Dodge RAM, none Factory Service Manual

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Page 1

8A 8B

8F 8G 8H

8I 8J 8L

8N 8O

8Q 8R

11 13 14 19 21 22 23 24 25

GROUP TAB LOCATOR

Introduction Lubrication & Maintenance

Suspension

Differential & Driveline

Vehicle Quick Reference

Brakes

Clutch

Cooling

Audio/Video Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Navigation/Telecommunication Wiring Engine

Exhaust System Frame & Bumpers Fuel System Steering Transmission and Transfer Case Tires/Wheels Body Heating & Air Conditioning Emissions Control Component and System Index DTC Index

Service Manual Comment Forms (Rear of Manual)

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DR INTRODUCTION 1

INTRODUCTION

TABLE OF CONTENTS

page page

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION – VIN CODING/LOCATIONS ......2

VEHICLE EMISSION CONTROL INFORMATION

(VECI)

DESCRIPTION .................................4

BODY CODE PLATE

DESCRIPTION .................................5

INTERNATIONAL VEHICLE CONTROL &

DISPLAY SYMBOLS

DESCRIPTION - INTERNATIONAL SYMBOLS .....9

FASTENER IDENTIFICATION

DESCRIPTION ................................10

FASTENER USAGE

DESCRIPTION

FASTENER USAGE .........................12

THREADED HOLE REPAIR

DESCRIPTION

THREADED HOLE REPAIR ..................13

METRIC SYSTEM

DESCRIPTION ................................14

TORQUE REFERENCES

DESCRIPTION ................................16

VEHICLE CERTIFICATION LABEL

DESCRIPTION ................................17

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2 INTRODUCTION DR

VEHICLE IDENTIFICATION NUMBER

DESCRIPTION – VIN CODING/LOCATIONS

The Vehicle Identification Number (VIN) plate (2) is located on the lower windshield fence near the left a-pillar. The VIN contains 17 characters that provide data concerning the vehicle. Refer to the VIN decoding chart to determine the identification of a vehicle.

The VIN is also imprinted on the:

• Body Code Plate.

• Equipment Identification Plate.

• Vehicle Safety Certification Label.

• Frame rail.

To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the VIN. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public.

POSITION INTERPRETATION CODE = DESCRIPTION

1 Country of Origin 1 = Manufactured By

DaimlerChrysler Corporation

3 = Manufactured By

DaimlerChrysler De Mexico 2 Make D = Dodge 3 Vehicle Type 2 = Incomplete with Side Airbag

5 = Truck with Side Airbag

6 = Incomplete Less Side Airbag

7 = Truck Less Side Airbag 4 Gross Vehicle Weight Rating G = 5,001-6000 lbs.

H = 6,001-7,000 lbs.

J = 7,001-8,000 lbs.

K = 8,001-9,000 lbs.

L = 9,001-10,000 lbs.

M = 10,001-14,000 lbs.

W = Buses/Incomplete Vehicles with

Hydraulic Brakes

5 Vehicle Line A = Ram Pickup 1500 4X2

U = Ram Pickup 1500 4X4 R = Ram Pickup 2500 4X2 S = Ram Pickup 2500 4X4

N = Ram Cab Chassis 4X2 DX

Family

L = Ram Pickup 3500 4X2

X = Ram Pickup 3500 4X4

6 Series 1 = 1500

2 = 2500 3 = 3500 Less Dual Rear Wheels 4 = 3500 With Dual Rear Wheels

5 = 4000 DX Family

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DR INTRODUCTION 3

POSITION INTERPRETATION CODE = DESCRIPTION

7 Body Style 6 = Conventional Cab/Cab Chassis

8 = Quad Cab Full Rear Doors

9 = Mega Cab Ram Pickup

8 Engine K = 3.7L 6 cyl. MPI Gasoline

N = 4.7L 8 cyl. MPI Gasoline

P = 4.7L 8 cyl. Flex Fuel

D = 5.7L 8 cyl. SMPI Gasoline

C = 5.9L 6 cyl. Turbo Diesel High

Output

H = 8.3L 10 cyl. SFI Gasoline

9 Check Digit 0 through 9 or X 10 Model Year 6 = 2006 11 Plant Location S = Dodge City

G = Saltillo

J = St. Louis (North)

12 – 17 Vehicle Build Sequence

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4 INTRODUCTION DR

VEHICLE EMISSION CONTROL INFORMATION (VECI)

DESCRIPTION

All models have a Vehicle Emission Control Information (VECI) Label (1). DaimlerChrysler permanently attaches the label in the engine compartment. The label cannot be removed without defacing label information and destroying label.

The label contains the vehicle’s emission specifications and vacuum hose routings. All hoses must be connected and routed according to the label.

The label also contains an engine vacuum schematic. There are unique labels for vehicles built for sale in the state of California and the country of Canada. Canadian labels are written in both the English and French languages.

The VECI label contains the following:

• Engine family and displacement

• Evaporative family

• Emission control system schematic

• Certification application

• Engine timing specifications (if adjustable)

• Idle speeds (if adjustable)

• Spark plug and gap

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DR INTRODUCTION 5

BODY CODE PLATE

DESCRIPTION

The Body Code Plate is located on the right front hydroform fender rail just behind the headlight assembly. There are seven lines of information on the body code plate. Lines 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 4 in the center of the plate to line 1 at the bottom of the plate.

The last code imprinted on a vehicle code plate will be followed by the imprinted word END. When two vehicle code plates are required, the last available spaces on the first plate will be imprinted with the letters CTD (for continued).

When a second vehicle code plate is necessary, the first four spaces on each row will not be used because of the plate overlap.

BODY CODE PLATE – LINE 4

DIGITS 1 THROUGH 12

Vehicle Order Number (15)

DIGITS 13, 14, AND 15

Transmission Codes (3)

• DDP = 5–speed Manual (NV4500)

• DEC = 6–speed Manual (NV5600)

• DEE = 6–speed Manual Tremec (T-56)

• DEG = 6–speed Manual (G56)

• DEJ = 6–speed Manual (GETRAG 238)

• DG4 = 4–speed Automatic (45RFE)

• DG8 = 4–speed Automatic (48RE)

• DGQ = 4–speed Automatic (5-45RFE)

DIGITS 16 and 17

Family (4)

• DR = 1500

• DH = 2500

• D1 = 3500

• DC = 3500 (Cab Chassis)

• DX = Mexico Work Truck

DIGIT 18

Vehicle Line (4)

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6 INTRODUCTION DR

2 - Wheel Drive

• 1 = 1500

• 2 = 2500

• 3 = 3500

4 - Wheel Drive

• 6 = 1500

• 7 = 2500

• 8 = 3500

DIGIT 19

Price Class (4)

• L = Low

• H = Highline

• P = Premium

• S=SRT-10

DIGITS 20 AND 21

Body Type (4)

• 41 = Ram Truck Quad Cab, 6.5’ Box

• 42 = Ram Truck Quad Cab, 8.0’ Box

• 61 = Ram Truck Standard Cab, 6.5’ Box

• 62 = Ram Truck Standard Cab, 8.0’ Box

• 81 = Ram Truck Mega Cab, 6.5’ Box

BODY CODE PLATE – LINE 3

DIGITS 1,2, AND 3

Paint Procedure (14)

• APA = Monotone

• AP9 = Special

• APD = Two-tone (Lower break)

DIGIT 4

Open Space

DIGITS 5 THROUGH 8

Primary Paint (1) (Refer to 23 - BODY/PAINT - SPECIFICATIONS) for

color codes.

DIGIT 9

Open Space

DIGITS 10 THROUGH 13

Secondary Paint (2)

DIGIT 14

Open Space

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DR INTRODUCTION 7

DIGITS 15 THROUGH 18

Interior Trim Code (6)

DIGIT 19

Open Space

DIGITS 20, 21, AND 22

Engine Code (5)

• EKG = 3.7L 6 cyl. MPI Gasoline

• EVA = 4.7L 8 cyl. MPI Gasoline

• EVD = 4.7L 8 cyl. Flex Fuel

• EZA = 5.7L 8 cyl. SMPI Gasoline

• ETH = 5.9L 6 cyl. Cummins Turbo Diesel High Output

• EWC = 8.3L 19 cyl. SFI Gasoline

BODY CODE PLATE – LINE 2

DIGIT 1 Open Space

DIGITS 2 AND 3 Species Code. (Used for Manufacturing) (13)

DIGIT 4

Open Space

DIGIT 5

Market Code (12)

• B = International

• C = Canada

• M = Mexico

• U = United States

DIGIT 6

Open Space

DIGITS 7 THROUGH 23

Vehicle Identification Number (VIN) (7) (Refer to VEHICLE DATA/VEHICLE INFORMATION/VEHICLE IDENTIFICATION NUMBER - DESCRIPTION) for

proper breakdown of VIN code.

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8 INTRODUCTION DR

BODY CODE PLATE – LINE 1

DIGITS 1 THROUGH 6 Body-in-white assembly sequence (11)

DIGIT 7

Open Space

DIGIT 8 Tailgate trim code (10)

DIGIT 9

Open Space

DIGITS 10 THROUGH 12 Cargo box code (9)

DIGIT 13

Open Space

DIGITS 14 THROUGH 16 Tailgate code (8)

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DR INTRODUCTION 9

INTERNATIONAL VEHICLE CONTROL & DISPLAY SYMBOLS

DESCRIPTION - INTERNATIONAL SYMBOLS

The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.

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FASTENER IDENTIFICATION

DESCRIPTION

The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and

10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts.

Bolt Markings and Torques - Metric

Bolt Markings 8.8/8.9 10.9 12.9

Bolt Dia. N·m Ft. Lbs. N·m Ft. Lbs. N·m Ft. Lbs.

6 12 105* 14 120* 16 12

8 25 250* 32 23 38 28 10 54 40 60 45 74 55 12 95 70 108 80 135 100 14 155 115 175 130 216 160 16 243 180 324 210 324 240

* Inch Lbs.

Bolt Markings and Torques - U. S. Customary

Bolt Markings Grade 5 Grade 8

Bolt Dia. N·m Ft. Lbs N·m Ft. Lbs

1/4 - 20 10 95* 14 125*

1/4 - 28 10 95* 17 150* 5/16 - 18 22 200* 30 270* 5/16 - 24 26 240* 33 300*

3/8-1640305540

3/8-2447356045 7/16-1468508865 7/16-2074559570

1/2 - 13 101 75 135 100

1/2 -20 115 85 150 110 9/16 - 12 135 105 182 135 9/16 - 18 155 115 202 150

5/8 - 11 202 150 263 195 5/8 - 18 215 160 284 210 3/4 - 10 230 170 297 220 3/4 - 16 236 175 304 225 7/8 - 14 405 300 540 400

* Inch Lbs.

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DR INTRODUCTION 11

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12 INTRODUCTION DR

FASTENER USAGE

DESCRIPTION FASTENER USAGE

WARNING: Use of an incorrect fastener may result in component damage or personal injury.

Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassem-

bly. If the fastener is not salvageable, a fastener of equivalent specification must be used.

