Dodge 2500 Diesel (2008 year). Instruction — part 25

4. By rotating the wheel wrench clockwise, raise the
vehicle until the wheel just clears the surface.

WARNING!

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

5. Remove the wheel nuts and pull the wheel off. Install
the spare wheel and wheel nuts with the cone shaped end
of the nuts toward the wheel on 2500/3500 single rear
wheel (SRW) models. On 3500 dual rear wheel models
(DRW) the lug nuts are a two piece assembly with a flat
face. Lightly tighten the nuts. To avoid risk of forcing the
vehicle off the jack, do not fully tighten the nuts until the
vehicle has been lowered.

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6

6. Using the wheel wrench, finish tightening the nuts
using a crisscross pattern. Correct nut tightness is 135 ft.
lbs. (183 N·m) torque for 2500/3500 single rear wheel
(SRW) models and 145 ft. lbs. (197 N·m) for 3500 dual rear
wheel models. If in doubt about the correct tightness,
have them checked with a torque wrench by your dealer
or at a service station.

WARNING!

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

7. Install wheel center cap and remove wheel blocks. Do
not install chrome or aluminum wheel center caps on the
spare wheel. This may result in cap damage.

8. Lower the jack to its fully closed position. If the jack
will not lower by turning the dial (thumbwheel) by hand,
it may be necessary to use the jack drive tube in order to
lower the jack. Stow the replaced tire, jack, and tools as
previously described.

9. Adjust the tire pressure when possible.

NOTE:

Do not oil wheel studs. For chrome wheels, do

not substitute with chrome plated wheel nuts.

Hub Caps/Wheel Covers
The hub caps must be removed before raising the vehicle
off the ground.

For 2500/3500 single rear wheel (SRW) models, use the
blade on the end of the lug wrench to pry the hub cap off.
Insert the blade end into the pryoff notch and carefully
pop off the hub cap with a back and forth motion.

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WHAT TO DO IN EMERGENCIES

On 3500 models with dual rear wheels (DRW), you must
first remove the hub caps. The jack handle driver has a
hook at one end that will fit in the pry off notch of the
rear hub caps. Position the hook and pull out on the
ratchet firmly. The hub cap should pop off. The wheel
skins can now be removed. For the front hub cap on 3500
models use the blade on the end of the lug wrench to pry
the caps off. The wheel skin can now be removed.

CAUTION!

Use a back and forth motion to remove the hub cap.
Do not use a twisting motion when removing the hub
cap, damage to the hub cap finish may occur.

CAUTION!

The rear hub caps on the dual rear wheel has two pry
off notches. Make sure that the hook of the jack
handle driver is located squarely in the cap notch
before attempting to pull off.

You must use the flat end of the lug wrench to pry off the
wheel skins. Insert the flat tip completely and using a
back and forth motion, loosen the wheel skin. Repeat this
procedure around the tire until the skin pops off.

Replace the wheel skins first using a rubber mallet. When
replacing the hub caps, tilt the cap retainer over the
lugnut bolt circle and strike the high side down with a
rubber mallet. Be sure that the hub caps and wheel skins
are firmly seated around the wheel.

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6

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

Slots in the wheels will assist in properly orienting the
inner and outer wheels. Align these slots when assem-
bling the wheels for best access to the tire valve on the
inner wheel. The tires of both dual wheels must be
completely off the ground when tightening to ensure
wheel centering and maximum wheel clamping.

Dual wheel models require a special heavy-duty lug nut
tightening adapter (included with the vehicle) to cor-
rectly tighten the lug nuts. Also, when it is necessary to
remove and install dual rear wheels, use a proper vehicle
lifting device.

NOTE:

When installing a spare tire as part of a dual rear

wheel end combination, the tire diameter of the two
individual tires must be compared. If there is a significant
difference, the larger tire should be installed in a front
location. Correct direction of rotation for dual tire instal-
lations must also be observed.

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WHAT TO DO IN EMERGENCIES

These dual rear wheels should be tightened as follows:

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

2. Retighten the wheel nuts in the same sequence to the
torques listed in the table. Go through the sequence a
second time to verify that specific torque has been
achieved. Retighten to specifications at 100 mi(160 km)
and after 500 mi (800 km).

It is recommended that wheel stud nuts be kept torqued
to specifications at all times. Torque wheel stud nuts to
specifications at each lubrication interval.

Wheel Nuts
All wheel nuts should be tightened occasionally to elimi-
nate the possibility of wheel studs being sheared or the
bolt holes in the wheels becoming elongated. This is
especially important during the first few hundred miles/
kilometers of operation to allow the wheel nuts to
become properly set. All nuts should first be firmly
seated against the wheel. The nuts should then be

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6

tightened to recommended torque. Tighten the nuts to
final torque in increments. Progress around the bolt
circle, tightening the nut opposite to the nut just previ-
ously tightened until final torque is achieved. Recom-
mended torques are shown in the following chart.

