Dodge 2500 Diesel (2005 year). Instruction — part 15

NOTE:

Excessive white smoke and poor engine perfor-

mance will result if manifold heaters are not recycled.

• Heat generated by the manifold heaters dissipates

rapidly in a cold engine. If more than two minutes
pass between the time the WAIT TO START light goes
OFF and the engine is started, recycle the manifold
heaters by turning the ignition OFF for at least 5
seconds and then back ON.

• If the vehicle is driven and vehicle speed exceeds 18

mph (29 km) before the manifold heater post-heat
(after start) cycle is complete, the manifold heaters will
shut off.

• If the engine is started before the WAIT TO START

light turns off, the preheat cycle will turn off.

• If the engine is cranked for more than 10 seconds, the

post-heat cycle will turn off.

NOTE:

Engine idle speed will automatically increase to

1000 rpm at low coolant temperatures to improve engine
warm-up.

NOTE:

When a diesel engine is allowed to run out of

fuel or the fuel gels at low temperatures, air is pulled into
the fuel system.

You may try priming as described below.

1. Add a substantial quantity of fuel to the tank (5 to 10
gallons) or eliminate the gelled fuel condition.

2. Crank the engine for 1 to 2 seconds. If the engine does
not start, then release the key or starter button back to the
RUN position (do not turn the key back to the OFF
position). The electric fuel transfer pump will continue to
run and purge air from the system for about 25 seconds.
After 25 seconds, attempt to start the engine again.

3. Start the engine using the Normal Starting Procedure.

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4. Repeat the procedure if the engine does not start.

WARNING!

Do not open the high pressure fuel system with the
engine running. Engine operation causes high fuel
pressure. High pressure fuel spray can cause serious
injury or death.

NOTE:

The engine may run rough until the air is forced

from all the fuel lines.

Starting Fluids

WARNING!

STARTING FLUIDS or flammable liquids are
NEVER TO BE USED in the Cummins Diesel (see
Warning label). Never pour diesel fuel, flammable
liquid, starting fluids (ether) into the air cleaner
canister, air intake piping, or turbocharger inlet in an
attempt to start the vehicle. This could result in a
flash fire and explosion causing serious personal
injury and engine damage.

The engine is equipped with an automatic electric air
preheating system. If the instructions in this instruction are
followed, the engine should start in all conditions.

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WARNING!

Do not leave children or animals inside parked
vehicles in hot weather. Interior heat build up may
cause serious injury or death.

NORMAL OPERATION
Observe the following when the engine is operating.

• All message center lights are off.
• Check Engine Lamp is off.
• Engine Oil Pressure is above 10 psi (69 kPa) at idle.
• Low Oil Pressure light is off.

• Voltmeter Operation:

• The voltmeter may show a gauge fluctuation if

certain engine temperatures are below 66°F (19°C).
This cycling operation is caused by the post-heat
cycle of the intake manifold heater system. The
number of cycles and the length of the cycling
operation is controlled by the engine control mod-
ule, this time will not exceed 150 seconds. The
needle should then stabilize at the approximate
operation point.

• The cycling action will cause temporary dimming of

the headlamps, interior lamps, and also a noticeable
reduction in blower motor speed.

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Cold Weather Precautions
Operation in ambient temperature below 32°F (0°C) may
require special considerations. The following charts sug-
gest these options:

Fuel Operating Range

*No. 1 diesel fuel should only be used where extended
arctic conditions (-10°F/-23°C) exist.

NOTE:

• Use of Climatized Diesel Fuel or Number 1 Diesel Fuel

results in a noticeable decrease in fuel economy.

• Climatized Diesel Fuel is a blend of Number 2 and

Number 1 Diesel Fuels which reduces the temperature
at which wax crystals form in fuel.

NOTE:

Refer to Fuel Requirements in this section for

further details on fuel recommendations.

Engine Block Heater
The engine block heater warms engine coolant and
permits quicker starts in cold weather. Connect the heater
cord to a ground–fault interrupter protected 110–115 volt
AC electrical outlet with a grounded, three-wire exten-
sion cord.

The engine block heater cord is routed under the hood to
the right side and can be located just behind the grille
near the headlamp.

NOTE:

The engine block heater cord is a factory in-

stalled option. If your vehicle is not equipped, heater
cords are available from your authorized Mopar

威 dealer.

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The block heater must be plugged in at least one hour to
have an adequate warming effect on the coolant.

WARNING!

Remember to disconnect the cord before driving.
Damage to the 110–115 volt electrical cord could
cause electrocution.

