RAM 4500 Chassis Cab (2022 year). Manual in english — page 22

SERVICING AND MAINTENANCE

347

along a rib (not across) are not normal. Any belt

with cracks running along a rib must be replaced.

Also have the belt replaced if it has excessive wear,

frayed cords or severe glazing.

Accessory Belt (Serpentine Belt)

Conditions that would require replacement:



Rib chunking (one or more ribs has separated

from belt body)



Rib or belt wear



Longitudinal belt cracking (cracks between two

ribs)



Belt slips



“Groove jumping" (belt does not maintain

correct position on pulley)



Belt broken (note: identify and correct problem

before new belt is installed)



Noise (objectionable squeal, squeak, or rumble

is heard or felt while drive belt is in operation)

Some conditions can be caused by a faulty

component such as a belt pulley. Belt pulleys

should be carefully inspected for damage and

proper alignment.
Belt replacement on some models requires the

use of special tools, we recommend having your

vehicle serviced at an authorized dealer.

D

RAINING

F

UEL

/W

ATER

S

EPARATOR

F

ILTER

There are two fuel filter assemblies. One is located

on the driver's side of the engine. The best access

to this water drain valve is from under the hood.

The second one is on the under body, located in

front of the rear axle above the drive shaft on

pick-up models. The second filter location is on the

frame behind the front axle. The best access to this

water drain valve is from under the vehicle.

If water is detected in the water separator while the

engine is running, or while the ignition switch is in

the ON position, the “Water In Fuel Indicator Light”

will illuminate and an audible chime will be heard

five times. At this point you should stop the engine

and drain the water from both of the filters.

If the “Water In Fuel Indicator Light” comes on and

a single chime is heard while you are driving, or

with the ignition switch in the ON position, there

may be a problem with your water separator wiring

or sensor. See an authorized dealer for service.
Upon proper draining of the water from both fuel

filters, the “Water In Fuel Indicator Light” will

remain illuminated for approximately 10 seconds.

If the water was drained while the engine was

running, the “Water In Fuel Indicator Light” may

remain on for approximately three minutes.

NOTE:

Care should be taken in disposing of used fluids

from your vehicle. Used fluids, indiscriminately

discarded, can present a problem to the envi

-

ronment. Contact an authorized dealer, service

CAUTION!



Do not drain the fuel/water separator filter

when the engine is running.



Diesel fuel will damage blacktop paving

surfaces. Drain the filter into an appropriate

container.

CAUTION!

If the “Water In Fuel Indicator Light” remains on,

DO NOT START the engine before you drain water

from the fuel filters to avoid engine damage.

8

348

SERVICING AND MAINTENANCE

station, or government agency for advice on recy

-

cling programs and for where used fluids and

filters can be properly disposed of in your area.
Drain the fuel/water separator filters when the

“Water In Fuel Indicator Light” is ON. Within

10 minutes of vehicle shutdown, turn the engine

mounted filter drain valve (located on the side of

the filter assembly) counterclockwise a quarter

turn, and turn the under body mounted filter drain

valve (located on the bottom of the filter assembly)

counterclockwise 1 full turn. Then turn the ignition

switch to the ON position, and allow any

accumulated water to drain. Leave the drain valve

open until all water and contaminants have been

removed. When clean fuel is visible, close the drain

valve following these guidelines:
1. Rotate the drain clockwise to close until you

feel resistance from the internal seal.

2. Continue turning the drain half of a turn to

properly compress the seal.

NOTE:

Over-compression of the seal due to overtightening

of the drain will damage the seal, cause a leak, and

require the entire sensor to be replaced.
3. Turn the ignition switch to OFF.

The sensor drain should not be overtightened

during normal service operations to avoid internal

damage and future fuel leaks. The drain should be

closed and secured without the use of tools.
If more than a couple ounces/milliliters of fuel

have been drained, follow the directions

Ú

page 350

E

NGINE

M

OUNTED

F

UEL

F

ILTER

R

EPLACEMENT

NOTE:



Using a fuel filter that does not meet the manu

-

facturer's filtration and water separating

requirements can severely impact fuel system

life and reliability.



The engine mounted filter housing is equipped

with a No-Filter-No-Run (NFNR) feature. Engine

will not run if:



No filter is installed.



Inferior/Non-approved filter is used. Use of

OEM filter is required to ensure vehicle will

run.

Engine Mounted Fuel Filter Assembly

1 — Drain Valve

CAUTION!



Diesel fuel will damage blacktop paving

surfaces. Drain the filter into an appropriate

container.



Do not prefill the fuel filter when installing a

new fuel filter. There is a possibility debris

could be introduced into the fuel filter during

this action. It is best to install the filter dry and

allow the in-tank lift pump to prime the fuel

system.

SERVICING AND MAINTENANCE

349

1. Ensure engine is turned off.
2. Place drain pan under the fuel filter drain hose.
3. Open the water drain valve a quarter turn

counterclockwise and completely drain fuel

and water into the approved container.

