Dodge Lubrication Service Manual

DR LUBRICATION & MAINTENANCE 0 - 1

LUBRICATION & MAINTENANCE

TABLE OF CONTENTS

page page

INTERNATIONAL SYMBOLS

DESCRIPTION ..........................1

FLUID TYPES

DESCRIPTION

DESCRIPTION - FUEL REQUIREMENTS -

DIESEL ENGINE .......................1

DESCRIPTION - ENGINE OIL AND

LUBRICANTS .........................2

DESCRIPTION - POWER STEERING FLUID . . 3

DESCRIPTION - ENGINE COOLANT ........3

DESCRIPTION - TRANSFER CASE - NV241

GENII ...............................4

DESCRIPTION - TRANSFER CASE - NV271 . . 4
DESCRIPTION - TRANSFER CASE - NV243 . . 4
DESCRIPTION - TRANSFER CASE - NV273 . . 4

DESCRIPTION - AXLE ...................4

INTERNATIONAL SYMBOLS

DESCRIPTION

DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 1).

DESCRIPTION - MANUAL TRANSMISSION . . . 4
DESCRIPTION - AUTOMATIC

TRANSMISSION FLUID ..................4

OPERATION - AUTOMATIC TRANSMISSION

FLUID ...............................5

FLUID CAPACITIES

SPECIFICATIONS

FLUID CAPACITIES .....................5

MAINTENANCE SCHEDULES

DESCRIPTION ..........................6

JUMP STARTING

STANDARD PROCEDURE - JUMP STARTING

HOISTING

STANDARD PROCEDURE - HOISTING .......14

TOWING

STANDARD PROCEDURE - TOWING ........15

...13

FLUID TYPES

DESCRIPTION

DESCRIPTION - FUEL REQUIREMENTS ­DIESEL ENGINE

Fig. 1 INTERNATIONAL SYMBOLS

DESCRIPTION

WARNING: Do not use alcohol or gasoline as a fuel
blending agent. They can be unstable under certain
conditions and hazardous or explosive when mixed
with diesel fuel.

Use good quality diesel fuel from a reputable sup­plier in your Dodge truck. For most year-round ser­vice, number 2 diesel fuel meeting ASTM
specification D-975 will provide good performance. If
the vehicle is exposed to extreme cold (below 0°F/­18°C), or is required to operate at colder-than-normal
conditions for prolonged periods, use climatized No. 2
diesel fuel or dilute the No. 2 diesel fuel with 50%
No. 1 diesel fuel. This will provide better protection
from fuel gelling or wax-plugging of the fuel filters.

0 - 2 LUBRICATION & MAINTENANCE DR

FLUID TYPES (Continued)

Diesel fuel is seldom completely free of water. To
prevent fuel system trouble, including fuel line freez­ing in winter, drain the accumulated water from the
fuel/water separator using the fuel/water separator
drain provided. If you buy good-quality fuel and fol­low the cold-weather advice above, fuel conditioners
should not be required in your vehicle. If available in
your area, a high cetane “premium” diesel fuel may
offer improved cold starting and warm-up perfor­mance.

DESCRIPTION - ENGINE OIL AND LUBRICANTS

WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN­MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.

When service is required, DaimlerChrysler Corpo­ration recommends that only Mopart brand parts,
lubricants and chemicals be used. Mopart provides
the best engineered products for servicing
DaimlerChrysler Corporation vehicles.

Only lubricants bearing designations defined by
the following organization should be used.

• Society of Automotive Engineers (SAE)

• American Petroleum Institute (API)

• National Lubricating Grease Institute (NLGI)

API SERVICE GRADE CERTIFIED

Use an engine oil that is API Certified. MOPARt
provides engine oils, that meet or exceed this
requirement.

Fig. 2 TEMPERATURE/ENGINE OIL VISCOSITY

CONTAINER IDENTIFICATION

Standard engine oil identification notations have
been adopted to aid in the proper selection of engine
oil. The identifying notations are located on the front
label of engine oil plastic bottles and the top of
engine oil cans (Fig. 3).

This symbol means that the oil has been certified
by the American Petroleum Institute (API). Diamler­Chrysler only recommend API Certified engine oils.
Use Mopart engine oil or equivalent.