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DR INTRODUCTION 13

THREADED HOLE REPAIR

DESCRIPTION THREADED HOLE REPAIR

Most stripped threaded holes can be repaired using a HelicoilT. Follow the vehicle or HelicoilT recommendations for application and repair procedures.

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14 INTRODUCTION DR

METRIC SYSTEM

DESCRIPTION

The metric system is based on quantities of one, ten, one hundred, one thousand and one million. The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa.

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DR INTRODUCTION 15

CONVERSION FORMULAS AND EQUIVALENT VALUES

MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x

0.11298

ft-lbs x

1.3558

Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x

psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi Inches x 25.4 = Millimeters (mm) mm x

Feet x

0.3048

Yards x

0.9144

mph x

1.6093

Feet/Sec x

0.3048

mph x

0.4470

Kilometers/Hr. (Km/h) x

0.27778

= Newton Meters (N·m)

= Meters (M) M x 3.281 = Feet

= Meters M x

= Kilometers/Hr. (Km/h)

= Meters/Sec (M/S) M/S x 3.281 = Feet/Sec

= Meters/Sec (M/S) M/S x 2.237 = mph

= Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h)

N·m x 8.851 = in-lbs

N·m x

0.7376

0.2961

0.03937

1.0936

Km/h x

0.6214

= ft-lbs

= Inches Hg

= Inches

= Yards

= mph

COMMON METRIC EQUIVALENTS

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters 1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter 1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter 1 Mile = 1.6 Kilometers

Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.).

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16 INTRODUCTION DR

TORQUE REFERENCES

DESCRIPTION

Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifications Chart for torque references not listed in the individual torque charts.

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DR INTRODUCTION 17

VEHICLE CERTIFICATION LABEL

DESCRIPTION

A vehicle certification label is attached to every DaimlerChrysler Corporation vehicle. The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle Standards. The label also lists:

• Month and year of vehicle manufacture.

• Gross Vehicle Weight Rating (GVWR). The gross

front and rear axle weight ratings (GAWR’s) are based on a minimum rim size and maximum cold tire inflation pressure.

• Vehicle Identification Number (VIN).

• Type of vehicle.

• Type of rear wheels.

• Bar code.

• Month, Day and Hour (MDH) of final assembly.

• Paint and Trim codes.

• Country of origin.

The label is located on the driver-side door shut-face.

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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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0 - 2 LUBRICATION & MAINTENANCE DR

INTERNATIONAL SYMBOLS

DESCRIPTION

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

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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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0 - 4 LUBRICATION & MAINTENANCE DR

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.

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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.

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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

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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.

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.

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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.

Page 28

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.)

Page 29

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.

Page 30

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.

Page 31

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.

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

Page 32

DR LUBRICATION & MAINTENANCE 0 - 13

Miles 18,000 21,000 24,000 27,000 30,000 (Kilometers) (30 000) (35 000) (40 000) (45 000) (50 000)

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 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 Check transfer case fluid level (4X4). X Inspect brake linings. X

Inspect engine air cleaner filter, replace if necessary.

Replace spark plugs. X Inspect PCV valve, replace as necessary. ** X

XXXXX

XXX

Miles 33,000 36,000 39,000 42,000 45,000 (Kilometers) (55 000) (60 000) (65 000) (70 000) (75 000)

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.

Miles 48,000 51,000 54,000 57,000 60,000 (Kilometers) (80 000) (85 000) (90 000) (95 000) (100

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 X Check spare tire for proper pressure and correct

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

only. Flush and replace engine coolant at 60 months, or

102, 000 miles (170 000 km) whichever comes first.

XXXXX

000)

XXXXX

XXX

Page 33

0 - 14 LUBRICATION & MAINTENANCE DR

Miles 48,000 51,000 54,000 57,000 60,000 (Kilometers) (80 000) (85 000) (90 000) (95 000) (100

000)

Drain and refill transfer case fluid (4X4). X Change rear axle fluid. X Change front axle fluid (4X4). X Change 6-spd manual transmission fluid 2500/3500

models only. Inspect brake linings. X X

Inspect engine air cleaner filter, replace if necessary.

Replace spark plugs. X Inspect and replace ignition cables if necessary. X Inspect PCV valve, replace as necessary. ** X

Drain and refill automatic transmission fluid and change main sump filter*.

Miles 63,000 66,000 69,000 72,000 75,000 (Kilometers) (105

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.

Inspect engine air cleaner filter, replace if necessary.

Change rear axle fluid. X Change front axle fluid (4X4). X Inspect brake linings. X Inspect auto tension drive belt and replace if required.

(3.7L/4.7L/5.7L).

XXXXX

(110 000) (115

000)

(120

000)

(125

000)

Miles 78,000 81,000 84,000 87,000 90,000 (Kilometers) (130

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 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

XXXXX

XXX

(135 000) (140

000)

(145

000)

(150

000)

Page 34

DR LUBRICATION & MAINTENANCE 0 - 15

Miles 78,000 81,000 84,000 87,000 90,000 (Kilometers) (130

000)

Change front axle fluid (4X4). X Check transfer case fluid level (4X4). X Inspect brake linings. X

Inspect engine air cleaner filter, replace if necessary.

Replace spark plugs. X Inspect PCV valve, replace as necessary. ** X

Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L).****

Miles 93,000 96,000 99,000 102,000 (Kilometers) (155 000) (160 000) (165 000) (170 000)

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 Rotate tires. X X Check spare tire for proper pressure and correct stowage. X X Lubricate outer tie rod ends 2500/3500 (4X4) models only. X X Flush and replace engine coolant, if not replaced at 60

months. Inspect brake linings. X

(135 000) (140

000)

XXXX

(145

000)

(150

000)

Miles 105,000 108,000 111,000 114,000 117,000 120,000 (Kilometers) (175

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).

Rotate tires. X X X Check spare tire for proper pressure and correct

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

models only. Drain and refill transfer case fluid (4X4). X Change rear axle fluid. X X Change front axle fluid (4X4). X X Change 6-spd manual transmission fluid

2500/3500 models only. Inspect brake linings. X X

Inspect engine air cleaner filter, replace if necessary.

Replace spark plugs. X Inspect and replace ignition cables if

necessary.

X X XXXX

(180

000)

XXX

(185

000)

(190

000)

(195

000)

(200

000)

Page 35

0 - 16 LUBRICATION & MAINTENANCE DR

Miles 105,000 108,000 111,000 114,000 117,000 120,000 (Kilometers) (175

000)

Inspect PCV valve, replace as necessary. ** X

Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L).

Drain and refill automatic transmission fluid and change main sump and spin-on cooler return filter (if equipped)*.

Flush and replace engine coolant at 120 months if not replaced at 102,000 miles (170 000 km).

* This applies only if the vehicle is used for frequent trailer towing, snowplowing, fleet vehicle or commercial service. ** This maintenance is recommended by the manufacturer to the owner, but not required to maintain the emissions

warranty. **** This maintenance is not required if the belt was previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all

receipts.

(180

000)

(185

000)

(190

000)

(195

000)

(200

000)

Schedule “A”

Miles 6,000 12,000 18,000 24,000 30,000 (Kilometers) (10 000) (20 000) (30 000) (40 000) (50 000) [Months] [6] [12] [18] [24] [30]

Change engine oil and engine oil filter. X X X X X Rotate tires. X X X X X Check transfer case fluid level (4X4). X Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). X X X X X Lubricate outer tie rod ends 2500/3500 (4X4) models

only. Inspect brake linings. X

Inspect engine air cleaner filter, replace if necessary.

Replace spark plugs. X

Miles 36,000 42,000 48,000 54,000 60,000 66,000 (Kilometers) (60 000) (70 000) (80

[Months] [36] [42] [48] [54] [60] [66]

Change engine oil and engine oil filter. X X X X X X Rotate tires. X X X X X X Check transfer case fluid level (4X4). X Lubricate Front Drive Shaft Fitting (2500/3500,

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

models only. Flush and replace engine coolant at 60 months,

if not replaced at 102,000 miles (170 000 km). Inspect brake linings. X X

XXXXX

(90

000)

X X XXXX

000)

(100

000)

(110

000)

Page 36

DR LUBRICATION & MAINTENANCE 0 - 17

Miles 36,000 42,000 48,000 54,000 60,000 66,000 (Kilometers) (60 000) (70 000) (80

000)

[Months] [36] [42] [48] [54] [60] [66] Inspect engine air cleaner filter, replace if

necessary. Replace spark plugs. X Inspect PCV valve, replace as necessary. ** X Inspect and replace ignition cables if

necessary.

Miles 72,000 78,000 84,000 90,000 96,000 (Kilometers) (120

000)

[Months] [72] [78] [84] [90] [96]

Change engine oil and engine oil filter. X X X X X Rotate tires. X X X X X Lubricate outer tie rod ends 2500/3500 (4X4) models

only. Check transfer case fluid level (4X4). X Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). X X X X X Inspect brake linings. X X

Inspect engine air cleaner filter, replace if necessary.

Replace spark plugs. X Inspect PCV valve, replace as necessary. ** X

Inspect auto tension drive belt and replace if required (3.7L/4.7L/5.7L).

XXXXX

(130 000) (140

000)

(90

000)

(100

000)

(150

000)

(110

000)

(160

000)

Miles 102,000 108,000 114,000 120,000 (Kilometers) (170 000) (180 000) (190 000) (200 000) [Months] [102] [108] [114] [120]

Change engine oil and engine oil filter. X X X X Rotate tires. X X X X Drain and refill transfer case fluid (4X4). X Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). X X X X Flush and replace engine coolant, if not replaced at 60

months. Flush and replace engine coolant at 120 months, if not

replaced at 102,000 miles (170 000 km). Lubricate outer tie rod ends 2500/3500 (4X4) models only. X X X X Inspect brake linings. X Inspect auto tension drive belt and replace if required

(3.7L/4.7L/5.7L).****

Inspect and replace ignition cables if necessary. X Inspect engine air cleaner filter, replace if necessary. X Replace spark plugs. X

Page 37

0 - 18 LUBRICATION & MAINTENANCE DR

Miles 102,000 108,000 114,000 120,000 (Kilometers) (170 000) (180 000) (190 000) (200 000) [Months] [102] [108] [114] [120]

Inspect PCV Valve, replace as necessary. ** X

** This maintenance is recommended by the manufacturer to the owner, but not required to maintain the emissions warranty.

**** This maintenance is not required if the belt was previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all

receipts.

WARNING: You can be badly injured working on or around a motor vehicle. Do only that service work for which you have the knowledge and the right equipment. If you have any doubt about your ability to perform a service job, take your vehicle to a competent mechanic.

MAINTENANCE SCHEDULES - 24-VALVE CUMMINS TURBO DIESEL

beginning of the schedule.

• Frequent short trips where the engine does not achieve full operating temperature (operating temperature defined as 190° F (66° C ) coolant temperature).

• Extensive engine idling (over 10 minutes per hour of operation) at ambient temperatures less than 32° F (0° C).

• Driving in dusty conditions.

• Frequent trailer towing.

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

• Off-road or desert operation.

• Extensive operation at high engine speeds (greater than 2900 rpm) and loads (greater than 70% throttle).

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.

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 15 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.

• Drain water from the fuel filter.