4. Close the water drain valve.
5. Remove lid using a socket or strap wrench.

Rotate counterclockwise for removal. Remove

used o-ring and discard it.

6. Remove the used filter cartridge from the

housing and dispose of according to your local

regulations.

7. Wipe clean the sealing surfaces of the lid and

housing.

8. Install new o-ring back into ring groove on the

filter housing and lubricate with clean engine

oil.

9. Remove new filter cartridge from plastic bag

and install into housing.

NOTE:

Do not remove cartridge from bag until you reach

this step in order to keep cartridge clean.
10. Push down on the cartridge to ensure it is

properly seated. Do not pre-fill the filter

housing with fuel.

11. Install lid onto housing and tighten to 22.5 ft lb

(30.5 N.m). Do not overtighten the lid.

12. Prime the engine, then start the engine and

confirm there are no leaks

Ú

page 350.

U

NDERBODY

M

OUNTED

F

UEL

F

ILTER

R

EPLACEMENT

NOTE:



Using a fuel filter that does not meet the manu

-

facturer's filtration and water separating

requirements can severely impact fuel system

life and reliability.



The underbody mounted filter housing will

cause the engine not to run if:

a. No filter is installed.

Underbody Mounted Fuel Filter Assembly

1. Ensure engine is turned off.
2. Place drain pan under the fuel filter drain hose.
3. Open the water drain valve one full turn

counterclockwise and completely drain fuel

and water into the approved container.

4. Close the water drain valve.
5. Remove lid using a socket or strap wrench.

Rotate counterclockwise for removal. Remove

used o-ring and discard it.

6. Remove the used filter cartridge from the

housing and dispose of according to your local

regulations.

7. Wipe clean the sealing surfaces of the lid and

housing.

1 — Drain Valve

CAUTION!



Diesel fuel will damage blacktop paving

surfaces. Drain the filter into an appropriate

container.



Do not prefill the fuel filter when installing a

new fuel filter. There is a possibility debris

could be introduced into the fuel filter during

this action. It is best to install the filter dry and

allow the in-tank lift pump to prime the fuel

system.

8

350

SERVICING AND MAINTENANCE

8. Install new o-ring back into ring groove on the

filter housing and lubricate with clean engine

oil.

NOTE:

Water In Fuel (WIF) sensor is re-usable. Service kit

comes with new o-ring for filter canister and WIF

sensor.

P

RIMING

I

F

T

HE

E

NGINE

H

AS

R

UN

O

UT

O

F

F

UEL

1. Add a substantial amount of fuel to the tank,

approximately 2 to 5 gal (8L to 19L).

2. Three priming cycles must be completed. Turn

ignition to the RUN position and wait approxi

-

mately 30 seconds. This will activate the in tank

fuel pump. Turn the ignition switch to the off

position, and leave off for at least 30 seconds.

Repeat this procedure three times before

cranking the engine.

3. Start the engine using the “Normal Starting”

procedure

Ú

page 108.

4. Once the engine starts, allow the engine to idle

for a minimum of 30 seconds.

NOTE:

The engine may run rough until the air is forced

from all the fuel lines.

NOTE:



A maximum blend of 5% biodiesel, meeting

ASTM specification D-975 may be used with

your Cummins® diesel engine.



A maximum blend of 20% biodiesel, meeting

ASTM specification D-7467 may be used with

your Cummins® diesel engine.



Use of biodiesel mixture in excess of 20% can

negatively impact the fuel filter's ability to sepa

-

rate water from the fuel, resulting in high pres

-

sure fuel system corrosion or damage.



Ethanol blends are not recommended or

approved for use with your Cummins® diesel

engine.



In addition, commercially available fuel addi

-

tives are not necessary for the proper operation

of your Cummins® diesel engine.

I

NTERVENTION

R

EGENERATION

S

TRATEGY

— M

ESSAGE

P

ROCESS

F

LOW

The Cummins® diesel engine meets all

Environmental Protection Agency (EPA) Heavy Duty

Diesel Engine Emissions Standards, resulting in

one of the lowest emitting diesel engines ever

produced.
To achieve these emissions standards, your

vehicle is equipped with a state-of-the-art engine

and exhaust system. The engine and exhaust

after-treatment system work together to achieve

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.

CAUTION!

Do not engage the starter motor for more than

15 seconds at a time. Allow two minutes

between the cranking intervals.

WARNING!

Do not use alcohol or gasoline as a fuel blending

agent. They can be unstable under certain

conditions and be hazardous or explosive when

mixed with diesel fuel.

CAUTION!

Due to lack of lubricants in alcohol or gasoline,

the use of these fuels can cause damage to the

fuel system.

SERVICING AND MAINTENANCE

351

the EPA Heavy Duty Diesel Engine Emissions

Standards. These systems are seamlessly

integrated into your vehicle and managed by the

Cummins® Powertrain Control Module (PCM). The

PCM manages engine combustion to allow the

exhaust system’s catalyst to trap and burn

Particulate Matter (PM) pollutants, with no input or

interaction on your part.
If the engine is allowed to idle or the truck is driven

on low engine speed drive cycles for more than two

hours, the system will automatically enter an

emissions operating mode that will increase the

engine idle speed to 1,050 RPM. While in this

mode, which is designed to help maintain the

Diesel Particulate Filter, the engine idle speed will

return to normal when the brake pedal is applied.

