Dodge Lubrication SRM 2006 Service Manual

DR LUBRICATION & MAINTENANCE 0 - 1

LUBRICATION & MAINTENANCE

TABLE OF CONTENTS

page page

INTERNATIONAL SYMBOLS

DESCRIPTION .................................2

PARTS & LUBRICANT RECOMMENDATION

DESCRIPTION

LUBRICANT RECOMMENDATIONS ............3

FLUID TYPES ...............................3

FLUID TYPES

DESCRIPTION

ENGINE OIL .................................4

ENGINE OIL - DIESEL ENGINES ..............5

FUEL REQUIREMENTS - DIESEL ENGINE .....5

POWER STEERING FLUID ....................6

ENGINE COOLANT ..........................6

TRANSFER CASE ............................7

AXLE .......................................7

MANUAL TRANSMISSION ....................7

AUTOMATIC TRANSMISSION FLUID ...........7

BRAKE FLUID ...............................8

OPERATION - AUTOMATIC TRANSMISSION

FLUID .......................................8

FLUID CAPACITIES

SPECIFICATIONS

FLUID CAPACITIES ..........................9

MAINTENANCE SCHEDULES

DESCRIPTION

MAINTENANCE SCHEDULES ................11

MAINTENANCE SCHEDULES - 24-VALVE

CUMMINS TURBO DIESEL...................18

MAINTENANCE SCHEDULES - SRT/10 .......25

JUMP STARTING

STANDARD PROCEDURE .....................32

HOISTING

STANDARD PROCEDURE .....................33

TOWING

STANDARD PROCEDURE .....................37

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INTERNATIONAL SYMBOLS

DESCRIPTION

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

DR LUBRICATION & MAINTENANCE 0 - 3

PARTS & LUBRICANT RECOMMENDATION

DESCRIPTION
LUBRICANT RECOMMENDATIONS

Chassis

Component Fluid, Lubricant, or Genuine Part

Steering Gear & Linkage, Ball
Joints, Prop Shafts & Yokes,
Wheel Bearings

Body

Component Fluid, Lubricant, and Genuine Part

Hinges:

Door & Hood MoparT Engine Oil

Swing Gate MoparT Multi-Purpose Lube NLGI Grade 2 EP, GC-LB

Latches: Door, Hood/Safety
Catch, Swing Gate

Seat Regulator & Track MoparT Multi-Purpose Lube NLGI Grade 2 EP, GC-LB
Lock Cylinders MoparT Lock Cylinder Lube

MoparT Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB

MoparT Multi-Purpose Lube NLGI Grade 2 EP, GC-LB

FLUID TYPES

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 to service a
DaimlerChrysler Corporation vehicle.

• Society of Automotive Engineers (SAE)

• American Petroleum Institute (API)

• National Lubricating Grease Institute (NLGI)

API QUALITY CLASSIFICATION

This symbol on the front of an oil container means
that the oil has been certified by the American Petro­leum Institute (API) to meet all the lubrication require­ments specified by DaimlerChrysler Corporation.

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.

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FLUID TYPES

DESCRIPTION
ENGINE OIL

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.

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)

• Association des Constructeurs Européens d’ Automobiles (European Automobile Manufacturers Association)

(ACEA)

API SERVICE GRADE CERTIFIED

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

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. For 3.7L/4.7L engines SAE

5W-30 engine oil is recommended for all operating
temperatures. For 5.7L engines SAE 5W-20 engine
oil is recommended for all operating temperatures­.These engine oils improve low temperature start­ing and vehicle fuel economy. Refer to your engine
oil filler cap for the recommended engine oil vis­cosity for your vehicle. Vehicles with 5.7L engines
equipped with Multiple Displacement System (MDS) must use SAE 5W-20 oil. Failure to do so may result in
improper operation of the Multiple Displacement System (MDS). Refer to Multi Displacement System under
Starting and Operating for details. Refer to the engine oil filler cap for the recommened engine oil viscosity
for each vehicle.

ACEA Categories

For countries that use the ACEA European Oil Categories for Service Fill Oils, use engine oils that meet the require­ments of ACEA A1/B1, A2/B2, or A3/B3.

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.

DR LUBRICATION & MAINTENANCE 0 - 5

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.

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.

ENGINE OIL - DIESEL ENGINES

Use only Diesel Engine Oil meeting standard MIL-2104C or API Classification CD or higher or CCML D4, D5.

SAE VISCOSITY GRADE

CAUTION: Low viscosity oils must have the proper API quality or the CCMC G5 designation.