Disc
Wheels

Type Nut Stud Size Torque

Ft. Lbs.

Torque
Newton
Meters

Cone

9/16-18

120-150

160-200

Flanged

9/16-18

130-160

190-220

To Stow The Flat Or Spare
Turn the wheel so that the valve stem is down. Slide the
wheel retainer through the center of the wheel and
position it properly across the wheel opening.

For convenience in checking the spare tire inflation, stow
with the valve stem toward the rear of the vehicle.

Attach the wheel wrench to the extension tube. Rotate the
winch mechanism until the wheel is drawn into place
against the underside of the vehicle. Continue to rotate
until you feel the winch mechanism slip or click three or
four times. It cannot be overtightened. Push against the
tire several times to be sure it is firmly in place.

HOISTING

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

CAUTION!

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

396

WHAT TO DO IN EMERGENCIES

JUMP-STARTING

WARNING!

To prevent personal injury or damage to clothing, do
not allow battery fluid to contact eyes, skin or fabrics.
Do not lean over a battery when connecting jumper
cables or allow cable clamps to touch each other.
Keep open flames or sparks away from battery vent
holes. Always wear eye protection when working
with batteries.

Do not use a booster battery or any other booster
source that has a greater than 12-volt system, i.e., do
not use a 24-volt power source.

NOTE:

Replacement batteries should both be of equal

size to prevent damage to the vehicle’s charging system.

Your vehicle is equipped with two 12–volt batteries. If it
becomes necessary to use a booster battery with jumper
cables to start a vehicle’s engine because its batteries are
discharged, the following procedure should be used:

Set the parking brake and place an automatic transmis-
sion in PARK (or NEUTRAL for a instruction transmission).
Turn off lights, heater and other electrical loads. Observe
charge indicator (if equipped) in both batteries. If indica-
tor (if equipped) is light or yellow on either battery,
replace that battery.

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6

CAUTION!

Use the Jump-Start Procedure only when the charge
indicator (if equipped) in both batteries is dark in the
center. Do not attempt jump-starting when either
battery charge indicator (if equipped) is bright or
yellow. If charge indicator (if equipped) has a green
dot in the center, failure to start is not due to a
discharged battery and cranking system should be
checked.

1. Attach one jumper cable to the positive terminal of
booster battery and the other end of the same cable to the
positive terminal of the discharged battery.

WARNING!

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

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WHAT TO DO IN EMERGENCIES

2. Connect one end of the other jumper cable to negative
(-) post of booster battery. Connect the other end of the
jumper cable to a good ground on the engine block of the
vehicle with the discharged battery. Make sure a good
connection is made, free of dirt and grease.

WARNING!

• Do not connect the cable to the negative post of the

discharge battery. The resulting electrical spark
could cause the battery to explode.

• During cold weather when temperatures are be-

low freezing point, electrolyte in a discharged
battery may freeze. Do not attempt jump-starting
because the battery could rupture or explode. The
battery temperature must be brought up above
freezing point before attempting to jump-start.

3. Take care that the clamps from one cable do not
inadvertently touch clamps from the other cable. Do not
lean over the battery when making connection. The
negative connection must provide good electrical con-
ductivity and current carrying capacity.

4. After the engine is started or if the engine fails to start,
cables must be disconnected in the following order:

a. Disconnect the negative cable at the engine ground.

b. Disconnect the negative cable at the negative post
on booster battery.

c. Disconnect the cable from the positive post of both
batteries.

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6

WARNING!

Any procedure other than above could result in:

1. Personal injury caused by electrolyte squirting out
the battery vent;

2. Personal injury or property damage due to battery
explosion;

3. Damage to charging system of booster vehicle or
of immobilized vehicle.

With Portable Starting Unit

There are many types of these units available. Follow the
manufacturer’s instructions for necessary precautions
and operation.

CAUTION!

It is very important that the starting unit operating
voltage does not exceed 12-Volts DC or damage to
battery, starter motor, alternator, or electrical system
may occur.

FREEING A STUCK VEHICLE

If the vehicle becomes stuck in snow, sand, or mud, it can
often be moved by a rocking motion. Move the gear
selector rhythmically between DRIVE and REVERSE
(automatic transmissions) or between 1st and REVERSE
(instruction transmissions), while applying slight pressure to
the accelerator.

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WHAT TO DO IN EMERGENCIES

In general, the least amount of accelerator pedal pressure
to maintain the rocking motion without spinning the
wheels or racing the engine, is most effective. Racing the
engine or spinning the wheels, due to the frustration of
not freeing the vehicle, may lead to transmission over-
heating and failure. Allow the engine to idle with the
transmission selector in NEUTRAL for at least one
minute after every five rocking-motion cycles. This will
minimize overheating and reduce the risk of transmis-
sion failure during prolonged efforts to free a stuck
vehicle.

EMERGENCY TOW HOOKS — IF EQUIPPED

Your vehicle may be equipped with emergency tow
hooks.