NOTE:

The block heater will require 110 Volts AC and

6.5 Amps to activate the heater element.

Block Heater Usage

A. Temperatures below 0°F (-18°C)

• Block Heater Required for 15W-40
• Block Heater Recommended for 5W-40

B. Temperatures below - 20°F (-29°C)

• Block Heater Required for 5W-40

Winter Front Usage
If a winter front or cold weather cover is to be used, a
percentage of the total grille opening area must be left
uncovered to provide sufficient air flow to the charge air
cooler and automatic transmission oil cooler. The per-
centage of opening must be increased with the increasing
ambient air temperature and/or engine load. If the
cooling fan can be heard cycling frequently, increase the
size of the opening in the winter front. A suitable cold
weather cover is available from your Mopar

威 dealer.

Battery Blanket Usage
A battery loses 60% of its cranking power as the battery
temperature decreases to 0°F (-18°). For the same de-
crease in temperature, the engine requires twice as much
power to crank at the same RPM. The use of 120 VAC
powered battery blankets will greatly increase starting
capability at low temperatures. Suitable battery blankets
are available from your authorized Mopar

威 dealer.

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Arctic Operation
Where there are no provisions to keep the engine warm
when it is operating in ambient temperatures consistently
below (-10°F/-23°C), use 5W-40 synthetic engine oil and
fuel that meets the requirements in Section 7, “Mainte-
nance Procedures,” Engine Oil Selection.

Engine Warm-Up
Avoid full throttle operation when the engine is cold.
When starting a cold engine, bring the engine up to
operating speed slowly to allow the oil pressure to
stabilize as the engine warms up.

NOTE:

High-speed, no-load running of a cold engine

can result in excessive white smoke and poor engine
performance. No-load engine speeds should be kept
under 1,200 rpm during the warm-up period, especially
in cold ambient temperature conditions.

If temperatures are below 32°F (0°C), operate the engine
at moderate speeds for 5 minutes before full loads are
applied.

Engine Idling — In Cold Weather
Avoid prolonged idling in ambient temperatures below
0°F. Long periods of idling may be harmful to your
engine because combustion chamber temperatures can
drop so low that the fuel may not burn completely.
Incomplete combustion allows carbon and varnish to
form on piston rings and injector nozzles. Also, the
unburned fuel can enter the crankcase, diluting the oil
and causing rapid wear to the engine.

NOTE:

An optional driver-controlled high idle speed is

available on automatic transmission equipped vehicles
with speed control. This feature allows the driver to
select an elevated idle speed between 1100 and 1500
rpms. Your dealer can enable this feature.

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NOTE:

• If ambient temperatures are low and the coolant

temperature is below 200°F (93°C), the engine idle
speed will slowly increase to 1000 RPM after 2 minutes
of idle, if the following conditions are met:

• foot is off brake pedal and throttle pedal
• automatic transmission is in Park (P)
• vehicle speed is zero
• Applying the throttle will cancel fast idle
• If the engine is equipped with an aftermarket exhaust

brake (instruction transmissions only), operating the ex-
haust brake at idle will greatly improve warm up rate
and will help keep the engine close to operating
temperature during extended idle.

Stopping The Engine
Idle the engine a few minutes before routine shutdown.
After full load operation, idle the engine 3 to 5 minutes
before shutting it down. This idle period will allow the
lubricating oil and coolant to carry excess heat away from
the combustion chamber, bearings, internal components,
and turbocharger. This is especially important for turbo-
charged, charge air cooled engines, like your Turbo Ram.

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Driving

Condition

Load

Turbocharger

Temperature

Idle Time

(min.) Before

Engine

Shutdown

Stop and Go

Empty

Cool

Less than

One

Stop and Go

Medium

One

Highway

Speeds

Medium

Warm

Two

City Traffic

Maximum

GCWR

Three

Highway

Speeds

Maximum

GCWR

Four

Uphill Grade

Maximum

GCWR

Hot

Five

Engine Speed Control

CAUTION!

Prevent overspeeding the engine going down hill.
When descending steep grades, use a combination of
gears and service brakes to control vehicle/engine
speed. Overspeed can cause severe engine damage.

Operating Precautions

Avoid Overheating The Engine
The temperature of the coolant (a mixture of 50%
ethylene-glycol and 50% water) must not exceed the
normal range of the temperature gauge (240°F/116°C)
with a 16 psi (110 kPa) radiator cap.

Usually the coolant temperature indicated during opera-
tion will be to the left of center in the normal range of the
gauge.

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Avoid Low Coolant Temperature Operation
Continual operation at low coolant temperature below
the normal range on the gauge (140°F/60°C) can be
harmful to the engine. Low coolant temperature can
cause incomplete combustion which allows carbon and
varnish to form on piston rings and injector nozzles.
Also, the unburned fuel can enter the crankcase, diluting
the lubricating oil and causing rapid wear to the engine.