A small change in engine tone or a slight change in

engine performance while accelerating may also

be noticeable at speeds below 20 mph (32 km/h).

This operating mode may last for up to an hour of

idle time, or around 20 minutes of driving time.
Additionally, your vehicle has the ability to alert you

to additional maintenance required on your truck

or engine

Ú

page 81.

D

IESEL

E

XHAUST

F

LUID

(DEF)

DEF sometimes known simply by the name of its

active component, UREA—is a key component of

Selective Catalytic Reduction (SCR) systems, which

help diesel vehicles meet stringent emission

regulations. DEF is a liquid reducing agent that

reacts with engine exhaust in the presence of a

catalyst to convert smog-forming nitrogen oxides

(NOx) into harmless nitrogen and water vapor

Ú

page 404.

You can receive assistance in locating DEF by

contacting an authorized dealer.

B

ODY

L

UBRICATION

Locks and all body pivot points, including such

items as seat tracks, door hinge pivot points and

rollers, liftgate, tailgate, decklid, sliding doors and

hood hinges, should be lubricated periodically with

a lithium-based grease, such as Mopar® Spray

White Lube to ensure quiet, easy operation and to

protect against rust and wear. Prior to the

application of any lubricant, the parts concerned

should be wiped clean to remove dust and grit;

after lubricating excess, oil and grease should be

removed. Particular attention should also be given

to hood latching components to ensure proper

function. When performing other underhood

services, the hood latch, release mechanism and

safety catch should be cleaned and lubricated.
The external lock cylinders should be lubricated

twice a year, preferably in the Autumn and Spring.

Apply a small amount of a high quality lubricant,

such as Mopar® Lock Cylinder Lubricant directly

into the lock cylinder.

W

INDSHIELD

W

IPER

B

LADES

Clean the rubber edges of the wiper blades and the

windshield periodically with a sponge or soft cloth

and a mild nonabrasive cleaner. This will remove

accumulations of salt or road film.
Operation of the wipers on dry glass for long

periods may cause deterioration of the wiper

blades. Always use washer fluid when using the

wipers to remove salt or dirt from a dry windshield.
Avoid using the wiper blades to remove frost or ice

from the windshield. Keep the blade rubber out of

contact with petroleum products such as engine

oil, gasoline, etc.

WARNING!

A hot exhaust system can start a fire if you park

over materials that can burn. Such materials

might be grass or leaves coming into contact

with your exhaust system. Do not park or oper

-

ate your vehicle in areas where your exhaust sys

-

tem can contact anything that can burn.

8

352

SERVICING AND MAINTENANCE

NOTE:

Life expectancy of wiper blades varies depending

on geographical area and frequency of use. Poor

performance of blades may be present with chat

-

tering, marks, water lines or wet spots. If any of

these conditions are present, clean the wiper

blades or replace as necessary.
The wiper blades and wiper arms should be

inspected periodically, not just when wiper

performance problems are experienced. This

inspection should include the following points:



Wear or uneven edges



Foreign material



Hardening or cracking



Deformation or fatigue

If a wiper blade or wiper arm is damaged, replace

the affected wiper arm or blade with a new unit. Do

not attempt to repair a wiper arm or blade that is

damaged.

Wiper Blade Removal/Installation

1. Lift the wiper arm to raise the wiper blade off

of the glass, until the wiper arm is in the full

up position.

Windshield Wiper Arm And Blade

2. To disengage the wiper blade from the wiper

arm, flip up the locking tab.

Wiper Locking Assembly

CAUTION!

Do not allow the wiper arm to spring back

against the glass without the wiper blade in

place or the glass may be damaged.

1 — Wiper
2 — Locking Tab
3 — Wiper Arm

1 — Wiper
2 — Locking Tab

SERVICING AND MAINTENANCE

353

3. Tilt the lower end of the wiper blade away from

the arm and with one finger, push the release

tab toward the wiper arm.

Wiper Disengaging

4. Slide the wiper blade down towards the base

of the wiper arm.

5. With the wiper blade disengaged, remove the

wiper blade from the wiper arm by holding the

wiper arm with one hand and separating the

wiper blade from the wiper arm with the other

hand (move the wiper blade down toward the

base of the wiper arm and away from the J

hook in the end of the wiper arm).

Removing Wiper From Wiper Arm

6. Gently lower the wiper arm onto the glass.

Installing The Front Wipers
1. Lift the wiper arm off of the glass, until the

wiper arm is in the full up position.

2. Position the wiper blade under the hook on the

tip of the wiper arm with the wiper locking tab

open.

3. Insert the receiver bracket on the wiper

assembly into the hook on the tip of the arm

through the opening in the wiper blade under

the locking tab.