Once a Month

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

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

• Check the fluid levels of coolant reservoir, brake master cylinder, and transmission and transfer case (if

equipped), add as needed.

• Check Filter Minder™. Replace air cleaner filter element if necessary.

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

Page 38

DR LUBRICATION & MAINTENANCE 0 - 19

At Each Oil Change

• Change the engine oil filter.

• 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 outer tie rod ends 2500/3500 (4X4) models only.

• 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.

• Frequent short trips where the engine does not achieve full operating temperature (operating temperature defined as 190° F (66° C ) coolant temperature).

• Extensive engine idling (over 10 minutes per hour of operation) at ambient temperatures less than 32° F (0° C).

• Driving in dusty conditions.

• Frequent trailer towing.

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

• Off-road or desert operation.

• Extensive operation at high engine speeds (greater than 2900 rpm) and loads (greater than 70% throttle).

NOTE: If ANY of these apply to you then change your coolant every 102,000 miles (163 000 km) or 60 months, whichever comes first and follow schedule “B” of the (Maintenance Schedules( section of this manual.

Miles 3,750 7,500 11,250 15,000 18,750 (Kilometers) (6 000) (12 000) (18 000) (24 000) (30 000)

Change engine oil and engine oil filter. X X 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. Inspect water pump weep hole for blockage. X Replace fuel filter element. Clean the water in fuel

sensor. Change rear axle fluid. X Change front axle fluid (4X4). X Inspect brake linings. X Inspect and adjust parking brake if necessary. X

Miles 22,500 26,250 30,000 33,750 37,500 (Kilometers) (36 000) (42 000) (48 000) (54 000) (60 000)

Change engine oil and engine oil filter. X X X Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). X X X X X Rotate tires. X X X

Page 39

0 - 20 LUBRICATION & MAINTENANCE DR

Miles 22,500 26,250 30,000 33,750 37,500 (Kilometers) (36 000) (42 000) (48 000) (54 000) (60 000)

Check spare tire for proper pressure and correct stowage.

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

Inspect drive belt, replace as required. X Inspect fan hub. X Inspect damper. X Inspect water pump weep hole for blockage. X Replace fuel filter element. Clean the water in fuel

sensor. Change rear axle fluid. X Change front axle fluid (4X4). X Check transfer case fluid level (4X4). X Drain and refill automatic transmission fluid. Replace

filter and adjust bands (48RE only).

XXX

Miles 41,250 45,000 48,750 52,500 56,250 (Kilometers) (66 000) (72 000) (78 000) (84 000) (90 000)

Change engine oil and engine oil filter. X X 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. Inspect drive belt, replace as required. X Inspect water pump weep hole for blockage. X Replace fuel filter element. Clean the water in fuel

sensor. Inspect brake linings. X Inspect and adjust parking brake if necessary. X Change rear axle fluid. X Change front axle fluid (4X4). X

Miles 60,000 63,750 67,500 71,250 75,000 (Kilometers)

Change engine oil and engine oil filter. X X X Lubricate Front Drive Shaft Fitting (2500/3500, 4X4). X X X X X Flush and replace engine coolant at 60 months, if not

replaced at 102,000 miles (163 000 km). Rotate tires. X X X Check spare tire for proper pressure and correct

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

only.

(96 000) (102 000)

XXX

(108

000)

(114

000)

(120

000)

Page 40

DR LUBRICATION & MAINTENANCE 0 - 21

Miles 60,000 63,750 67,500 71,250 75,000 (Kilometers)

Inspect drive belt, replace as required. X Inspect fan hub. X Inspect damper. X Inspect water pump weep hole for blockage. X X Replace fuel filter element. Clean the water in fuel

sensor. Inspect front wheel bearings. X Change rear axle fluid. X X Change front axle fluid (4X4). X X Change 6-spd manual transmission (G-56) fluid

2500/3500 models only. Inspect brake linings. X X Inspect and adjust parking brake if necessary. X X Drain and refill transfer case fluid (4X4). X Drain and refill automatic transmission fluid and

change main sump filter (545 RFE only). Drain and refill automatic transmission fluid. Replace

filter and adjust bands (48RE only).

(96 000) (102 000)

(108

000)

(114

000)

(120

000)

Miles 78,750 82,500 86,250 90,000 93,750 (Kilometers) (126

000)

Change engine oil and engine oil filter. X X 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. Inspect drive belt, replace as required. X Change rear axle fluid. X Change front axle fluid (4X4). X Check transfer case fluid level (4X4). X Inspect fan hub. X Inspect damper. X Inspect water pump weep hole for blockage. X Replace fuel filter element. Clean the water in fuel

sensor. Inspect front wheel bearings. X Inspect brake linings. X Inspect and adjust parking brake if necessary. X Drain and refill automatic transmission fluid. Replace

filter and adjust bands (48RE only).

(132 000)

(138

000)

(144

000)

(150

000)

Page 41

0 - 22 LUBRICATION & MAINTENANCE DR

Miles 97,500 100,000 101,250 105,000 108,750 112,500 (Kilometers) (156

000)

Change engine oil and engine oil filter. X X X Lubricate Front Drive Shaft Fitting (2500/3500,

4X4). Flush and replace engine coolant, if not replaced

at 60 months. Rotate tires. X X X Check spare tire for proper pressure and correct

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

models only. Flush and replace engine coolant. X Inspect drive belt, replace as required. X Inspect water pump weep hole for blockage. X Replace fuel filter element. Clean the water in

fuel sensor. Change rear axle fluid. X Change front axle fluid (4X4). X Inspect brake linings. X Inspect and adjust parking brake if necessary. X

X X XXXX

XXX

(160

000)

(162

000)

(168

000)

(174

000)

(180

000)

Miles 116,250 120,000 123,750 127,500 131,250 135,000 (Kilometers) (186

000)

Change engine oil and engine oil filter. X X X Lubricate Front Drive Shaft Fitting (2500/3500,

4X4). Rotate tires. X X X Check spare tire for proper pressure and correct

stowage. Flush and replace engine coolant at 120 months,

if not replaced at 102,000 miles (163 000 km). Lubricate outer tie rod ends 2500/3500 (4X4)

models only. Clean engine air filter assembly. X Adjust valve lash clearance. X Inspect drive belts, replace as required. X Drain and refill transfer case fluid (4X4). X Inspect fan hub. X Inspect damper. X Inspect water pump weep hole for blockage. X X Replace fuel filter element. Clean the water in

fuel sensor. Inspect front wheel bearings. X Change rear axle fluid. X X Change front axle fluid (4X4). X X

X X XXXX

(192

000)

XXX

(198

000)

(204

000)

(210

000)

(216

000)

Page 42

DR LUBRICATION & MAINTENANCE 0 - 23

Miles 116,250 120,000 123,750 127,500 131,250 135,000 (Kilometers) (186

000)

Change 6-spd manual transmission (G-56) fluid 2500/3500 models only.

Inspect brake linings. X X Inspect and adjust parking brake if necessary. X X Drain and refill automatic transmission fluid and

change main sump and spin-on cooler return filter (if equipped) (545 RFE only).

Drain and refill automatic transmission fluid. Replace filter and adjust bands (48RE only).

Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.

(192

000)

(198

000)

(204

000)

(210

000)

(216

000)

Schedule “A”

Miles 7,500 15,000 22,500 30,000 37,500 (Kilometers) (12 000) (24 000) (36 000) (48 000) (60 000) [Months] [6] [12] [18] [24] [30]

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

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

only. Check transfer case fluid level (4X4). X Inspect water pump weep hole for blockage X X Replace fuel filter element. Clean the water in fuel

sensor. Inspect drive belts, replace as necessary. X Inspect brake linings. X Inspect and adjust parking brake if necessary. X Inspect fan hub. X Inspect damper. X Inspect front wheel bearings. X

XXXXX

Miles 45,000 52,500 60,000 67,500 75,000 (Kilometers)

[Months] [36] [42] [48] [54] [60]

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

stowage.

(72 000) (84 000) (96 000)

XXXXX

(108

000)

(120

000)

Page 43

0 - 24 LUBRICATION & MAINTENANCE DR

Miles 45,000 52,500 60,000 67,500 75,000 (Kilometers)

[Months] [36] [42] [48] [54] [60]

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

Check transfer case fluid level. X Flush and replace engine coolant at 60 months, if not

replaced at 102,000 miles (163 000 km). Inspect drive belts, replace as necessary. X X Inspect water pump weep hole for blockage X X X Replace fuel filter element. Clean the water in fuel

sensor. Inspect brake linings. X X Inspect and adjust parking brake if necessary. X X Inspect fan hub. X Inspect damper. X Inspect front wheel bearings. X Replace fuel filter element. Clean the water in fuel

sensor

(72 000) (84 000) (96 000)

XXXXX

XXX

(108

000)

(120

000)

Miles 82,500 90,000 97,500 100,000 105,000 (Kilometers) (132

000)

[Months] [66] [72] [78] [84]

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

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

only. Flush and replace engine coolant, if not replaced at

60 mos. Check transfer case fluid level (4X4). X Inspect drive belt, replace as required. X Inspect fan hub. X Inspect damper. X Inspect water pump weep hole for blockage. X X Replace fuel filter element. Clean the water in fuel

sensor. Inspect front wheel bearings. X Inspect brake linings. X Inspect and adjust parking brake if necessary. X Drain and refill automatic transmission fluid. Replace

filter and adjust bands (48 RE only).

XXXXX

(144 000)

(156

000)

(160

000)

(168

000)

Page 44

DR LUBRICATION & MAINTENANCE 0 - 25

Miles 112,500 120,000 127,500 135,000 142,500 150,000 (Kilometers) (181

000)

[Months] [90] [96] [102] [108] [114] [120]

Change engine oil and engine oil filter. X X X Lubricate Front Drive Shaft Fitting (2500/3500,

4X4). Rotate tires. X X X X X X Check spare tire for proper pressure and correct

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

models only. Flush and replace engine coolant at 120 months,

if not replaced at 100,000 miles (160 000 km). Inspect drive belt, replace as required. X X Drain and refill transfer case fluid (4X4). X Check tranfer case fluid level (4X4). X Inspect fan hub. X X Inspect damper. X X Inspect water pump weep hole for blockage. X X X Replace fuel filter element. Clean the water in

fuel sensor. Inspect front wheel bearings. X X Inspect brake linings. X X Inspect and adjust parking brake if necessary. X X Adjust valve lash clearance. X

X X XXXX

(193

000)

XXX

(205

000)

(217

000)

(229

000)

(241

000)

Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all receipts.

MAINTENANCE SCHEDULES - SRT/10

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°).

• Drag Race Operation.

• Heavy Loading.

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

• Off-road or desert operation.

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

Page 45

0 - 26 LUBRICATION & MAINTENANCE DR

NOTE: If ANY of these apply to you then flush and replace your engine coolant every 102,000 miles (175 000 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 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.

At Each Oil Change

• Change the engine oil filter.

• 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.

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°).

• Drag Race Operation.

• Heavy Loading.

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

• Off-road or desert operation.

Page 46

DR LUBRICATION & MAINTENANCE 0 - 27

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

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.