To assure of properly formulated engine oils, it is rec­ommended that SAE Grade 10W-40 engine oils that
meet Chrysler material standard MS-6395, be used in
accordance to ACEA B3, B4 specification. European
Grade 10W-40 oils that meet Association des Con­structeurs Européens d’ Automobiles (European Auto­mobile Manufacturers Association) (ACEA)
specifications, are also acceptable.

Oils of the SAE 5W-40 grade number are preferred
when minimum temperatures consistently fall below -15° C (5° F).

ACEA Categories

For countries that use the ACEA European Oil Cate­gories for Service Fill Oils, use engine oils that meet
the requirements of ACEA A1/B1, A2/B2, or A3/B3.

FUEL REQUIREMENTS - DIESEL
ENGINE

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.

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.

0 - 6 LUBRICATION & MAINTENANCE DR

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 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.

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

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 coolant, may
result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion
protection.

COOLANT PERFORMANCE

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

Pure Distilled Water - Distilled 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 distilled
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 Distilled Water - Is the recommended mixture, it provides protection against freezing to

-37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If
percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided
with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage

DR LUBRICATION & MAINTENANCE 0 - 7

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.

TRANSFER CASE

Recommended lubricant for the NV241 GENII, NV271, NV243, NV244 GENII, and NV273 transfer cases is MoparT
ATF +4, Automatic Transmission Fluid.

AXLE

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

FRONT AXLE

• C205FD - MoparT Gear Lubricant 75W-90

• 9 1/4 AA - MoparT Synthetic Gear Lubricant 75W-90

• 9 1/4 AA EL- 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

• 10 1/2 AA EL- MoparT Synthetic Gear Lubricant 75W-90

• 11 1/2 AA - MoparT Synthetic Gear Lubricant 75W-90

• 248RBI - MoparT Gear & Axle Lubricant SAE 90

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

MANUAL TRANSMISSION

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

• Getrag 238 - MoparT ATF+4 Transmission Fluid

• G 56 - MoparT ATF+4 Transmission Fluid

• T-56 - MoparT Synthetic 75W-85 Manual Transmission Lubricant

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.

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.

0 - 8 LUBRICATION & MAINTENANCE DR

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.

BRAKE FLUID

The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type
of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an
equivalent from a tightly sealed container.

CAUTION: Never use reclaimed brake fluid or fluid from an container which has been left open. An open
container of brake fluid will absorb moisture from the air and contaminate the fluid.

CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type
fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake
system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid,
etc.

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.

DR LUBRICATION & MAINTENANCE 0 - 9

FLUID CAPACITIES

SPECIFICATIONS
FLUID CAPACITIES

DESCRIPTION SPECIFICATION

FUEL TANK
1500 Short Box 98 L (26 gal.)*
2500/3500 Short Box 128L (34 gal.)*
All Long Box 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 DIESEL 11.4 L (12.0 qts.)

8.3L - Oil Service Quantity 8.2L (8.75 qts.)

8.3L - Engine Overhaul Quantity 9.4L (10.0 qts.)
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 Diesel Engine 28L (29.5 qts.)**

8.3L 15.1L (18 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 - 42RLE 3.8L (4.0 qts)

Overhaul Fill - 42RLE 8.3L (17.6 pts)L

Service Fill - 45RFE/545RFE

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

Service Fill - 48RE 3.8 L (4.0 qts.)

Overhaul - 48RE 14-16L (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/AUTOMATIC/FLUID -

STANDARD PROCEDURE)

MANUAL TRANSMISSION

DIESEL ENGINE - G56 5.6 L (12 pts.)

5.7L ENGINE - G56 4.7 L (10 pts.)
GETRAG 238 2.2 L (4.6 pts.)

TREMEC T-56 2.27 L (4.8 pts.)

TRANSFER CASE

NV241 GENII 1.6 L (3.4 pts.)

NV243 1.6 L (3.4 pts.)

4X2 - 5.2 L (11.0 pts.)
4X4 - 6.2 L (13.0 pts.)

0 - 10 LUBRICATION & MAINTENANCE DR

DESCRIPTION SPECIFICATION

NV244 GENII 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)

C205FD 1.6 L (56 oz.)

9 1/4 AA 2.2 L (74 oz.)

9 1/4 AA EL 2.0 L (6.8 oz.)

REAR AXLE ± .03 L (1 oz)

9 1/4 2.1 L (72 oz.) ***

10 1/2 AA 2.5 L (85 oz.)

10 1/2 AA EL 2.5 L (85 oz.)

11 1/2 AA Open 4.2 L (142 oz.)

11 1/2 AA Trac-Rite 4.0 L (135 oz.)

