section of this manual.
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 replace- ment, of any device or element of design incor- porated 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 inop- erative by any person.
Among those acts presumed to constitute tampering are the acts listed below.
The manufacturer warrants that this vehicle as manufactured 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 Regulations.
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 stan- dards, are covered by this warranty for the life of the vehicle.
Maintenance Log and Service Chart (Diesel Engines)
Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest to the mileage at which service was performed.
|
MILES |
67,500 |
75,000 |
82,500 |
90,000 |
97,500 |
105,000 |
112,500 |
120,000 |
|
KILOMETERS |
108,000 |
120,000 |
132,000 |
144,000 |
156,000 |
168,000 |
180,000 |
192,000 |
|
Exhaust system-inspect |
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|
Air cleaner assembly- inspect |
A conventional floor jack may be used at the jacking locations. 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. |
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