4. Slide the wiper blade up into the hook on the

wiper arm until it is latched (engagement will

be accompanied by an audible click). Fold

down the latch release tab and snap it into its

locked position.

5. Gently lower the wiper blade onto the glass.

E

XHAUST

S

YSTEM

The best protection against carbon monoxide entry

into the vehicle body is a properly maintained

engine exhaust system.
If you notice a change in the sound of the exhaust

system; or if the exhaust fumes can be detected

inside the vehicle; or when the underside or rear of

the vehicle is damaged; have an authorized

technician inspect the complete exhaust system

and adjacent body areas for broken, damaged,

deteriorated, or mispositioned parts. Open seams

or loose connections could permit exhaust fumes

to seep into the passenger compartment. In

addition, have the exhaust system inspected each

time the vehicle is raised for lubrication or oil

change. Replace as required.

1 — Locking Tab
2 — Wiper
3 — Release Tab

1 — Wiper
2 — Locking Tab
3 — Wiper Arm J Hook

8

354

SERVICING AND MAINTENANCE

(Continued)

(Continued)

Under normal operating conditions, the catalytic

converter will not require maintenance. However, it

is important to keep the engine properly tuned to

ensure proper catalyst operation and prevent

possible catalyst damage.

NOTE:

Intentional tampering with emissions control

systems can result in civil penalties being

assessed against you.
In unusual situations involving grossly

malfunctioning engine operation, a scorching odor

may suggest severe and abnormal catalyst

overheating. If this occurs, stop the vehicle, turn off

the engine and allow it to cool. Service, including a

tune-up to manufacturer's specifications, should

be obtained immediately.

To minimize the possibility of catalytic converter

damage:



Do not interrupt the ignition when the transmis

-

sion is in gear and the vehicle is in motion.



Do not try to start the vehicle by pushing or

towing the vehicle.



Do not idle the engine with any ignition compo

-

nents disconnected or removed, such as when

diagnostic testing, or for prolonged periods

during very rough idle or malfunctioning oper

-

ating conditions.

C

OOLING

S

YSTEM

WARNING!



Exhaust gases can injure or kill. They contain

carbon monoxide (CO), which is colorless and

odorless. Breathing it can make you uncon

-

scious and can eventually poison you

Ú

page 309.



A hot exhaust system can start a fire if you

park over materials that can burn. Such mate

-

rials might be grass or leaves coming into

contact with your exhaust system. Do not park

or operate your vehicle in areas where your

exhaust system can contact anything that can

burn.

CAUTION!



The catalytic converter requires the use of

unleaded fuel only. Leaded gasoline will

destroy the effectiveness of the catalyst as an

emissions control device and may seriously

reduce engine performance and cause

serious damage to the engine.



Damage to the catalytic converter can result if

your vehicle is not kept in proper operating

condition. In the event of engine malfunction,

particularly involving engine misfire or other

apparent loss of performance, have your

vehicle serviced promptly. Continued opera

-

tion of your vehicle with a severe malfunction

could cause the converter to overheat,

resulting in possible damage to the converter

and vehicle.

CAUTION!

WARNING!



You or others can be badly burned by hot

engine coolant (antifreeze) or steam from your

radiator. If you see or hear steam coming from

under the hood, do not open the hood until the

radiator has had time to cool. Never open a

cooling system pressure cap when the radi

-

ator or coolant bottle is hot.



Keep hands, tools, clothing, and jewelry away

from the radiator cooling fan when the hood is

raised. The fan starts automatically and may

start at any time, whether the engine is

running or not.

SERVICING AND MAINTENANCE

355

Engine Coolant Checks

Check the engine coolant (antifreeze) protection

every 12 months (before the onset of freezing

weather, where applicable). If the engine coolant is

dirty or rusty in appearance, the system should be

drained, flushed and refilled with fresh coolant.

Check the front of the A/C condenser or radiator

for any accumulation of bugs, leaves, etc. If dirty,

clean by gently spraying water from a garden hose

vertically down the face of the A/C condenser or

the back of the radiator core.
Check the engine cooling system hoses for brittle

rubber, cracking, tears, cuts and tightness of the

connection at the coolant recovery bottle and

radiator. Inspect the entire system for leaks.
DO NOT REMOVE THE COOLANT PRESSURE CAP

WHEN THE COOLING SYSTEM IS HOT.

Cooling System — Drain, Flush And Refill

NOTE:

Some vehicles require special tools to add coolant

properly. Failure to fill these systems properly

could lead to severe internal engine damage. If any

coolant is needed to be added to the system

please contact an authorized dealer.
If the engine coolant (antifreeze) is dirty or

contains visible sediment, have an authorized

dealer clean and flush with Organic Additive

Technology (OAT) coolant (conforming to

MS.90032).
For the proper maintenance intervals

Ú

page 329.

Selection Of Coolant

For further information

Ú

page 404.