NOTE:

For off-road recovery, it is recommended to use

both of the front tow hooks to minimize the risk of
damage to the vehicle.

WARNING!

Chains are not recommended for freeing a stuck
vehicle. Chains may break, causing serious injury or
death.

WARNING!

Stand clear of vehicles when pulling with tow hooks.
Tow straps and chains may break, causing serious
injury.

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6

CAUTION!

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

TOWING A DISABLED VEHICLE

Proper towing or lifting equipment is required to prevent
damage to your vehicle. Use only tow bars and other
equipment designed for the purpose, following equip-
ment manufacturer’s instructions. Use of safety chains is
mandatory. Attach a tow bar or other towing device to
the main structural members of the vehicle—not to
bumpers or associated brackets. State and local laws
applying to vehicles under tow must be observed.

4-Wheel Drive Vehicles

CAUTION!

To avoid damage to the transfer case while towing,
always use one of the following methods.

NOTE:

The transfer case must be in the neutral position,

and the transmission must be in PARK (automatic trans-
mission), or in gear (instruction transmission) to tow a 4WD
vehicle with one end of the vehicle raised.

The manufacturer recommends towing with all wheels
OFF

the ground. Acceptable methods are to tow the

vehicle on a flatbed or with one end of vehicle raised and
the opposite end on a towing dolly.

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WHAT TO DO IN EMERGENCIES

2–Wheel Drive Vehicles

Provided that the transmission is operable, tow with the
transmission in NEUTRAL and the ignition key in the
OFF position along with the front wheels raised and the
rear wheels on the ground. Speed must not exceed 30
mph (50 km/h) and distance must not exceed 15 mi (25
km).

CAUTION!

Towing faster than 30 mph (50 km/h) or for more than
15 mi (25 km) can cause severe damage to the
transmission.

If the vehicle is to be towed faster than 30 mph (50 km/h)
or more than 15 mi (25 km) the vehicle must be towed
with the rear wheels raised and the front wheels on the
ground. It may also be towed on a flatbed or with the
front wheels raised and the rear wheels on a dolly.

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6

MAINTAINING YOUR VEHICLE

CONTENTS

m Engine Compartment — 6.7L Diesel Engine . . . . 408
m Onboard Diagnostic System (OBD II) . . . . . . . . . 409
m Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 409
m Engine Data Plate . . . . . . . . . . . . . . . . . . . . . . 410
m Authorized Dealer Service . . . . . . . . . . . . . . . . 410
m Service Information . . . . . . . . . . . . . . . . . . . . . 410
m Maintenance Procedures . . . . . . . . . . . . . . . . . . 412

▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 413
▫ Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 418

▫ Engine Air Cleaner Filter (6.7L Diesel

Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

▫ Draining Fuel/Water Separator Filter (6.7L

Diesel Engine) . . . . . . . . . . . . . . . . . . . . . . . 422

▫ Intervention Regeneration Strategy – EVIC

Message Process Flow (Catalyst Full Message)
(6.7L Diesel Engines Only) . . . . . . . . . . . . . . . 425

▫ Maintenance Free Batteries . . . . . . . . . . . . . . . 428
▫ Air Conditioner Maintenance . . . . . . . . . . . . . 430
▫ Power Steering — Fluid Check . . . . . . . . . . . . 431

7

▫ Front Suspension Ball Joints . . . . . . . . . . . . . . 431
▫ Steering Linkage — Inspection . . . . . . . . . . . . 432
▫ Front Prop Shaft Lubrication . . . . . . . . . . . . . 432
▫ Front Axle Universal Drive Joints And Ball

Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

▫ Body Lubrication . . . . . . . . . . . . . . . . . . . . . 433
▫ Windshield Wiper Blades . . . . . . . . . . . . . . . . 433
▫ Windshield Washers . . . . . . . . . . . . . . . . . . . 434
▫ Exhaust System . . . . . . . . . . . . . . . . . . . . . . 435
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . . . 436
▫ Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
▫ Charge Air Cooler (Inter-Cooler) . . . . . . . . . . 442
▫ Hoses And Vacuum/Vapor Harnesses . . . . . . . 443

▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . . 443
▫ Clutch Linkage . . . . . . . . . . . . . . . . . . . . . . . 445
▫ Clutch Hydraulic System . . . . . . . . . . . . . . . . 445
▫ Rear Axle And 4X4 Front Driving Axle Fluid

Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446

▫ Transfer Case — If Equipped . . . . . . . . . . . . . 446
▫ Instruction Transmission — If Equipped . . . . . . . 447
▫ Automatic Transmission . . . . . . . . . . . . . . . . 447
▫ Front Wheel Bearings . . . . . . . . . . . . . . . . . . 450
▫ Noise Control System Required Maintenance

& Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 451

▫ Appearance Care And Protection From

Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 455

m Fuses (Integrated Power Module) . . . . . . . . . . . 459

406

MAINTAINING YOUR VEHICLE