Cooling System Tips — Automatic Transmission
To reduce potential for engine and transmission over-
heating in high ambient temperature conditions, take the
following actions:

• City Driving —
when stopped, put transmission in neutral and increase
engine idle speed.

• Highway Driving —
reduce your speed.

• Up Steep Hills —
select a lower transmission gear, but try and keep the
torque converter locked.

• Air Conditioning —
turn it off temporarily.

Do Not Operate The Engine With Low Oil
Pressure
When the engine is at normal operating temperature, the
minimum oil pressures required are:
Idle 700 to 800 RPM . . . . . . . . . . . . 10 psi (69 kPa)
Full speed and load . . . . . . . . . . . . 30 psi (207 kPa)

CAUTION!

If oil pressure falls to less than normal readings, shut
the engine off immediately. Failure to do so could
result in immediate and severe engine damage.

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Do Not Operate The Engine With Failed Parts
Practically all failures give some warning before the parts
fail. Be on the alert for changes in performance, sounds,
and visual evidence that the engine requires service.
Some important clues are:

• engine misfiring or vibrating severely
• sudden loss of power
• unusual engine noises
• fuel, oil or coolant leaks
• sudden change, outside the normal operating range, in

the engine operating temperature

• excessive smoke
• oil pressure drop

TRANSMISSION SHIFTING

Automatic Transmission with Overdrive— If
Equipped
The gear shift selector display, located in the instrument
panel cluster, indicates the transmission gear range (the
selector is illuminated for night driving). The selector
lever is mounted on the right side of the steering column.
You must depress the brake pedal, to pull the selector
lever out of park (P) position (Brake Interlock System). To
drive, move the selector lever from Park or Neutral to the
desired drive position. Pull the selector lever toward you
when shifting into Reverse, Second, First or Park, or
when shifting out of Park.

Gear Ranges
DO NOT race the engine when shifting from Park or
Neutral position into another gear range.

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“P” Park
This gear position supplements the parking brake by
locking the transmission. The engine can be started in
this range. Never use Park while the vehicle is in motion.
Apply the parking brake when leaving the vehicle in this
range. Always apply parking brake first, then place the
selector in Park position. On 4-wheel drive vehicles be
sure that the transfer case is in a drive position!

WARNING!

Your vehicle could move and injure you and others if
it is not completely in P (Park). Check by trying to
move the gearshift lever back and forth without first
pulling it toward you after you have set it in P. Make
sure it is in Park before leaving the vehicle.

WARNING!

It is dangerous to shift the selector lever out of “P” or
“N” if the engine speed is higher than idle speed. If
your foot is not firmly on the brake pedal, the
vehicle could accelerate quickly forward or in re-
verse. You could lose control of the vehicle and hit
someone or something. Only shift into gear when
the engine is idling normally and when your right
foot is firmly on the brake pedal.

“R” Reverse
Use this range only after the vehicle has come to a
complete stop.

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“N” Neutral
Shift to Neutral when the vehicle is standing for pro-
longed periods with the engine running. The engine may
be started in this range. Set the parking brake if you must
leave the vehicle.

“D” Drive
This position provides all forward gears, including 3rd
gear direct and 4th or 5th (if equipped) gear overdrive
(see Overdrive Operation). Use this range for most city
and highway driving.

“2” Second
Use this position for driving slowly in heavy city traffic
or on mountain roads where more precise speed control
is desirable. Use it also when climbing long grades, and
for engine braking when descending moderately steep
grades. To prevent excessive engine speed do not exceed
45 mph (72 km/h) in this range.

“1” First
Use this position for driving up very steep hills and for
engine braking at low speeds 20 mph (32 km/h) or less
when going downhill. To prevent excessive engine speed,
do not exceed 25 mph (40 km/h) in this range.

NOTE:

Use caution when operating a heavily loaded

vehicle in “2” Second or “1” First gear selections in high
ambients as torque converter slip can impose significant
additional heat load on the cooling system.

WARNING!

Never use Park position on an automatic transmis-
sion as a substitute for the parking brake. Always
apply parking brake fully when parked to guard
against vehicle movement and possible injury or
damage.

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When To Use “TOW/HAUL” Mode

When driving in hilly areas, towing a trailer, carrying a
heavy load, etc., and frequent transmission shifting oc-
curs, press the “TOW/HAUL” button. This will improve
performance and reduce the potential for transmission
overheating or failure due to excessive shifting. When
operating in “TOW/HAUL” mode, 5th gear (if

equipped) is disabled and 2-3 and 3-4 shift patterns are
modified. Shifts into Overdrive (4th gear) are allowed
during steady cruise (for improved fuel economy) and
automatic closed-throttle downshifts to 3rd gear (for
improved braking) will occur during steady braking.