NOTE:



Mixing of engine coolant (antifreeze) other than

specified Organic Additive Technology (OAT)

engine coolant, may result in engine damage

and may decrease corrosion protection. OAT

engine coolant is different and should not be

mixed with Hybrid Organic Additive Technology

(HOAT) engine coolant or any “globally compat

-

ible” coolant. If a non-OAT engine coolant is

introduced into the cooling system in an emer

-

gency, the cooling system will need to be

drained, flushed, and refilled with fresh OAT

coolant (conforming to MS.90032), by an autho

-

rized dealer as soon as possible.



Do not use water alone or alcohol-based engine

coolant products. Do not use additional rust

inhibitors or anti-rust products, as they may not

be compatible with the radiator engine coolant

and may plug the radiator.



This vehicle has not been designed for use with

propylene glycol-based engine coolant. Use of

propylene glycol-based engine coolant is not

recommended.



Some vehicles require special tools to add

coolant properly. Failure to fill these systems

properly could lead to severe internal engine

damage. If any coolant is needed to be added to

the system please contact an authorized dealer.

Adding Coolant

Your vehicle has been built with an improved engine

coolant (OAT coolant conforming to MS.90032) that

allows extended maintenance intervals. This engine

coolant (antifreeze) can be used up to ten years or

150,000 miles (240,000 km) before replacement.

To prevent reducing this extended maintenance

period, it is important that you use the same engine

coolant (OAT coolant conforming to MS.90032)

throughout the life of your vehicle.



When working near the radiator cooling fan,

disconnect the fan motor lead or turn the igni

-

tion to the OFF mode. The fan is temperature

controlled and can start at any time the igni

-

tion is in the ON mode.

WARNING!

8

356

SERVICING AND MAINTENANCE

Please review these recommendations for using

Organic Additive Technology (OAT) engine coolant

that meets the requirements of the manufacturer

Material Standard MS.90032. When adding

engine coolant:



We recommend using Mopar® Antifreeze/

Coolant 10 Year/150,000 Mile (240,000 km)

Formula OAT that meets the requirements of the

manufacturer Material Standard MS.90032.



Mix a minimum solution of 50% OAT engine

coolant that meets the requirements of the

manufacturer Material Standard MS.90032

and distilled water. Use higher concentrations

(not to exceed 70%) if temperatures below

−34°F (−37°C) are anticipated. Please contact

an authorized dealer for assistance.



Use only high purity water such as distilled or

deionized water when mixing the water/engine

coolant solution. The use of lower quality water

will reduce the amount of corrosion protection

in the engine cooling system.

NOTE:



It is the owner's responsibility to maintain the

proper level of protection against freezing

according to the temperatures occurring in the

area where the vehicle is operated.



Some vehicles require special tools to add

coolant properly. Failure to fill these systems

properly could lead to severe internal engine

damage. If any coolant is needed to be added to

the system, please contact a local authorized

dealer.



Mixing engine coolant types is not recom

-

mended and can result in cooling system

damage. If HOAT and OAT coolant are mixed in

an emergency, have an authorized dealer drain,

flush, and refill with OAT coolant (conforming to

MS.90032) as soon as possible.

Cooling System Pressure Cap

The cap must be fully tightened to prevent loss of

engine coolant (antifreeze), and to ensure that

engine coolant will return to the radiator from the

coolant expansion bottle/recovery tank (if

equipped).
The cap should be inspected and cleaned if there

is any accumulation of foreign material on the

sealing surfaces.

Disposal Of Used Coolant

Used ethylene glycol-based coolant (antifreeze) is

a regulated substance requiring proper disposal.

Check with your local authorities to determine the

disposal rules for your community. To prevent

ingestion by animals or children, do not store

ethylene glycol-based coolant in open containers

or allow it to remain in puddles on the ground,

clean up any ground spills immediately. If ingested

by a child or pet, seek emergency assistance

immediately.

WARNING!



Do not open a hot engine cooling system.

Never add engine coolant (antifreeze) when

the engine is overheated. Do not loosen or

remove the cap to cool an overheated engine.

Heat causes pressure to build up in the

cooling system. To prevent scalding or injury,

do not remove the pressure cap while the

system is hot or under pressure.



Do not use a pressure cap other than the one

specified for your vehicle. Personal injury or

engine damage may result.

SERVICING AND MAINTENANCE

357

Checking Coolant Level — 6.4L Engine

The level of the coolant in the pressurized coolant

bottle should be between the “MIN” and “MAX”

range on the bottle when the engine is cold.
The radiator normally remains completely full, so

there is no need to remove the cap unless

checking for coolant freeze point or replacing

engine coolant (antifreeze). Advise your service

attendant of this. As long as the engine operating

temperature is satisfactory, the coolant bottle

need only be checked once a month. When

additional engine coolant is needed to maintain

the proper level, it should be added to the coolant

bottle. Do not overfill.

Cooling System Notes

NOTE:

When the vehicle is stopped after a few miles/kilo

-

meters of operation, you may observe vapor

coming from the front of the engine compartment.