Fig. 3 API SYMBOL

GEAR LUBRICANTS

SAE ratings also apply to multigrade gear lubri­cants. In addition, API classification defines the
lubricants usage. Such as API GL-5 and SAE 75W-

90.

SAE VISCOSITY

An SAE viscosity grade is used to specify the vis­cosity of engine oil. Use only engine oils with multi­ple viscosities such as 5W-30 or 10W-30. These are
specified with a dual SAE viscosity grade which indi­cates the cold-to-hot temperature viscosity range.
Select an engine oil that is best suited to your par­ticular temperature range and variation (Fig. 2).

ENERGY CONSERVING OIL

An Energy Conserving type oil is recommended for
gasoline engines. The designation of ENERGY CON­SERVING is located on the label of an engine oil con­tainer.

LUBRICANTS AND GREASES

Lubricating grease is rated for quality and usage
by the NLGI. All approved products have the NLGI
symbol (Fig. 4) on the label. At the bottom of the
NLGI symbol is the usage and quality identification
letters. Wheel bearing lubricant is identified by the
letter “G”. Chassis lubricant is identified by the letter
“L”. The letter following the usage letter indicates
the quality of the lubricant. The following symbols
indicate the highest quality.

DR LUBRICATION & MAINTENANCE 0 - 3

FLUID TYPES (Continued)

ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT.

CAUTION: Use of Propylene Glycol based coolants
is not recommended, as they provide less freeze
protection and less corrosion protection.

The cooling system is designed around the coolant.
The coolant must accept heat from engine metal, in
the cylinder head area near the exhaust valves and

Fig. 4 NLGI SYMBOL

1 - WHEEL BEARINGS
2 - CHASSIS LUBRICATION
3 - CHASSIS AND WHEEL BEARINGS

SPECIALIZED LUBRICANTS AND OILS

Some maintenance or repair procedures may
require the use of specialized lubricants or oils. Con­sult the appropriate sections in this manual for the
correct application of these lubricants.

DESCRIPTION - POWER STEERING FLUID

Mopart ATF +4, Automatic Transmission Fluid is
required in the power steering system. Substitute
fluids can induce power steering system failure.

Mopart ATF +4, Automatic Transmission Fluid
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal. ATF+4 also has a unique odor that
may change with age. Consequently, odor and color
cannot be used to indicate the fluid condition or the
need for a fluid change.

engine block. Then coolant carries the heat to the
radiator where the tube/fin radiator can transfer the
heat to the air.

The use of aluminum cylinder blocks, cylinder
heads, and water pumps requires special corrosion
protection. Mopart Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769), or the equiva­lent ethylene glycol base coolant with organic corro­sion inhibitors (called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% Ethylene Glycol and 50% distilled
water to obtain a freeze point of -37°C (-35°F). If it
loses color or becomes contaminated, drain, flush,
and replace with fresh properly mixed coolant solu­tion.

CAUTION: MoparT Antifreeze/Coolant, 5
Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Mixing of
coolants other than specified (non-HOAT or other
HOAT), may result in engine damage that may not
be covered under the new vehicle warranty, and
decreased corrosion protection.

COOLANT PERFORMANCE

DESCRIPTION - ENGINE COOLANT

WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL
BASE COOLANT AND IS HARMFUL IF SWAL­LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT­ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
WASH SKIN AND CLOTHING THOROUGHLY AFTER
COMING IN CONTACT WITH ETHYLENE GLYCOL.
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF
GLYCOL BASE COOLANT PROPERLY, CONTACT
YOUR DEALER OR GOVERNMENT AGENCY FOR
LOCATION OF COLLECTION CENTER IN YOUR
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR
HOT UNDER PRESSURE, PERSONAL INJURY CAN
RESULT. AVOID RADIATOR COOLING FAN WHEN

The required ethylene-glycol (antifreeze) and water
mixture depends upon climate and vehicle operating
conditions. The coolant performance of various mix­tures follows:

Pure Water-Water can absorb more heat than a
mixture of water and ethylene-glycol. This is for pur­pose of heat transfer only. Water also freezes at a
higher temperature and allows corrosion.