Drain and refill automatic transmission fluid. Replace filter and adjust bands.*

Rotate tires. X X Check spare tire for proper pressure and correct

stowage. Change rear axle fluid. X Inspect brake linings. X

Inspect engine air cleaner filter, replace if necessary.

XXXXX

Miles 18,000 21,000 24,000 27,000 30,000 (Kilometers) (30 000) (35 000) (40 000) (45 000) (50 000)

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

Drain and refill automatic transmission fluid. Replace filter and adjust bands.

Rotate tires. X X X Check spare tire for proper pressure and correct

stowage. Change rear axle fluid. X Inspect brake linings. X

Inspect engine air cleaner filter, replace if necessary.

Replace spark plugs. X Inspect and replace, if necessary, the PCV valve.** X**

Miles 33,000 36,000 39,000 42,000 45,000 (Kilometers) (55 000) (60 000) (65 000) (70 000) (75 000)

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

Drain and refill automatic transmission fluid. Replace filter and adjust bands.*

Rotate tires. X X

XXXXX

Page 47

0 - 28 LUBRICATION & MAINTENANCE DR

Miles 33,000 36,000 39,000 42,000 45,000 (Kilometers) (55 000) (60 000) (65 000) (70 000) (75 000)

Check spare tire for proper pressure and correct stowage.

Change rear axle fluid. X Inspect brake linings. X

Inspect engine air cleaner filter, replace if necessary.

Miles 48,000 51,000 54,000 57,000 60,000 (Kilometers) (80 000) (85 000) (90 000) (95 000) (100

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

Drain and refill automatic transmission fluid. Replace filter and adjust bands.

Rotate tires. X X X Check spare tire for proper pressure and correct

stowage. Change rear axle fluid. X Inspect brake linings. X X

Inspect engine air cleaner filter, replace if necessary.

Replace spark plugs. X Replace ignition cables. X Inspect and replace, if necessary, the PCV valve.** X**

Flush and replace engine coolant at 60 months , if not relaced at 102,000 miles (180 000 km)

XXXXX

000)

Miles 63,000 66,000 69,000 72,000 75,000 (Kilometers) (105

000)

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

Drain and refill automatic transmission fluid. Replace filter and adjust bands.*

Rotate tires. X X Check spare tire for proper pressure and correct

stowage. Inspect engine air cleaner filter. X Change rear axle fluid. X Inspect brake linings. X Inspect auto tension drive belt and replace if required. X

XXXXX

(110 000) (115

000)

(120

000)

(125

000)

Page 48

DR LUBRICATION & MAINTENANCE 0 - 29

Miles 78,000 81,000 84,000 87,000 90,000 (Kilometers) (130

000)

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

Drain and refill automatic transmission fluid. Replace filter and adjust bands.

Rotate tires. X X X Check spare tire for proper pressure and correct

stowage. Change rear axle fluid. X Inspect brake linings. X

Inspect engine air cleaner filter, replace if necessary.

Replace spark plugs. X Inspect PCV valve, replace as necessary.** X**

Inspect auto tension drive belt and replace if required. X

XXXXX

(135 000) (140

000)

(145

000)

(150

000)

Miles 93,000 96,000 99,000 100,000 102,000 (Kilometers) (155

000)

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

Rotate tires. X X Check spare tire for proper pressure and correct

stowage. Flush and replace engine coolant, if not replaced at

60 months. Inspect brake linings. X

Miles 105,000 108,000 111,000 114,000 117,000 120,000 (Kilometers) (180

000)

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

Drain and refill automatic transmission fluid. Replace filter and adjust bands.*

Drain and refill automatic transmission fluid. Replace filter and adjust bands.

Rotate tires. X X X Check spare tire for proper pressure and correct

stowage. Change rear axle fluid. X X Inspect brake linings. X X

Inspect engine air cleaner filter, replace if necessary.

Replace spark plugs. X Replace ignition cables. X

XXX X

X X XXXX

(160 000) (165

(185

000)

(190

000)

(195

000)

(170

000)

(200

000)

(175

000)

(205

000)

Page 49

0 - 30 LUBRICATION & MAINTENANCE DR

Miles 105,000 108,000 111,000 114,000 117,000 120,000 (Kilometers) (180

000)

Inspect and replace, if necessary, the PCV valve.**

Inspect auto tension drive belt and replace if required.

Flush and replace engine coolant at 120 months, if not replaced at 102,000 miles (175 000 km).

* Drain and refill automatic transmission fluid. Replace filter and adjust bands every 15, 000 miles if vehicle is used for frequent wide open throttle upshifts (For example Drag Racing).

‡ This maintenance is not required if previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all

receipts.

(185

000)

(190

000)

(195

000)

(200

000)

(205

000)

X**

Schedule “A”

Miles 6,000 12,000 18,000 24,000 30,000 (Kilometers) (10 000) (20 000) (30 000) (40 000) (50 000) [Months] [6] [12] [18] [24] [30]

Change engine oil and engine oil filter. X X X X X Rotate tires. X X X X X Check spare tire for proper pressure and correct

stowage. Inspect brake linings. X

Replace engine air cleaner filter. X Replace spark plugs. X

Miles 36,000 42,000 48,000 54,000 60,000 66,000 (Kilometers) (60 000) (70 000) (80

000)

[Months] [36] [42] [48] [54] [60] [66]

Change engine oil and engine oil filter. X X X X X X Rotate tires. X X X X X X Check spare tire for proper pressure and correct

stowage. Flush and replace engine coolant at 60 months,

if not replaced at 102,000 miles (180 000 km). Inspect brake linings. X X

Replace engine air cleaner filter. X Replace spark plugs. X Inspect and replace, if necessary, the PCV

valve.** Replace ignition cables. X

XXX

(90

000)

(100

000)

X**

(110

000)

Page 50

DR LUBRICATION & MAINTENANCE 0 - 31

Miles 72,000 78,000 84,000 90,000 96,000 100,000 (Kilometers) (120

000)

[Months] [72] [78] [84] [90] [96]

Change engine oil and engine oil filter. X X X X X Drain and refill automatic transmission fluid.

Replace filter and adjust bands. Rotate tires. X X X X X Check spare tire for proper pressure and correct

stowage. Inspect brake linings. X X

Replace engine air cleaner filter. X Replace spark plugs. X Inspect and replace, if necessary, the PCV

valve.**

Inspect auto tension drive belt and replace if required.

XXX

(130

000)

(140

000)

(150

000)

X**

(160

000)

(170

000)

Miles 102,000 108,000 114,000 120,000 (Kilometers) (180 000) (190 000) (200 000) (210 000) [Months] [102] [108] [114] [120]

Change engine oil and engine oil filter. X X X X Rotate tires. X X X X Check spare tire for proper pressure and correct stowage. X X Flush and replace engine coolant, if not done at 60 mos. X Flush and replace engine coolant at 120 months, if not

replaced at 102,000 miles (180 000 km). Inspect brake linings. X Inspect auto tension drive belt and replace if required. X X

Replace ignition cables. X Replace engine air cleaner filter. X Replace spark plugs. X Inspect and replace, if necessary, the PCV valve.** X**

* This maintenance is recommended by the manufacture to the owner, but is not required to maintain the emissions warranty.

‡ This maintenance is not required if previously replaced. Inspection and service should also be performed anytime a malfunction is observed or suspected. Retain all

receipts.

Page 51

0 - 32 LUBRICATION & MAINTENANCE DR

JUMP STARTING

STANDARD PROCEDURE

WARNING: review all safety precautions and warnings in the battery system section of the service manual. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - STANDARD PROCEDURE)

• Do not jump start a frozen battery, personal injury can result.

• If equipped, do not jump start when maintenance free battery indicator dot is yellow or bright color.

• Do not jump start a vehicle when the battery fluid is below the top of lead plates.

• Do not allow jumper cable clamps to touch each other when connected to a booster source.

• Do not use open flame near battery.

• Remove metallic jewelry worn on hands or wrists to avoid injury by accidental arcing of battery current.

• When using a high output boosting device, do not allow battery voltage to exceed 16 volts. Refer to

instructions provided with device being used. Failure to follow these instructions may result in personal injury.

CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle.

TO JUMP START A DISABLED VEHICLE:

1. Raise hood on disabled vehicle and visually inspect engine compartment for:

• Battery cable clamp condition, clean if necessary.

• Frozen battery.

• Yellow or bright color test indicator, if equipped.

• Low battery fluid level.

• Generator drive belt condition and tension.

• Fuel fumes or leakage, correct if necessary.

CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result.

2. When using another vehicle as a booster source, park the booster vehicle within cable reach. Turn off all accessories, set the parking brake, place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF.

3. On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories.

4. Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure.

5. On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible.

6. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery.

CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will overheat and could fail.

7. Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 min.), before cranking again.

DISCONNECT CABLE CLAMPS AS FOLLOWS:

• Disconnect BLACK cable clamp from engine ground on disabled vehicle.

• When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED

cable clamp from battery positive terminal.

• Disconnect RED cable clamp from battery positive terminal on disabled vehicle.

Page 52

DR LUBRICATION & MAINTENANCE 0 - 33

HOISTING

STANDARD PROCEDURE

Refer to the Owner’s Manual for emergency vehicle lifting procedures.

WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When a chassis or drivetrain component is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist.

Page 53

0 - 34 LUBRICATION & MAINTENANCE DR

FLOOR JACK

When properly positioned, a floor jack can be used to lift a vehicle. Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails.

CAUTION: Do not lift vehicle with a floor jack positioned under:

• An axle tube.

• A body side sill.

• A steering linkage component.

• A drive shaft.

• The engine or transmission oil pan.

• The fuel tank.

• A front suspension arm.

NOTE: Use the correct front frame rail lifting locations only.

Page 54

DR LUBRICATION & MAINTENANCE 0 - 35

NOTE: Use the correct rear frame rail lifting locations only.

HOIST

A vehicle can be lifted with:

• A single-post, frame-contact hoist.

• A twin-post, chassis hoist.

• A ramp-type, drive-on hoist.

NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly.

Page 55

0 - 36 LUBRICATION & MAINTENANCE DR

NOTE: The forward lifting pads should be positioned against the forward flange of the transmission crossmember brackets at the bottom of the frame rail.

NOTE: The real lifting pads should be wedged between the forward flange of the leaf spring bracket and the frame rail. Safety stands should be placed under the frame rails at the front and rear ends.

Page 56

DR LUBRICATION & MAINTENANCE 0 - 37

TOWING

STANDARD PROCEDURE

A vehicle equipped with SAE approved sling-type towing equipment can be used to tow all vehicles. When towing a 4WD vehicle using a wheel-lift towing device, use tow dollies under the opposite end of the vehicle. A vehicle with flat-bed device can also be used to transport a disabled vehicle.

A wooden crossbeam may be required for proper connection when using the sling-type, front-end towing method.

SAFETY PRECAUTIONS

CAUTION: The following safety precautions must be observed when towing a vehicle:

• Secure loose and protruding parts.

• Always use a safety chain system that is independent of the lifting and towing equipment.

• Do not allow towing equipment to contact the disabled vehicle’s fuel tank.