248RBI (DANA 60) 2.8 L (46 oz.) ****

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

**** Add 147 ml (5 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.

DR LUBRICATION & MAINTENANCE 0 - 11

MAINTENANCE SCHEDULES

DESCRIPTION
MAINTENANCE SCHEDULES

There are two maintenance schedules that show the required service for your vehicle.
First is Schedule “B”. It is for vehicles that are operated under the conditions that are listed below and at the

beginning of the schedule.

• Day or night temperatures are below 32° F (0° C).

• Stop and go driving.

• Extensive engine idling.

• Driving in dusty conditions.

• Short trips of less than 10 miles (16 km).

• More than 50% of your driving is at sustained high speeds during hot weather, above 90° F C (32°).

• Trailer towing.

• Snowplowing.

• Heavy Loading.

• Taxi, police, or delivery service (commercial service).

• Off-road or desert operation.

• If equipped for and operating with E-85 (ethanol) fuel.

NOTE: If ANY of these apply to you then change your engine oil every 3,000 miles (5 000 km) or 3 months,
whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this manual.

NOTE: If ANY of these apply to you then flush and replace your engine coolant every 102,000 miles (170 000
km) or 60 months, whichever comes first and follow schedule “B” of the (Maintenance Schedules( section
of this manual.

NOTE: Most vehicles are operated under the conditions listed for Schedule (B(.
Second is Schedule “A”. It is for vehicles that are not operated under any of the conditions listed under Schedule

9B9.
Use the schedule that best describes your driving conditions. Where time and mileage are listed, follow the interval

that occurs first.

NOTE: Under no circumstances should oil change intervals exceed 6000 miles (10 000 km) or 6 months
whichever comes first.

CAUTION: Failure to perform the required maintenance items may result in damage to the vehicle.

At Each Stop for Fuel

• Check the engine oil level about 5 minutes after a fully warmed engine is shut off. Checking the oil level while
the vehicle is on level ground will improve the accuracy of the oil level reading. Add oil only when the level is
at or below the ADD or MIN mark.

• Check the windshield washer solvent and add if required.

Once a Month

• Check tire pressure and look for unusual wear or damage.

• Inspect the battery and clean and tighten the terminals as required.

• Check the fluid levels of coolant bottle, brake master cylinder, and transmission and add as needed.

• Check all lights and all other electrical items for correct operation.

0 - 12 LUBRICATION & MAINTENANCE DR

At Each Oil Change

• Change the engine oil filter.

• Lubricate Drivetrain/Steering/Suspension Grease Fittings (if equipped)

• Inspect the exhaust system.

• Inspect the brake hoses.

• Inspect the CV joints (if equipped) and front suspension components.

• Check the automatic transmission fluid level.

• Check the manual transmission fluid level.

• Check the coolant level, hoses, and clamps.

• Lubricate Front Drive Shaft Fitting (2500/3500, 4X4).

Schedule “B”

Follow schedule “B” if you usually operate your vehicle under one or more of the following conditions.

• Day or night temperatures are below 32° F (0° C).

• Stop and go driving.

• Extensive engine idling.

• Driving in dusty conditions.

• Short trips of less than 10 miles (16 km).

• More than 50% of your driving is at sustained high speeds during hot weather, above 90° F C (32°).

• Trailer towing.

• Snowplowing.

• Heavy Loading.

• Taxi, police, or delivery service (commercial service).

• Off-road or desert operation.

• If equipped for and operating with E-85 (ethanol) fuel.

NOTE: If ANY of these apply to you then change your engine oil every 3,000 miles (5 000 km) or 3 months,
whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this manual.

NOTE: If ANY of these apply to you then flush and replace your engine coolant every 102,000 miles (170 000
km) or 60 months, whichever comes first and follow schedule “B” of the (Maintenance Schedules( section
of this manual.

If none of these apply to you, then change your engine oil at every interval shown on schedule 9A9 of the 9Main­tenance Schedules9 section of this manual.

Miles 3,000 6,000 9,000 12,000 15,000
(Kilometers) (5 000) (10 000) (15 000) (20 000) (25 000)

Change engine oil and engine oil filter at interval
shown or 3 months, whichever comes first.

Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). X X X X X
Rotate tires. X X
Check spare tire for proper pressure and correct

stowage.
Lubricate outer tie rod ends 2500/3500 (4X4) models

only.
Change rear axle fluid. X
Change front axle fluid (4X4). X
Inspect brake linings. X

Inspect engine air cleaner filter, replace if
necessary.

XXXXX

XX

XX

X