This is normally a result of moisture from rain,

snow, or high humidity accumulating on the

radiator and being vaporized when the thermostat

opens, allowing hot engine coolant (antifreeze) to

enter the radiator.
If an examination of your engine compartment

shows no evidence of radiator or hose leaks, the

vehicle may be safely driven. The vapor will soon

dissipate.



Do not overfill the coolant expansion bottle.



Check the coolant freeze point in the radiator

and in the coolant expansion bottle. If engine

coolant (antifreeze) needs to be added, the

contents of the coolant expansion bottle must

also be protected against freezing.



If frequent engine coolant additions are

required, the cooling system should be pressure

tested for leaks.



Maintain engine coolant concentration at a

minimum of 50% OAT coolant (conforming to

MS.90032) and distilled water for proper corro

-

sion protection of your engine which contains

aluminum components.



Make sure that the coolant expansion bottle

overflow hoses are not kinked or obstructed.



Keep the front of the radiator clean. If your

vehicle is equipped with air conditioning, keep

the front of the condenser clean.



Do not change the thermostat for Summer or

Winter operation. If replacement is ever neces

-

sary, install ONLY the correct type thermostat.

Other designs may result in unsatisfactory

engine cooling performance, poor gas mileage,

and increased emissions.

C

HARGE

A

IR

C

OOLER

— I

NTER

-C

OOLER

The charge air cooler is positioned below the

radiator and the air conditioner condenser. Air

enters the engine through the air cleaner and

passes through the turbocharger, where it is

pressurized. This pressurized air rapidly reaches

high temperature. The air is then directed through

a hose to the charge air cooler and through

another hose to the intake manifold of the engine.

The air entering the engine has been cooled by

about 50° to 100°F (10° to 38°C). This cooling

process enables more efficient burning of fuel

resulting in fewer emissions.
To guarantee optimum performance of the system,

keep the surfaces of the charge air cooler,

condenser and radiator clean and free of debris.

Periodically check the hoses leading to and from

the charge air cooler for cracks or loose clamps

resulting in loss of pressure and reduced engine

performance.

8

358

SERVICING AND MAINTENANCE

(Continued)

B

RAKE

S

YSTEM

In order to ensure brake system performance, all

brake system components should be inspected

periodically

Ú

page 329.

Fluid Level Check — Brake Master Cylinder

The fluid level of the master cylinder should be

checked when performing under the hood service

or immediately if the Brake System Warning Light

indicates system failure.
If necessary, add fluid to bring level within the

designated marks on the side of the reservoir of

the brake master cylinder. Be sure to clean the top

of the master cylinder area before removing cap.
With disc brakes the fluid level can be expected to

fall as the brake linings wear. However, an

unexpected drop in fluid level may be caused by a

leak and a system check should be conducted.
For further information

Ú

page 407.

A

UTOMATIC

T

RANSMISSION

Special Additives

The manufacturer strongly recommends against

using any special additives in the transmission.

Automatic Transmission Fluid (ATF) is an

engineered product and its performance may be

impaired by supplemental additives. Therefore, do

not add any fluid additives to the transmission. The

only exception to this policy is the use of special

dyes for diagnosing fluid leaks in 6-speed

transmissions. Avoid using transmission sealers as

they may adversely affect seals.

WARNING!

Riding the brakes can lead to brake failure and

possibly a collision. Driving with your foot resting

or riding on the brake pedal can result in

abnormally high brake temperatures, excessive

lining wear, and possible brake damage. You

would not have your full braking capacity in an

emergency.

WARNING!



Use only manufacturer's recommended brake

fluid

Ú

page 407. Using the wrong type of

brake fluid can severely damage your brake

system and/or impair its performance. The

proper type of brake fluid for your vehicle is

also identified on the original factory installed

hydraulic master cylinder reservoir.



To avoid contamination from foreign matter or

moisture, use only new brake fluid or fluid that

has been in a tightly closed container. Keep

the master cylinder reservoir cap secured at

all times. Brake fluid in an open container

absorbs moisture from the air resulting in a

lower boiling point. This may cause it to boil

unexpectedly during hard or prolonged

braking, resulting in sudden brake failure. This

could result in a collision.



Overfilling the brake fluid reservoir can result

in spilling brake fluid on hot engine parts,

causing the brake fluid to catch fire. Brake

fluid can also damage painted and vinyl

surfaces, care should be taken to avoid its

contact with these surfaces.



Do not allow petroleum based fluid to contam

-

inate the brake fluid. Brake seal components

could be damaged, causing partial or

complete brake failure. This could result in a

collision.

CAUTION!

Do not use chemical flushes in your

transmission as the chemicals can damage your

transmission components. Such damage is not

covered by the New Vehicle Limited Warranty.

WARNING!

SERVICING AND MAINTENANCE

359

Fluid Level Check — 8-Speed Transmission

The fluid level is preset at the factory and does not

require adjustment under normal operating

conditions. Routine fluid level checks are not

required, therefore the transmission has no

dipstick. An authorized dealer can check your

transmission fluid level using special service tools.
If you notice fluid leakage or transmission

malfunction, visit an authorized dealer

immediately to have the transmission fluid level

checked. Operating the vehicle with an improper

fluid level can cause severe transmission damage.