• Do not allow anyone under the disabled vehicle while it is lifted by the towing device.

• Do not allow passengers to ride in a vehicle being towed.

• Always observe state and local laws regarding towing regulations.

• Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motor-

ists.

• Do not attach tow chains, T-hooks, J-hooks, or a tow sling to a bumper, steering linkage, drive shafts or a non-reinforced frame hole.

• Do not tow a heavily loaded vehicle. Damage to the cab, cargo box or frame may result. Use a flatbed device to transport a loaded vehicle.

GROUND CLEARANCE

CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums or rotors.

A towed vehicle should be raised until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate ground clearance at the opposite end of the vehicle, especially when towing over rough terrain or steep rises in the road. If necessary, remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground, to increase the ground clearance at the opposite end of the vehicle. Install lug nuts on wheel attaching studs to retain brake drums or rotors.

RAMP ANGLE

If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15 degrees.

Page 57

0 - 38 LUBRICATION & MAINTENANCE DR

TOWING WHEN KEYS ARE NOT AVAILABLE

When the vehicle is locked and keys are not available, use a flat bed hauler. A Wheel-lift or Sling-type device can be used on 4WD vehicles provided all the wheels are lifted off the ground using tow dollies.

FOUR-WHEEL-DRIVE VEHICLE TOWING

DaimlerChrysler Corporation recommends that a vehicle be transported on a flat-bed device. A Wheel-lift or Slingtype device can be used provided all the wheels are lifted off the ground using tow dollies.

WARNING: When towing a disabled vehicle and the drive wheels are secured in a wheel lift or tow dollies, ensure the transmission is in the park position (automatic transmission) or a forward drive gear (manual transmission).

CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended.

Page 58

DR SUSPENSION 2 - 1

SUSPENSION

TABLE OF CONTENTS

page page

SUSPENSION - ELECTRICAL DIAGNOSTICS ..... 1 SUSPENSION - SERVICE INFORMATION....... 27

SUSPENSION - ELECTRICAL DIAGNOSTICS

TABLE OF CONTENTS

page

ACTIVE CHASSIS - ELECTRICAL

DIAGNOSTICS ...........................2

Page 59

2 - 2 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS

TABLE OF CONTENTS

page page

ACTIVE CHASSIS - ELECTRICAL

DIAGNOSTICS

DIAGNOSIS AND TESTING

C143D-STABILIZER SELECT SWITCH

PERFORMANCE.............................4

C143E - STABILIZER BAR SWITCH CIRCUIT

LOW........................................8

C143F-STABILIZER SELECT SWITCH

CIRCUIT HIGH..............................12

C2124-STABILIZER BAR INDICATOR

CONTROL CIRCUIT.........................16

CHECKING STABILIZER SELECT SWITCH

OPERATION................................22

STANDARD PROCEDURE

FDCM VERIFICATION TEST .................26

Page 60

DR ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS 2 - 3

ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS

DIAGNOSIS AND TESTING

Page 61

2 - 4 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

C143D-STABILIZER SELECT SWITCH PERFORMANCE

For a complete wiring diagram Refer to Section 8W.

Page 62

DR ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS 2 - 5

• When Monitored:

Ignition on.

• Set Condition:

During switch operation, the FDCM senses the Disconnecting Stabilizer Switch resistance is out of specification.

Possible Causes

Disconnecting Stabilizer Switch (T531) STABILIZER BAR SWITCH SENSE CIRCUIT OPEN/HIGH RESISTANCE (T536) SWITCH SUPPLY CIRCUIT FDCM

DTC ACTIVE

CAUTION: Before removing the FDCM harness connector, clean the connector and locking cam area of dirt and debris. Failure to do so can result in the connector being jammed or damage to the locking cams on the harness connector or module. Do not force the assist arm when releasing or installing the harness connector.

Turn the ignition on, engine not running With the scan tool, read FDCM DTC(s).

Is the DTC active at this time?

Yes >> No >>

Disconnecting Stabilizer Switch OPERATION

NOTE: Before continuing with the below diagnostic test, ensure the FDCM harness connector seal is installed correctly. Inspect the terminals on both harness connector and the module for damage. Failure to do so can result in misdiagnoses of the system.

Turn the ignition off. Disconnect the Disconnecting Stabilizer Switch harness connector. Remove the Disconnecting Stabilizer Switch. Measure the resistance on the Disconnecting Stabilizer Switch between the Switch Supply terminal and the Stabi-

lizer Bar Switch Sense terminal. The resistance must read as follows for each position of the switch.

• Off Road: 33 ohms +/- 5%

• On Road: 510 ohms +/- 5%

• Switch Not Applied: 2.2k ohms +/- 5%

Does the ohmmeter read correctly for each position of the Disconnecting Stabilizer Switch ?

Yes >> No >>

Go To 2 Go To 5

Go To 3 Replace the Disconnecting Stabilizer Switch.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Page 63

2 - 6 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

(T531) STABILIZER BAR SWITCH SENSE CIRCUIT OPEN

Disconnect the FDCM harness connector. Measure the resistance of the (T531) Stabilizer Bar Switch Sense circuit

between the Disconnecting Stabilizer Switch and the FDCM harness connectors.

Is the resistance below 5.0 ohms?

Yes >> No >>

(T536) SWITCH SUPPLY CIRCUIT OPEN

Measure the resistance of the (T536) Switch Supply circuit between the Disconnecting Stabilizer Switch and the FDCM harness connectors.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Go To 4 Repair the open or high resistance in the (T531) Stabilizer

Bar Switch Sense circuit. Perform FDCM VERIFICATION TEST. (Refer to 2 - SUS-

PENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Replace the FDCM in accordance with the Service Information

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Repair the open or high resistance in the (T536) Switch Supply circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Page 64

DR ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS 2 - 7

INTERMITTENT WIRING AND CONNECTORS

The conditions necessary to set this DTC are not present at this time. Using the schematics as a guide, inspect the wiring and connectors specific to this circuit. Wiggle test the wiring harness and connectors while checking for shorted and open circuits. Using the scan tool, monitor the data related to this circuit while performing the wiggle test. Look for the data to

change or for the DTC to reset. While monitoring the Stabilizer Bar State on the scan tool, move the switch to each position. The scan tool display

must match the position on the actual switch.

Were there any problems found?

Yes >>

No >>

Repair as necessary. Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD

PROCEDURE) Test Complete.

Page 65

2 - 8 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

C143E - STABILIZER BAR SWITCH CIRCUIT LOW

For a complete wiring diagram Refer to Section 8W.

Page 66

DR ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS 2 - 9

• When Monitored:

Ignition on.

• Set Condition:

During switch operation, the FDCM senses the Disconnecting Stabilizer Bar Switch sense is below 0.25 volt.

Possible Causes

SWITCH INTERMITTENT DISCONNECTING STABILILZER BAR SWITCH (T536) SWITCH SUPPLY CIRCUIT SHORTED TO GROUND (T531) STABILIZER BAR SWITCH SENSE CIRCUIT SHORT TO GROUND FDCM

DTC ACTIVE

Turn the ignition on, engine not running With the scan tool, read FDCM DTC(s).

Is the DTC active at this time?

Yes >> No >>

DISCONNECTING STABILIZER BAR SWITCH OPERATION

lizer Switch Sense terminal. The resistance must read as follows for each position of the switch.

• Off Road: 33 ohms +/- 5%

• On Road: 510 ohms +/- 5%

• Switch Not Applied: 2.2k ohms +/- 5%

Does the ohmmeter read correctly for each position of the Stabilizer Bar Switch

Yes >> No >>

Go To 2 Go To 5

Go To 3 Replace the Disconnecting Stabilizer Switch.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Page 67

2 - 10 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

(T531) STABILIZER BAR SWITCH SENSE CIRCUIT SHORTED TO GROUND

Disconnect the FDCM harness connector. Measure the resistance of the (T531) Stabilizer Bar Switch Sense circuit

in the Disconnecting Stabilizer Switch harness connector to ground.

Is the resistance below 5.0 ohms?

Yes >>

No >>

(T536) SWITCH SUPPLY CIRCUIT SHORT TO GROUND

Measure the resistance of the (T536) Switch Supply circuit in the Disconnecting Stabilizer Switch harness connector to ground.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Repair the short to ground in the (T531) Disconnecting Stabilizer Switch Sense circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Go To 4

Repair the short to ground in the (T536) Switch Supply circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Replace the FDCM in accordance with the Service Information

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Page 68

DR ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS 2 - 11

INTERMITTENT WIRING AND CONNECTORS

change or for the DTC to reset. While monitoring the Stabilizer Bar State on the scan tool, move the switch to each position. The scan tool display

must match the position on the actual switch.

Were there any problems found?

Yes >>

No >>

Repair as necessary. Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD

PROCEDURE) Test Complete.

Page 69

2 - 12 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

C143F-STABILIZER SELECT SWITCH CIRCUIT HIGH

For a complete wiring diagram Refer to Section 8W.

Page 70

DR ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS 2 - 13

• When Monitored:

Ignition on.

• Set Condition:

During switch operation, the FDCM senses the Stabilizer Bar Switch Sense circuit is above 4.0 volts.

Possible Causes

SWITCH INTERMITTENT STABILIZER BAR SWITCH (T531) STABILIZER BAR SWITCH SENSE CIRCUIT SHORT TO VOLTAGE (T536) SWITCH SUPPLY CIRCUIT SHORTED TO (T531) STABILIZER BAR SWITCH SENSE CIRCUIT (T536) STABILIZER BAR SWITCH SENSE CIRCUIT OPEN FDCM

DTC ACTIVE

Turn the ignition on, engine not running With the scan tool, read FDCM DTC(s).

Is the DTC active at this time?

Yes >> No >>

DISCONNECTING STABILIZER BAR SWITCH OPERATION

Turn the ignition off. Disconnect the Disconnecting Stabilizer Bar Switch harness connector. Remove the Disconnecting Stabilizer Bar Switch. Measure the resistance on the Disconnecting Stabilizer Bar Switch between the Switch Supply terminal and the

Stabilizer Bar Switch Sense terminal. The resistance must read as follows for each position of the switch.

• Off Road: 33 ohms +/- 5%

• On Road: 510 ohms +/- 5%

• Switch Not Applied: 2.2k ohms +/- 5%

Does the ohmmeter read correctly for each position of the Disconnecting Stabilizer Bar Switch

Yes >> No >>

Go To 2 Go To 6

Go To 5 Replace the Disconnecting Stabilizer Bar Switch.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Page 71

2 - 14 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

(T531) STABILIZER BAR SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE

Disconnect the FDCM harness connector. Turn the ignition on. Measure the voltage of the (T531) Stabilizer Bar Switch Sense circuit in

the Disconnecting Stabilizer Bar Switch harness connector.

Does the voltmeter indicate voltage present?