The “TOW/HAUL” light will illuminate in the instru-
ment cluster to indicate when the switch has been
activated. Pressing the switch a second time restores
normal operation. If the “TOW/HAUL” mode is desired,
the button must be pressed each time the engine is
started.

When To Lock Out Overdrive
When driving in hilly areas, towing a trailer, carrying a
heavy load, etc., and frequent 4–3–4 transmission shifting
occurs, press the “TOW/HAUL” button. This will im-
prove performance and reduce the potential for transmis-
sion overheating or failure due to excessive shifting.

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Torque Converter Clutch
A feature, designed to improve fuel economy, has been
included in the automatic transmission on your vehicle.
A clutch within the torque converter engages automati-
cally at calibrated speeds. This may result in a slightly
different feeling or response during normal operation in
high gear. When the vehicle speed drops or during
acceleration when the transmission downshifts to second
gear, the clutch automatically disengages.

NOTE:

The torque converter clutch will not engage

until the transmission fluid and engine coolant are warm
[usually after 1-3 miles (1.6 – 4.8 km) of driving]. Because
the engine speed is higher when the torque converter
clutch is not engaged, it may seem as if the transmission
is not shifting into Overdrive when cold. This is normal.
Pressing the “TOW/HAUL” button, when the transmis-
sion is sufficiently warm, will demonstrate that the
transmission is able to shift into and out of overdrive.

NOTE:

If the vehicle has not been driven in several

days, the first few seconds of operation after shifting the
transmission into gear may seem sluggish. This is due to
the fluid partially draining from the torque converter into
the transmission. This condition is normal and will not
cause damage to the transmission. The torque converter
will refill within five seconds of shifting from Park into
any other gear position.

Instruction Transmission — 6-Speed — If Equipped

NOTE:

The parking brake should be engaged before

leaving the vehicle, especially on an incline.

Truck models with instruction transmission are equipped
with a clutch interlocking ignition system. The clutch
pedal must be fully depressed to start the vehicle.

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5

Fully depress the clutch pedal before shifting gears. As
you release the clutch pedal, lightly depress the accelera-
tor pedal. When launching a stationary vehicle, keep the
engine speed low until the clutch is fully engaged.

This transmission has a “creeper” 1st gear which should
be used to start from a standing position when carrying
a payload or towing a trailer. Damage to the clutch can
result from starting in 2nd or 3rd gear with a loaded
vehicle. Use each gear in numerical order – do not skip a
gear.

For steady highway driving with light acceleration, 6th
gear is recommended. When shifting from 4th to 5th gear,
apply side effort away and forward without pushing
hard enough to engage Reverse gear. Shifting from 5th to
6th requires the same side effort or the lever will return to
center resulting in a shift into 4th gear and damage the
transmission, clutch, or engine.

You should use low gear when starting from a standing
position if under a heavy load.

To shift into Reverse, come to a complete stop. Depress
the clutch and pause briefly to allow the gear train to
stop. Move the shift lever from the Neutral position
straight across and up into Reverse.

Never drive with your foot resting on the clutch pedal, or
attempt to hold the vehicle on a hill with the clutch pedal
partially engaged, as this will cause abnormal wear on
the clutch.

Downshifting
Moving from a high gear down to a lower gear is
recommended to preserve brakes when driving down
steep hills. In addition, downshifting at the right time
provides better acceleration when you desire to resume
speed. Downshift progressively. Do not skip gears to

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avoid overspeeding the engine and clutch. For accelera-
tion at speeds less than 15 mph (25 km/h), 2nd gear is
recommended.

CAUTION!

When descending a hill, be very careful to downshift
one gear at a time to prevent overspeeding the
engine which can cause valve damage.

FOUR-WHEEL- DRIVE OPERATION — IF
EQUIPPED

• Four-Wheel-Drive Dodge Ram Trucks are equipped

with either a Instructionly Shifted transfer case or an
Electronically Shifted transfer case. See the operating
instructions for your transfer case, located within this
section.

Instructionly Shifted Transfer Case Operating
Information/Precautions
The transfer case provides 4 mode positions - 2 (rear)-
wheel-drive high range, 4-wheel-drive high range, neu-
tral, and 4-wheel-drive low range.

This transfer case is intended to be driven in the 2-wheel-
drive position (2H) for normal street and highway con-
ditions such as dry hard surfaced roads.

When additional traction is required the transfer case 4H
and 4L positions can be used to lock the front and rear
driveshafts together and force the front and rear wheels
to rotate at the same speed. This is accomplished by
simply moving the shift lever to the desired positions.
The 4H and 4L positions are intended for loose, slippery
road surfaces only. Driving in the 4H and 4L positions on
dry hard surfaced roads may cause increased tire wear
and damage to the driveline components.

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