Fluid Level Check — 6-Speed Transmission

It is best to check the fluid level when the

transmission is at normal operating temperature

(158-176°F / 70-80°C). This normally occurs

after at least 15 miles (25 km) of driving. At normal

operating temperature the fluid cannot be held

comfortably between the fingertips. You can read

the transmission sump temperature in the

instrument cluster screen

Ú

page 81.

Use the following procedure to check the

transmission fluid level properly:
1. Monitor the transmission temperature using

the instrument cluster display, and operate

the vehicle as required to reach the normal

operating temperature. If the transmission is

not functioning properly, or the vehicle cannot

be driven, see the NOTE and CAUTION below

about checking the fluid level at colder

temperatures.

2. Park the vehicle on level ground.
3. Run the engine at normal idle speed for at

least 60 seconds, and leave the engine

running for the rest of this procedure.

4. Fully apply the parking brake, and press the

brake pedal.

5. Place the gear selector momentarily into each

gear position (allowing time for the

transmission to fully engage in each position),

ending with the transmission in PARK.

6. Remove the dipstick, wipe it clean and reinsert

it until seated.

7. Remove the dipstick again and note the fluid

level on both sides. The fluid level reading is

only valid if there is a solid coating of oil on

both sides of the dipstick. Note that the holes

in the dipstick will be full of fluid if the actual

level is at or above the hole. The fluid level

should be between the “HOT” (upper)

reference holes on the dipstick at normal

operating temperature. If the fluid level is low,

add fluid through the dipstick tube to bring it to

the proper level. Do not overfill. Use ONLY the

specified fluid

Ú

page 407. After adding any

quantity of oil through the dipstick tube, wait a

minimum of two minutes for the oil to fully

drain into the transmission before rechecking

the fluid level.

NOTE:

If it is necessary to check the transmission below

the operating temperature, the fluid level should

be between the two “COLD” (lower) holes on the

dipstick with the fluid at 60-70°F / 16-21°C. Only

use the COLD region of the dipstick as a rough

reference when setting the fluid level after a trans

-

mission service or fluid change. Re-check the fluid

level, and adjust as required, once the trans

-

mission reaches normal operating temperature.

8. Reinsert the dipstick. Check for leaks. Release

the parking brake.

CAUTION!

If a transmission fluid leak occurs, visit an

authorized dealer immediately. Severe

transmission damage may occur. An authorized

dealer has the proper tools to adjust the fluid

level accurately.

CAUTION!

If the fluid temperature is below 50°F (10°C) it

may not register on the dipstick. Do not add fluid

until the temperature is elevated enough to

produce an accurate reading. Run the engine at

idle, in PARK, to warm the fluid.

8

360

SERVICING AND MAINTENANCE

NOTE:

If it is necessary to check the transmission below

the operating temperature, the fluid level should

be between the two COLD (lower) holes on the

dipstick with the fluid at 68-86°F / 20-30°C. Only

use the COLD region of the dipstick as a rough

reference when setting the fluid level after a trans

-

mission service or fluid change. Re-check the fluid

level, and adjust as required, once the trans

-

mission reaches normal operating temperature.

Fluid And Filter Changes — 8-Speed

Transmission

Under normal operating conditions, the fluid

installed at the factory will provide satisfactory

lubrication for the life of the vehicle.
Routine fluid and filter changes are not required.

However, change the fluid and filter if the fluid

becomes contaminated (with water, etc.), or if the

transmission is disassembled for any reason.

Fluid And Filter Changes — 6-Speed

Transmission

For the proper maintenance intervals

Ú

page 329.

In addition, change the fluid and filters if the fluid

becomes contaminated (with water, etc.), or if the

transmission is disassembled for any reason.

Selection Of Lubricant

It is important to use the proper transmission fluid

to ensure optimum transmission performance and

life. Use only the manufacturer’s specified

transmission fluid

Ú

page 407. It is important to

maintain the transmission fluid at the correct level

using the recommended fluid. No chemical flushes

should be used in any transmission; only the

approved lubricant should be used.

R

EAR

A

XLE

A

ND

4

X

4 F

RONT

D

RIVING

A

XLE

F

LUID

L

EVEL

For normal service, periodic fluid level checks are

not required. When the vehicle is serviced for other

reasons the exterior surfaces of the axle assembly

should be inspected. If gear oil leakage is

suspected inspect the fluid level. This inspection

should be made with the vehicle in a level position.
When checking the fluid level, the vehicle should

be in a level position. The fluid level at room

temperature should be as follows:
3500 Front Axle: ¼ inch ± ¼ inch (6.4 mm ±

6.4 mm) below the bottom of the fill hole.
3500 Rear Axle: ¼ inch ± ¼ inch (6.4 mm ±

6.4 mm) below the bottom of the fill hole.
4500/5500 Front Axle: ¼ inch +/- ¼ inch (6.4 mm

± 6.4 mm) below the bottom of the fill hole.
4500/5500 Rear Axle: 1/8 inch +/- 1/8 inch

(3.2 mm +/- 3.2 mm) below the bottom of the fill

hole.