Yes >>

No >>

(T536) SWITCH SUPPLY CIRCUIT SHORTED TO (T351) STABILIZER BAR SWITCH SENSE CIRCUIT

Measure the resistance between (T536) Switch Supply circuit and the (T531) Stabilizer Bar Switch Sense circuit in the Disconnecting Stabilizer Bar Switch harness connector.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Repair the short to voltage in the (T531) Stabilizer Bar Switch Sense circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Go To 4

Repair the short between (T536) Switch Supply circuit and the (T531) Stabilizer Bar Switch Sense circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Go To 5

Page 72

DR ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS 2 - 15

(T531) STABILIZER BAR SWITCH SENSE CIRCUIT OPEN

Measure the resistance of the (T531) Stabilizer Bar Switch Sense circuit between the Disconnecting Stabilizer Bar Switch and the FDCM harness connectors.

Is the resistance below 5.0 ohms?

Yes >>

No >>

INTERMITTENT WIRING AND CONNECTORS

change or for the DTC to reset. While monitoring the Stabilizer Bar State on the scan tool, move the switch to each position. The scan tool display

must match the position on the actual switch.

Were there any problems found?

Replace the FDCM in accordance with the Service Information.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Repair the open in the (T531) Stabilizer Bar Switch Sense circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Yes >>

No >>

Repair as necessary. Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD

PROCEDURE) Test Complete.

Page 73

2 - 16 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

C2124-STABILIZER BAR INDICATOR CONTROL CIRCUIT

For a complete wiring diagram Refer to Section 8W.

Page 74

DR ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS 2 - 17

• When Monitored:

Ignition on.

• Set Condition:

The FDCM has detected a short to voltage, ground or an open in the Stabilizer Bar Disengage or Engage Illumination Sense circuits.

Possible Causes

DISCONNECTING STABILIZER SWITCH (T530) STABILIZER BAR DISENGAGE ILLUMINATION SENSE SHORT TO VOLTAGE (T530) STABILIZER BAR DISENGAGE ILLUMINATION SENSE SHORT TO GROUND (T530) STABILIZER BAR DISENGAGE ILLUMINATION SENSE OPEN (T529) STABILIZER BAR ENGAGE ILLUMINATION SENSE SHORT VOLTAGE (T529) STABILIZER BAR ENGAGE ILLUMINATION SENSE SHORT GROUND (T529) STABILIZER BAR ENGAGE ILLUMINATION SENSE OPEN FDCM

DTC ACTIVE

NOTE: If set along with this DTC, diagnostic any Locker/Differential Indicator Control Circuit DTC(s) first before continuing.

Turn the ignition on, engine not running With the scan tool, read FDCM DTC(s).

Is the DTC active at this time?

Yes >> No >>

(T530) STABILIZER BAR DISENGAGE ILLUMINATION SENSE OPERATION

Turn the ignition off. Disconnect the Disconnecting Stabilizer Bar Switch harness connector. Using a 12-volt test light connected to battery voltage, probe the (T530)

Stabilizer Bar Disengage Illumination Sense circuit. Turn the ignition on. With the scan tool, actuate the Stabilizer Bar Disengage Illumination

Sense circuit.

Does the test light illuminate and flash on and off?

Yes >> No >>

Go To 2 Go To 11

Go to 3 Go To 4

Page 75

2 - 18 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

(T529) STABILIZER BAR ENGAGE ILLUMINATION SENSE OPERATION

Probe the Stabilizer Bar Disengage Illumination Sense circuit with the test light.

With the scan tool, actuate the (T529) Stabilizer Bar Engage Illumination Sense circuit.

Does the test light illuminate and flash on and off?

Yes >>

No >>

(T530) STABILIZER BAR DISENGAGE ILLUMINATION SENSE CIRCUIT SHORTED TO VOLTAGE

Turn the ignition off. Disconnect the FDCM harness connector. Turn the ignition on. Measure the voltage on the (T530) Stabilizer Bar Disengage Illumination

Sense circuit in the FDCM harness connector.

Does the voltmeter indicate voltage present?

Yes >>

No >>

Replace the Disconnecting Stabilizer Bar Switch. Perform FDCM VERIFICATION TEST. (Refer to 2 - SUS-

PENSION/ACTIVE CHASSIS - STANDARD PROCEDURE) Go to 7

Repair the short to voltage in the (T530) Stabilizer Bar Disengage Illumination Sense circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Go To 5

Page 76

DR ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS 2 - 19

(T530) STABILIZER BAR DISENGAGE ILLUMINATION SENSE CIRCUIT SHORTED TO GROUND

Turn the ignition off. Measure the resistance of the (T530) Stabilizer Bar Disengage Illumina-

tion Sense circuit between ground and the FDCM harness connector.

Is the resistance below 100 ohms?

Yes >>

No >>

(T530) STABILIZER BAR DISENGAGE ILLUMINATION SENSE CIRCUIT OPEN

Measure the resistance of the (T530) Stabilizer Bar Disengage Illumination Sense circuit between the Disconnecting Stabilizer Bar Switch harness connector and the FDCM harness connector.

Is the resistance below 5.0 ohms?

Yes >> No >>

Repair the short to ground in the (T530) Stabilizer Bar Disengage Illumination Sense circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Go To 6

Go To 10 Repair the open in the (T530) Stabilizer Bar Disengage Illu-

mination Sense circuit. Perform FDCM VERIFICATION TEST. (Refer to 2 - SUS-

PENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Page 77

2 - 20 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

(T529) STABILIZER BAR ENGAGE ILLUMINATION SENSE CIRCUIT SHORTED TO VOLTAGE

Turn the ignition off. Disconnect the FDCM harness connector. Turn the ignition on. Measure the voltage on the (T529) Stabilizer Bar Engage Illumination

Sense circuit in the FDCM harness connector.

Does the voltmeter indicate voltage present?

Yes >>

No >>

(T529) STABILIZER BAR ENGAGE ILLUMINATION SENSE CIRCUIT SHORTED TO GROUND

Turn the ignition off. Measure the resistance of the (T529) Stabilizer Bar Engage Illumination

Sense circuit between ground and the FDCM harness connector.

Is the resistance below 100 ohms?

Yes >>

No >>

Repair the short to voltage in the (T529) Stabilizer Bar Engage Illumination Sense circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Go To 8

Repair the short to ground in the (T529) Stabilizer Bar Engage Illumination Sense circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Go To 9

Page 78

DR ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS 2 - 21

(T529) STABILIZER BAR ENGAGE ILLUMINATION SENSE CIRCUIT OPEN

Measure the resistance of the (T529) Stabilizer Bar Engage Illumination Sense circuit between the Disconnecting Stabilizer Bar Switch harness connector and the FDCM harness connector.

Is the resistance below 5.0 ohms?

Yes >> No >>

10.

NOTE: Before continuing, check the FDCM harness connector terminals for corrosion, damage, or terminal push out. Repair as necessary.

Using the schematics as a guide, inspect the wire harness and connectors. Pay particular attention to all Power and Ground circuits.

Were there any problems found?

Yes >>

No >>

Go To 10 Repair the open in the (T529) Stabilizer Bar Engage Illumi-

nation Sense circuit. Perform FDCM VERIFICATION TEST. (Refer to 2 - SUS-

PENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

FDCM

Repair as necessary. Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD

PROCEDURE) Replace and program the Final Drive Control Module in accordance with Service Information.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

INTERMITTENT WIRING AND CONNECTORS

11.

change or for the DTC to reset.

Were there any problems found?

Yes >>

No >>

Repair as necessary. Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD

PROCEDURE) Test Complete.

Page 79

2 - 22 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

CHECKING STABILIZER SELECT SWITCH OPERATION

For a complete wiring diagram Refer to Section 8W.

Page 80

DR ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS 2 - 23

Possible Causes

STABILIZER BAR SWITCH (T531) STABILIZER BAR SWITCH SENSE CIRCUIT SHORT TO VOLTAGE (T536) SWITCH SUPPLY CIRCUIT SHORTED TO (T531) STABILIZER BAR SWITCH SENSE CIRCUIT (T536) STABILIZER BAR SWITCH SENSE CIRCUIT OPEN FDCM

Diagnostic Test

STABILIZER SELECT SWITCH OPERATION

Turn the ignition off. Secure the vehicle by blocking the rear wheels from the front and back. Disconnect the Stabilizer Bar Link on the passenger side. Turn the ignition on, Stabilizer Select Switch in the ON ROAD position. The Stabilizer Bar should not move up and down. Using the Stabilizer Select Switch, select OFF ROAD. Attempt to move the Stabilizer Bar up and down.

Does the Stabilizer Bar operate as described above?

Yes >> No >>

DISCONNECTING STABILIZER BAR SWITCH OPERATION

Stabilizer Bar Switch Sense terminal. The resistance must read as follows for each position of the switch.

• Off Road: 33 ohms +/- 5%

• On Road: 510 ohms +/- 5%

• Switch Not Applied: 2.2k ohms +/- 5%

Does the ohmmeter read correctly for each position of the Disconnecting Stabilizer Bar Switch

Yes >> No >>

Stabilizer Select Switch is operating normally. Test complete. Go To 2

Go To 3 Replace the Disconnecting Stabilizer Bar Switch.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Page 81

2 - 24 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

(T531) STABILIZER BAR SWITCH SENSE CIRCUIT SHORTED TO VOLTAGE

Disconnect the FDCM harness connector. Turn the ignition on. Measure the voltage of the (T531) Stabilizer Bar Switch Sense circuit in

the Disconnecting Stabilizer Bar Switch harness connector.

Does the voltmeter indicate voltage present?

Yes >>

No >>

(T536) SWITCH SUPPLY CIRCUIT SHORTED TO (T351) STABILIZER BAR SWITCH SENSE CIRCUIT

Measure the resistance between (T536) Switch Supply circuit and the (T531) Stabilizer Bar Switch Sense circuit in the Disconnecting Stabilizer Bar Switch harness connector.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Repair the short to voltage in the (T531) Stabilizer Bar Switch Sense circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Go To 4

Repair the short between (T536) Switch Supply circuit and the (T531) Stabilizer Bar Switch Sense circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Go To 5

Page 82

DR ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS 2 - 25

(T531) STABILIZER BAR SWITCH SENSE CIRCUIT OPEN

Measure the resistance of the (T531) Stabilizer Bar Switch Sense circuit between the Disconnecting Stabilizer Bar Switch and the FDCM harness connectors.

Is the resistance below 5.0 ohms?

Yes >>

No >>

Replace the FDCM in accordance with the Service Information.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Repair the open in the (T531) Stabilizer Bar Switch Sense circuit.

Perform FDCM VERIFICATION TEST. (Refer to 2 - SUSPENSION/ACTIVE CHASSIS - STANDARD PROCEDURE)

Page 83

2 - 26 ACTIVE CHASSIS - ELECTRICAL DIAGNOSTICS DR

STANDARD PROCEDURE FDCM VERIFICATION TEST Diagnostic Test

PERFORM FDCM VERIFICATION TEST

NOTE: If the SKIM, PCM or FCM was replaced, refer to the service information for proper programming procedures.

1. Disconnect all jumper wires and reconnect all previously disconnected components and connectors.

2. Ensure that all accessories are turned off.

3. Ensure that the battery is fully charged.

4. With the DRBIIIT, record and erase all DTC(s) from the FDCM

5. Start and run the engine for 2 minutes while operating all functions of the system that caused the original

concern.