100 percent Ethylene-Glycol-The corrosion
inhibiting additives in ethylene-glycol need the pres­ence of water to dissolve. Without water, additives
form deposits in system. These act as insulation
causing temperature to rise to as high as 149°C
(300°F). This temperature is hot enough to melt plas­tic and soften solder. The increased temperature can
result in engine detonation. In addition, 100 percent
ethylene-glycol freezes at -22°C (-8°F).

50/50 Ethylene-Glycol and Water-Is the recom­mended mixture, it provides protection against freez­ing to -37°C (-34°F). The antifreeze concentration

0 - 4 LUBRICATION & MAINTENANCE DR

FLUID TYPES (Continued)

must always be a minimum of 44 percent, year­round in all climates. If percentage is lower, engine
parts may be eroded by cavitation. Maximum protec­tion against freezing is provided with a 68 percent
antifreeze concentration, which prevents freezing
down to -67.7°C (-90°F). A higher percentage will
freeze at a warmer temperature. Also, a higher per­centage of antifreeze can cause the engine to over­heat because specific heat of antifreeze is lower than
that of water.

CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl­ene-glycol.

COOLANT SELECTION AND ADDITIVES

NOTE: Refer to the vehicle’s coolant bottle to iden­tify HOAT or Non-HOAT coolant. Non-HOAT coolant
is green in color.

The use of aluminum cylinder blocks, cylinder
heads and water pumps requires special corrosion
protection. Only Mopart Antifreeze/Coolant, 5
Year/100,000 Mile Formula (glycol base coolant with
corrosion inhibitors called HOAT, for Hybrid Organic
Additive Technology) is recommended. This coolant
offers the best engine cooling without corrosion when
mixed with 50% distilled water to obtain to obtain a
freeze point of -37°C (-35°F). If it loses color or
becomes contaminated, drain, flush, and replace with
fresh properly mixed coolant solution.

CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.

DESCRIPTION - TRANSFER CASE - NV241
GENII

Recommended lubricant for the NV241 GENII
transfer case is Mopart ATF +4, Automatic Trans­mission Fluid.

DESCRIPTION - TRANSFER CASE - NV271

Recommended lubricant for the NV271 transfer
case is Mopart ATF +4, Automatic Transmission
Fluid.

DESCRIPTION - TRANSFER CASE - NV243

Recommended lubricant for the NV243 transfer case
is Mopart ATF +4, Automatic Transmission Fluid.

DESCRIPTION - TRANSFER CASE - NV273

Recommended lubricant for the NV273 transfer case
is Mopart ATF +4, Automatic Transmission Fluid.

DESCRIPTION - AXLE

NOTE: DaimlerChrysler recommends using MoparT
lubricants or lubricants of equal quality.

FRONT AXLE

• C205F - Mopart Gear Lubricant 75W-90

• 9 1/4 AA - Mopart Synthetic Gear Lubricant

75W-90

REAR AXLE

•

9 1/4 - Mopart Synthetic Gear Lubricant 75W-140

• 10 1/2 AA - Mopart Synthetic Gear Lubricant

75W-90

• 11 1/2 AA - Mopart Synthetic Gear Lubricant

75W-90

NOTE: Trac-LokT differentials require Limited Slip
Additive in the lubricant. Trac-Rite™ differentials
DO NOT require Limited Slip Additive.

DESCRIPTION - MANUAL TRANSMISSION

NOTE: DaimlerChrysler recommends using MoparT
lubricants or lubricants of equal quality.

NV3500 - Mopart Manual Transmission Lubricant

•

• NV4500 - Mopart Synthetic 75W85 Manual

Transmission Lubricant

• NV5600 - Mopart Manual Transmission Lubri-

cant

DESCRIPTION - AUTOMATIC TRANSMISSION
FLUID

NOTE: Refer to Service Procedures in this group for
fluid level checking procedures.

Mopart ATF +4, Automatic Transmission Fluid is
the recommended fluid for DaimlerChrysler auto­matic transmissions.

Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.

Mopart ATF +4, Automatic Transmission Fluid
when new is red in color. The ATF is dyed red so it
can be identified from other fluids used in the vehicle
such as engine oil or antifreeze. The red color is not
permanent and is not an indicator of fluid condition.
As the vehicle is driven, the ATF will begin to look
darker in color and may eventually become brown.
This is normal. ATF+4 also has a unique odor that
may change with age. Consequently, odor and color
cannot be used to indicate the fluid condition or the
need for a fluid change.