CAUTION!

If the fluid temperature is below 50°F (10°C) it

may not register on the dipstick. Do not add fluid

until the temperature is elevated enough to

produce an accurate reading. Run the engine at

idle, in PARK, to warm the fluid.

CAUTION!

Using a transmission fluid other than the

manufacturer’s recommended fluid may cause

deterioration in transmission shift quality and/or

torque converter shudder, and (for 6-speed

transmissions) will require more frequent fluid

and filter changes

Ú

page 407.

SERVICING AND MAINTENANCE

361

Drain And Refill

On 4500/5500 vehicles, remove the lower bolt to

drain the axle fluid.

4500/5500 Rear Axle Plugs

For the proper maintenance intervals

Ú

page 329.

Lubricant Selection

For further information

Ú

page 407.

NOTE:

The presence of water in the gear lubricant will

result in corrosion and possible failure of differ

-

ential components. Operation of the vehicle in

water, as may be encountered in some off-highway

types of service, will require draining and refilling

the axle to avoid damage.

Limited-Slip Differentials DO REQUIRE limited slip

oil additive (friction modifiers).

NOTE:

Slight noise and mild shuddering may be evident

while turning a vehicle with limited slip differential

on concrete or dry pavement. These conditions

should be considered normal operation of the

limited slip differential.

T

RANSFER

C

ASE

Fluid Level Check

This fluid level can be checked by removing the

filler plug. The fluid level should be to the bottom

edge of the filler plug hole with the vehicle in a level

position.

Drain And Refill

For the proper maintenance intervals

Ú

page 329.

Selection Of Lubricant

Use only the manufacturer's recommended fluid

Ú

page 407.

N

OISE

C

ONTROL

S

YSTEM

R

EQUIRED

M

AINTENANCE

& W

ARRANTY

All vehicles built over 10,000 lb (4,535 kg) Gross

Vehicle Weight Rating and manufactured for sale

and use in the United States are required to

comply with the Federal Government's Exterior

Noise Regulations. These vehicles can be

identified by the Noise Emission Control Label

located in the operator's compartment.

Required Maintenance For Noise Control

Systems

The following maintenance services must be

performed every six months or 7,500 miles

(12,000 km) whichever comes first, to ensure

proper operation of the noise control systems. In

addition, inspection and service should be

performed anytime a malfunction is observed or

suspected. Proper maintenance of the entire

vehicle will help the effectiveness of the noise

control systems.

1 — 4500/5500 Rear Axle Fluid Fill Plug
2 — 4500/5500 Rear Axle Fluid Drain Plug

8

362

SERVICING AND MAINTENANCE

Exhaust System
Inspect the entire exhaust system for leaks and

damaged parts. Devices such as hangers, clamps,

and U-bolts should be tight and in good condition.

Damaged components, burned or blown out

mufflers, burned or rusted out exhaust pipes

should be replaced according to the procedures

and specifications outlined in the appropriate

service manual.
Air Cleaner Assembly
Inspect air cleaner housing for proper assembly

and fit. Make certain that the air cleaner is properly

positioned and that the cover is tight. Check all

hoses leading to the air cleaner for tightness. The

air filter element must also be clean and serviced

according to the instructions outlined in the

Scheduled Maintenance section of this manual.

Tampering With Noise Control System

Prohibited

Federal law prohibits the following acts or the

causing thereof: (1) the removal or rendering

inoperative by any person, other than for purposes

of maintenance, repair, or replacement, of any

device or element of design incorporated into any

new vehicle for the purpose of noise control prior to

its sale or delivery to the ultimate purchaser or

while it is in use, or (2) the use of the vehicle after

such device or element of design has been

removed or rendered inoperative by any person.
Among those acts presumed to constitute

tampering are the acts listed below.
AIR CLEANER



Removal of the air cleaner.



Removal of the air cleaner filter element from

the air cleaner housing.



Removal of the air ducting.

EXHAUST SYSTEM



Removal or rendering inoperative exhaust

system components including the muffler or tail

-

pipe.

ENGINE COOLING SYSTEM



Removal or rendering inoperative the fan clutch.



Removal of the fan shroud.

Noise Emission Warranty

The manufacturer warrants that this vehicle as

manufactured by the manufacturer, was designed,

built and equipped to conform at the time it left the

manufacturer's control with all applicable US EPA

Noise Control Regulations.
This warranty covers this vehicle as designed, built

and equipped by the manufacturer, and is not

limited to any particular part, component or system

of the vehicle manufactured by the manufacturer.

Defects in design, assembly or in any part,

component or system of the vehicle as

manufactured by the manufacturer, which, at the

time it left the manufacturer's control, caused

noise emissions to exceed Federal standards, are

covered by this warranty for the life of the vehicle.