NOTE: When a Stabilizer System DTC diagnostic is complete and all repairs have been made, running the Stabilizer Motor System Test and/or LED System Test can also provide verification that the DTC has been repaired and the system is operating normally.

7. Turn the ignition off, wait 5 seconds, then turn the ignition on. Using the DRBIIIT, read DTC(s) from the

FDCM.

Are any FDCM DTC(s) present or is the original condition still present?

Yes >> No >>

The repair is not complete. Refer to the related category for the DTC or symptom that is still present. The repair is complete.

Page 84

DR SUSPENSION - SERVICE INFORMATION 2 - 27

SUSPENSION - SERVICE INFORMATION

TABLE OF CONTENTS

page page

WHEEL ALIGNMENT .....................27

FRONT - INDEPENDENT FRONT SUSPENSION .34

WHEEL ALIGNMENT

TABLE OF CONTENTS

page page

WHEEL ALIGNMENT

DESCRIPTION ................................28

OPERATION ..................................28

DIAGNOSIS AND TESTING

PRE-ALIGNMENT INSPECTION ..............28

STANDARD PROCEDURE

CAMBER AND CASTER ADJUSTMENT .......30

FRONT - LINK/COIL ......................84

REAR ................................114

TOE ADJUSTMENT .........................30

CAMBER, CASTER AND TOE ADJUSTMENT . . 31

ALIGNMENT LINK/COIL SUSPENSION ........32

SPECIFICATIONS

ALIGNMENT ................................32

Page 85

2 - 28 WHEEL ALIGNMENT DR

WHEEL ALIGNMENT

DESCRIPTION

NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur.

Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe.

CAUTION: Never attempt to modify suspension or steering components by heating or bending.

OPERATION

• CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns

• CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire

• TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause’s unstable steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment

• THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle

DIAGNOSIS AND TESTING PRE-ALIGNMENT INSPECTION

Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart below for additional information.

1. Inspect tires for size, air pressure and tread wear.

2. Inspect front wheel bearings for wear.

3. Inspect front wheels for excessive radial or lateral runout and balance.

4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding.

5. Inspect suspension components for wear and noise.

6. Road test the vehicle.

Page 86

DR WHEEL ALIGNMENT 2 - 29

SUSPENSION AND STEERING SYSTEM DIAGNOSIS

CONDITION POSSIBLE CAUSES CORRECTION

FRONT END NOISE 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

2. Loose or worn steering or suspension components.

3. Loose or worn steering or suspension components.

EXCESSIVE PLAY IN STEERING

FRONT WHEELS SHIMMY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

VEHICLE INSTABILITY 1. Loose or worn wheel bearing. 1. Replace wheel bearing.

1. Loose or worn wheel bearing. 1. Replace wheel bearing.

2. Loose or worn steering or suspension components.

3. Loose or worn steering gear. 3. Replace steering gear.

2. Loose or worn steering or suspension components.

3. Tires worn or out of balance. 3. Replace or balance tires.

4. Alignment. 4. Align vehicle to specifications.

2. Loose or worn steering or suspension components.

3. Tire pressure. 3. Adjust tire pressure.

4. Alignment. 4. Align vehicle to specifications.

2. Tighten or replace components as necessary.

3. Tighten or replace components as necessary.

2. Tighten or replace components as necessary.

EXCESSIVE STEERING EFFORT

VEHICLE PULLS TO ONE SIDE

1. Loose or worn steering gear. 1. Replace steering gear.

2. Column coupler binding. 2. Replace coupler.

3. Tire pressure. 3. Adjust tire pressure.

4. Alignment. 4. Align vehicle to specifications.

1. Tire pressure. 1. Adjust tire pressure.

2. Tire. 2. Criss-Cross Front Tires.

3. Alignment. 3. Align vehicle to specifications.

4. Loose or worn steering or suspension components.

5. Radial tire lead. 5. Rotate or replace tire as necessary.

6. Brake pull. 6. Repair brake as necessary.

7. Weak or broken spring. 7. Replace spring.

4. Tighten or replace components as necessary.

Page 87

2 - 30 WHEEL ALIGNMENT DR

STANDARD PROCEDURE CAMBER AND CASTER ADJUSTMENT

Camber and caster angle adjustments involve changing the position of the lower control arm (2) in conjunction with the slotted holes in the frame brackets (1). Vehicle should be at normal ride height.

TOE ADJUSTMENT

The wheel toe position adjustment is the final adjustment.

1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position.

2. Loosen the tie rod jam nuts (1).

NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straightahead.

3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary.

4. Tighten the tie rod jam nut (1) to 127 N·m (94 ft. lbs.).

5. Verify the specifications

6. Turn off engine.

Page 88

DR WHEEL ALIGNMENT 2 - 31

CAMBER, CASTER AND TOE ADJUSTMENT

Camber and caster angle adjustments involve changing the position of the lower control arm with the slots in the frame brackets (1).

CASTER

Moving the front or rear position of the lower control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the lower control arm in or out. Then move the other pivot bolt of the lower control arm in the opposite direction.

To increase positive caster angle, move the rear position of the lower control arm inward (toward the engine). Move the front of the lower control arm outward (away from the engine) slightly until the desired camber angle is obtained.

CAMBER

Move both pivot bolts of the lower control arm together in or out. This will change the camber angle significantly and little effect on the caster angle.

After adjustment is made tighten the lower control arm nuts to proper torque specification.

TOE ADJUSTMENT

The wheel toe position adjustment is the final adjustment.

1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position.

2. Loosen the tie rod jam nuts (1).

NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straightahead.

3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary.

4. Tighten the tie rod jam nut (1) to 127 N·m (94 ft. lbs.).

5. Verify the specifications

6. Turn off engine.

Page 89

2 - 32 WHEEL ALIGNMENT DR

ALIGNMENT LINK/COIL SUSPENSION

Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in the down position. Set the front end alignment to specifica-

tions while the vehicle is in its NORMALLY LOADED CONDITION.

CAMBER: The wheel camber angle is preset and is

not adjustable. CASTER: Check the caster of the front axle for cor-

rect angle. Be sure the axle is not bent or twisted. Road test the vehicle and make left and right turn. Observe the steering wheel return-to-center position. Low caster will cause poor steering wheel returnability.

Caster can be adjusted by rotating the cams (3) on the lower suspension arm.

TOE POSITION: The wheel toe position adjustment should be the final adjustment.

1. Start the engine and turn wheels both ways before straightening the wheels. Center and Secure the steering wheel and turn off engine.

2. Loosen the adjustment sleeve clamp bolts.

3. Adjust the right wheel toe position with the drag link. Turn the sleeve until the right wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting

does not change during clamp tightening.

4. Adjust left wheel toe position with tie rod at left knuckle. Turn the sleeve until the left wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe

setting does not change during clamp tightening.

NOTE: Toe setting will change during tightening, Make sure to verify reading after tightening.

5. Verify the right toe setting and a straight steering wheel.

6. Road test the vehicle.

SPECIFICATIONS ALIGNMENT

NOTE: All alignment specifications are in degrees.

SPECIFICATIONS

DESCRIPTION SPECIFICATION

VEHICLE

1500

4X2 4X2 120.5 in 3.35° ± 0.75° 3.75° ± 0.75° 0.10° ± 0.50° 0.10° ± 0.50° 0.05° ± 0.05° 4X2 140.5 in 3.35° ± 0.75° 3.75° ± 0.75° 0.10° ± 0.50° 0.10° ± 0.50° 0.05° ± 0.05° 4X2 160.5 in 3.35° ± 0.75° 3.75° ± 0.75° 0.10° ± 0.50° 0.10° ± 0.50° 0.05° ± 0.05°

MAX RT/LT

DIFFERENCE

4X2

1500

WHEEL

BASE

— -.40° ± 0.50° 0.20° ± 0.50° 0°±.06°

INDIVIDUAL

CASTER

LEFT SIDE

INDIVIDUAL

CASTER

RIGHT SIDE

INDIVIDUAL

CAMBER

LEFT SIDE

INDIVIDUAL

CAMBER

RIGHT SIDE

INDIVIDUAL

TOE

Page 90

DR WHEEL ALIGNMENT 2 - 33

DESCRIPTION SPECIFICATION

VEHICLE

1500

4X4 4X4 120.5 in 3.35° ± 0.75° 3.75° ± 0.75° 0.10° ± 0.50° 0.10° ± 0.50° 0.05° ± 0.05° 4X4 140.5 in 3.35° ± 0.75° 3.75° ± 0.75° 0.10° ± 0.50° 0.10° ± 0.50° 0.05° ± 0.05° 4X4 160.5 in 3.35° ± 0.75° 3.75° ± 0.75° 0.10° ± 0.50° 0.10° ± 0.50° 0.05° ± 0.05°

MAX RT/LT

DIFFERENCE

4X4

1500

VEHICLE

SRT 10 SRT 10 120.5 4.50° ± 0.5° -0.15° + 0.15° -0.25° 0.12° ± 0.08° SRT 10 140.5 4.50° ± 0.5° -0.15° + 0.15° -0.25° 0.12° ± 0.08°

MAX RT/LT

DIFFERENCE

SRT 10

VEHICLE

4X2

2500 & 3500

4X2

2500&3500

4X2

2500&3500 MAX RT/LT

DIFFERENCE

4X2

2500&3500

VEHICLE

4X4

2500&3500

4X4

2500&3500

4X4

2500&3500 MAX RT/LT

DIFFERENCE

4X4

2500&3500

DESCRIPTION REAR SPECIFICATION

LD & HD INDIVIDUAL

SRT 10 INDIVIDUAL

WHEEL

BASE

— -.40° ± 0.50 0.20° ± 0.50° 0°±.06°

WHEELBASE INDIVIDUAL

— 0.00° ± 0.30° 0.00° ± 0.30° 0°±.06°

WHEEL

BASE

140.5 4.00° ± 0.75° 0.00° ± 0.50° 0.10° ± 0.05°

160.5 4.00° ± 0.75° 0.00° ± 0.50° 0.10° ± 0.05°

— 0.00° ± 0.50° 0.00° ± 0.50° 0°±.06°

WHEEL

BASE

140.5 4.50° ± 0.5° 0.25° ± 0.50° 0.10° ± 0.05°

160.5 4.50° ± 0.5° 0.25° ± 0.50° 0.10° ± 0.05°

— 0.00° ± 0.50° 0.00° ± 0.50° 0°±.06°

CAMBER

(-.10° ± 0.5°)

CAMBER

(0.00° ±

0.25°

INDIVIDUAL

CASTER

LEFT SIDE

CASTER

INDIVIDUAL

CASTER

INDIVIDUAL

CASTER

MAX RT/LT

DIFFERENCE

(0.00° ±

0.50°)

MAX RT/LT

DIFFERENCE

INDIVIDUAL

CASTER

RIGHT SIDE

TOTAL TOE

(0.30° ±

0.50°)

TOTAL TOE

SRT 10

(0.30° ±

0.16°)