DR LUBRICATION & MAINTENANCE 0 - 5

FLUID TYPES (Continued)

FLUID ADDITIVES

DaimlerChrysler strongly recommends against the
addition of any fluids to the transmission, other than
those automatic transmission fluids listed above.
Exceptions to this policy are the use of special dyes
to aid in detecting fluid leaks.

Various “special” additives and supplements exist
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
clutch operation and inhibit overheating, oxidation,
varnish, and sludge. These claims have not been sup­ported to the satisfaction of DaimlerChrysler and
these additives must not be used. The use of trans­mission “sealers” should also be avoided, since they
may adversely affect the integrity of transmission
seals.

OPERATION - AUTOMATIC TRANSMISSION
FLUID

The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con­stant through the temperature range of operation,
transmission operation and shift feel will remain con­sistent. Transmission fluid must also be a good con­ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.

FLUID CAPACITIES

SPECIFICATIONS

FLUID CAPACITIES

2DESCRIPTION

FUEL TANK

Short Box (Lt. Duty) 98 L (26 gal.)*
Long Box (Lt. Duty) 132 L (35 gal.)*

ENGINE OIL WITH FILTER

3.7L 4.7 L (5.0 qts.)

4.7L 5.6 L (6.0 qts.)

5.7L 6.6 L (7.0 qts.)

5.9L 4.7 L (5.0 qts.)

8.0L 6.6 L (7.0 qts.)

5.9L DIESEL 10.4 L (11.0 qts.)

SPECIFICATION

2DESCRIPTION SPECIFICATION

COOLING SYSTEM

3.7L 15.4 L (16.2 qts.)**

4.7L 15.4 L (16.2 qts.)**

5.7L 15.4L (16.2 qts.)**

5.9L 15.5 L (16.3 qts.)**

8.0L 24L (24.3 qts.)**

5.9L Diesel Engine 28L (29.5 qts.)**
POWER STEERING

Power steering fluid capacities are dependent on engine/
chassis options as well as steering gear/cooler options.
Depending on type and size of internal cooler, length and
inside diameter of cooler lines, or use of an auxiliary cooler,
these capacities may vary. Refer to 19, Steering for proper
fill and bleed procedures.

AUTOMATIC TRANSMISSION

Service Fill - 46RE 3.8 L (4.0 qts.)

O-haul - 46RE 9-9.5L (19-20 pts.) L

Service Fill - 45RFE/

545RFE

O-haul - 45RFE/545RFE 14-16 L (29-33 pts.) L

L Dry fill capacity Depending on type and size of internal

cooler, length and inside diameter of cooler lines, or use of

an auxiliary cooler, these figures may vary. (Refer to 21 -

TRANSMISSION/TRANSAXLE/AUTOMATIC/FLUID -

STANDARD PROCEDURE)

MANUAL TRANSMISSION
NV3500 4X2 2.3 L (4.8 pts.)
NV3500 4X4 2.0 L (4.2 pts.)

NV4500 3.8 L (8.0 pts.)
NV5600 4.5 L (9.5 pts.)

TRANSFER CASE

NV241 GENII 1.6 L (3.4 pts.)

NV243 1.6 L (3.4 pts.)
NV271 1.89 L (4.0 pts.)
NV273 1.89 L (4.0 pts.)

FRONT AXLE ± .03 L (1 oz)

C205F 1.66 L (3.5 pts.)

9 1/4 AA 2.25 L (4.75 pts.)

REAR AXLE ± .03 L (1 oz)

9 1/4 2.32 L (4.9 pts.)***
10 1/2 AA 2.25 L (4.75 pts.)
11 1/2 AA 3.62 L (7.65 pts)

*** With Trac-Lok add 118 ml (4 oz.) of Limited Slip Additive.

** Includes 0.9L (1.0 qts.) for coolant reservoir.

*Nominal refill capacities are shown. A variation may be

observed from vehicle to vehicle due to manufacturing

tolerance and refill procedure.

4X2 - 5.2 L (11.0 pts.)

4X4 - 6.2 L (13.0 pts.)