INDIVIDUAL

CAMBER

LEFT SIDE

INDIVIDUAL

CAMBER

INDIVIDUAL

CAMBER

INDIVIDUAL

CAMBER

THRUST

ANGLE 0° ±

0.4° 4X2

4X4

1500

THRUST ANGLE 0° ± 0.17° SRT 10

INDIVIDUAL

CAMBER

RIGHT SIDE

THRUST ANGLE -0.2° ± 0.2°

2500&3500

INDIVIDUAL

4X2

4X4

TOE

Page 91

2 - 34 FRONT - INDEPENDENT FRONT SUSPENSION DR

FRONT - INDEPENDENT FRONT SUSPENSION

TABLE OF CONTENTS

page page

FRONT - INDEPENDENT FRONT SUSPENSION

DESCRIPTION

4X2 FRONT SUSPENSION ..................35

1500 4X4 FRONT SUSPENSION .............35

CONTROL ARMS ...........................36

SPECIFICATIONS

TORQUE ...................................37

SPECIAL TOOLS

FRONT SUSPENSION .......................39

BUSHINGS

REMOVAL

LOWER CONTROL ARM BUSHINGS - 4X4

(LD)........................................41

LOWER CONTROL ARM BUSHINGS - 4X2

(LD)........................................41

UPPER CONTROL ARM BUSHINGS - IFS

(LD)........................................41

UPPER CONTROL ARM BUSHINGS - IFS

(HD).......................................42

LOWER CONTROL ARM SHOCK BUSHING -

IFS 4X4....................................42

INSTALLATION

LOWER CONTROL ARM BUSHINGS - 4X4

(LD)........................................44

LOWER CONTROL ARM BUSHINGS - 4X2 -

(LD)........................................45

UPPER CONTROL ARM BUSHINGS - IFS

(LD)........................................46

UPPER CONTROL ARM BUSHINGS - IFS

(HD).......................................46

LOWER CONTROL ARM SHOCK BUSHING -

IFS 4X4....................................47

HUB / BEARING

REMOVAL

4X4 ........................................48

4X2 ........................................48

INSTALLATION

4X4 ........................................49

4X2 ........................................49

KNUCKLE

DESCRIPTION ................................50

OPERATION ..................................50

REMOVAL

(LD) 4X2 & 4X4 .............................50

(HD) 4X2 ...................................52

INSTALLATION

(LD) 4X2 & 4X4 .............................52

(HD) 4X2 ...................................53

UPPER CONTROL ARM

REMOVAL ....................................54

INSTALLATION ...............................55

UPPER BALL JOINT

DIAGNOSIS AND TESTING

UPPER BALL JOINT ........................56

REMOVAL ....................................56

INSTALLATION ...............................57

LOWER CONTROL ARM

REMOVAL

4X4 (LD) ...................................58

4X2 ........................................59

INSTALLATION

4X4 (LD) ...................................61

4X2 ........................................62

LOWER BALL JOINT

DIAGNOSIS AND TESTING

LOWER BALL JOINT ........................63

REMOVAL

4X2 (LD) ...................................63

4X4 (LD) ...................................64

4X2 (HD) ...................................65

INSTALLATION

4X2 (LD) ...................................66

4X4 (LD) ...................................67

4X2 (HD) ...................................68

SHOCK

DIAGNOSIS AND TESTING ....................69

REMOVAL

4X2 ........................................69

4X4-COIL OVER ............................70

INSTALLATION

4X2 ........................................72

4X4-COIL OVER ............................72

SPRING

REMOVAL

4X2 ........................................74

4X4–COIL OVER ............................75

INSTALLATION

4X2 ........................................77

4X4-COIL OVER ............................78

STABILIZER BAR

DESCRIPTION ................................80

OPERATION ..................................80

REMOVAL ....................................80

INSTALLATION ...............................80

STABILIZER LINK

REMOVAL

4X4 ........................................82

4X2 ........................................82

INSTALLATION

4X4 ........................................83

4X2 ........................................83

Page 92

DR FRONT - INDEPENDENT FRONT SUSPENSION 2 - 35

FRONT - INDEPENDENT FRONT SUSPENSION

DESCRIPTION 4X2 FRONT SUSPENSION

The front suspension is designed to allow each wheel to adapt to different road surfaces independently. The wheels are mounted to hub/bearings units bolted to the steering knuckle. The double-row hub bearings are sealed and lubricated for life. The steering knuckles turn (pivot) on ball joints.

The front suspension is comprised of:

• Shock absorbers

• Coil Spring

• Control arms (1&3)

• Steering knuckles (2)

• Stabilizer bar

• Stabilizer link

• Tie Rod Ends

• Hub/Bearing

• Rack & Pinion

• Ball Joints

NOTE: The SRT-10 vehicle is not equipped with front brake dust shields.

NOTE: Components attached with a nut must be torqued to specification.

1500 4X4 FRONT SUSPENSION

Page 93

2 - 36 FRONT - INDEPENDENT FRONT SUSPENSION DR

The front suspension is comprised of:

• Coil over Shock absorbers (5)

• Coil over Springs (4)

• Control arms (1&7)

• Steering knuckles (3)

• Stabilizer bar (9)

• Stabilizer link (8)

• Tie Rod Ends (6)

• Hub/Bearing

• Rack & Pinion

• Ball Joints (2)

NOTE: The SRT-10 vehicle is not equipped with front brake dust shields.

NOTE: Components attached with a nut must be torqued to specification.

CONTROL ARMS

The lower control arm (2) bolts in frame brackets. The frame brackets have slotted holes which allow the arms (2) to be adjusted with cambolts (1) for caster and camber adjustment.

Page 94

DR FRONT - INDEPENDENT FRONT SUSPENSION 2 - 37

The upper control arms (2) bolt to the upper frame brackets and pivots through bushings.

The control arms have lube for life ball studs (3). The control arm travel (jounce) is limited through the use of rubber/urethane bumpers. Rebound travel is limited by the shock absorber.

Having the suspension at curb ride height when torquing bolts ensures good ride characteristics and longer bushing life by preventing excessive 9wind-up9 of the bushing.

SPECIFICATIONS TORQUE

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Shock Absorber

Upper Nut

4X4

Shock Absorber

Lower Bolt

4X4

Shock Absorber

Upper Nut

4X2

Shock Absorber

Lower Bolt

4X2

Lower Suspension Arm

Frame Nuts

LD 4X2 & 4X4

Lower Suspension Arm

Frame Nuts

HD 4X2

Lower Suspension Arm

Ball Joint Nut

1500 series only

Lower Suspension Arm

Ball Joint Nut

(HD 4X2 only

Upper Suspension Arm

Frame Nuts

(LD)

Upper Suspension Arm

Frame Nuts

(HD 4X2 only)

61 45 —

210 155 —

54 40 —

35 25 —

204 150 —

237 175 —

Then an additional 90°

135 100 —

176 130 —

170 125 —

Then an additional 90°

—

Page 95

2 - 38 FRONT - INDEPENDENT FRONT SUSPENSION DR

DESCRIPTION N·m Ft. Lbs. In. Lbs.

Upper Suspension Arm

Ball Joint Nut

1500 series only

Stabilizer Bar

Frame Bolt

Stabilizer Link

Lower Control Arm Nut

Stabilizer Link

Stabilizer Bar Nut

Hub/Bearing

Bolts

(LD)

Hub/Bearing

Bolts

(HD 4X2)

Tie Rod End

Nut

Then an additional 90°

61 45 —

102 75 —

27 20 —

163 120 —

176 130 —

Then an additional 90°

—

Page 96

DR FRONT - INDEPENDENT FRONT SUSPENSION 2 - 39

SPECIAL TOOLS FRONT SUSPENSION

RECEIVER/DRIVER BALL JOINT - 9770

PULLER - 8677

RECEIVER/ DRIVER BALLJOINT - 8698

BALL JOINT PRESS - C-4212F

BUSHING CUP - 9771

REMOVE/INSTALL BUSHING KIT - 9772

Wrench, Shock Nut 9362

BUSHING CUP - 9773

Page 97

2 - 40 FRONT - INDEPENDENT FRONT SUSPENSION DR

BUSHING REMOVE/INSTALL KIT - 9775

BUSHING REMOVE/INSTALL KIT - 9777

Remover, Ball Stud 9360

Compressor, Coil Spring DD-1278

Page 98

DR FRONT - INDEPENDENT FRONT SUSPENSION 2 - 41

BUSHINGS

REMOVAL LOWER CONTROL ARM BUSHINGS - 4X4 (LD)

1. Remove the lower control arm (Refer to 2 - SUSPENSION/FRONT/LOWER CONTROL ARM - REMOVAL).

2. Secure the control arm in a soft jaw vise.

NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process.

3. Remove the bushing (3) using special tool C–4212F (PRESS) (1), 9772-6 (receiver) (6), 9772-4 (SPACER) (5) and 9772-3 (driver) (2)

LOWER CONTROL ARM BUSHINGS - 4X2 (LD)

1. Remove the lower control arm (Refer to 2 - SUSPENSION/FRONT/LOWER CONTROL ARM - REMOVAL).

2. Secure the control arm in a soft jaw vise.

3. Install the special tools onto the lower control arm (5) to press out the bushing (6) using C–4212F (PRESS) (1), 9775-1 (receiver) (2), 9772-3 (driver) (4) and 9775-2 (SPACER) (3)

UPPER CONTROL ARM BUSHINGS - IFS (LD)

1. Remove the upper control arm (Refer to 2 - SUSPENSION/FRONT/UPPER CONTROL ARM - REMOVAL).

2. Secure the control arm in a soft jaw vise.

Page 99

2 - 42 FRONT - INDEPENDENT FRONT SUSPENSION DR

3. Remove the bushing (3) from the upper control arm (5) using special tool C–4212F (PRESS) (1), 9777-3 (receiver) (4), and 9601-1 (driver) (2).

UPPER CONTROL ARM BUSHINGS - IFS (HD)

1. Remove the upper control arm (Refer to 2 - SUSPENSION/FRONT/UPPER CONTROL ARM - REMOVAL).

2. Secure the control arm in a soft jaw vise.

3. Remove the bushing (3) from the upper control arm (5) using special tool C–4212F (PRESS) (1), 9777-3 (receiver) (4), and 9777-2 (driver) (2).

LOWER CONTROL ARM SHOCK BUSHING - IFS 4X4

1. Raise and support the vehicle.

2. Remove the tire and wheel assembly.

3. Support the lower control arm outboard end.

4. Remove the caliper adapter with the caliper (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER ADAPTER - REMOVAL).

5. Remove the rotor (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ROTORS - REMOVAL).

Page 100

DR FRONT - INDEPENDENT FRONT SUSPENSION 2 - 43

6. Remove the upper ball joint retaining nut and separate the upper ball joint (4) from the knuckle (6) using separator 9360 (5).

7. Disconnect the wheel speed sensor wire (3) from the knuckle and upper control arm.

8. Remove the stabilizer link lower nut (1).

9. Remove the axle hub nut.

10. Remove the shock lower bolt/nut from the lower

control arm (5) then move the shock out of the way to allow the C4212–F press (4) to used.

11. Install special tools to press the bushing (3) out of

the lower control arm (4) using special tools C-4212-F (Press) (1), 9653–1 (driver) (5) and 9653-2 (Receiver) (2).

Dodge RAM, none Factory Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual