RAM 5500 Chassis Cab (2021 year). Manual in english — page 24

378

SERVICING AND MAINTENANCE

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.

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

approximately 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 119.

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. (Chassis Cab

models not configured with B20 capability.)



A maximum blend of 20% biodiesel, meeting

ASTM specification D-7467 may be used with

your Cummins diesel engine. (Pickup models

and Chassis Cab models configured with B20

capability.)

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

379



Use of biodiesel mixture in excess of 20% can

negatively impact the fuel filter's ability to

separate water from the fuel, resulting in

high pressure 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 opera

-

tion 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

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 900 RPM

(1,050 RPM for Chassis Cab). 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 90.

D

IESEL

E

XHAUST

F

LUID

Diesel Exhaust Fluid (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 440.

You can receive assistance in locating DEF in

the United States by calling 866-RAM-INFO

(866-726-4636). In Canada call

1–800–465–2001 (English) or

1–800–387–9983 (French)

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 operate your vehicle in areas where

your exhaust system can contact anything

that can burn.

8

380

SERVICING AND MAINTENANCE

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.

NOTE:

Life expectancy of wiper blades varies

depending on geographical area and frequency

of use. Poor performance of blades may be

present with chattering, 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

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.

SERVICING AND MAINTENANCE

381

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

3. Tilt the lower end of the wiper blade away

from the arm and use 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.

1 — Wiper
2 — Locking Tab
3 — Wiper Arm

1 — Wiper
2 — Locking Tab

1 — Locking Tab
2 — Wiper
3 — Release Tab

8

382

SERVICING AND MAINTENANCE

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

WARNING!



Exhaust gases can injure or kill. They

contain carbon monoxide (CO), which is

colorless and odorless. Breathing it can

make you unconscious and can eventually

poison you

Ú

page 333.



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 operate your vehicle in areas

where your exhaust system can contact

anything that can burn.

SERVICING AND MAINTENANCE

383

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 trans

-

mission 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

components disconnected or removed, such

as when diagnostic testing, or for prolonged

periods during very rough idle or malfunc

-

tioning operating conditions.

C

OOLING

S

YSTEM

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 seri

-

ously 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 malfunc

-

tion, particularly involving engine misfire or

other apparent loss of performance, have

your vehicle serviced promptly. Continued

operation of your vehicle with a severe

malfunction could cause the converter to

overheat, resulting in possible damage to

the converter and vehicle.

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 radiator

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 automati

-

cally and may start at any time, whether the

engine is running or not.



When working near the radiator cooling fan,

disconnect the fan motor lead or turn the

ignition to the OFF mode. The fan is

temperature controlled and can start at any

time the ignition is in the ON mode.

8

384

SERVICING AND MAINTENANCE

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 354.

Selection Of Coolant

For further information

Ú

page 440.

NOTE:



Mixing of engine coolant (antifreeze) other

than specified Organic Additive Technology

(OAT) engine coolant, may result in engine

damage and may decrease corrosion protec

-

tion. OAT engine coolant is different and

should not be mixed with Hybrid Organic

Additive Technology (HOAT) engine coolant

or any “globally compatible” coolant. If a

non-OAT engine coolant is introduced into the

cooling system in an emergency, the cooling

system will need to be drained, flushed, and

refilled with fresh OAT coolant (conforming to

MS.90032), by an authorized dealer as soon

as possible.



Do not use water alone or alcohol-based

engine coolant products. Do not use addi

-

tional 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.

SERVICING AND MAINTENANCE

385

Please review these recommendations for

using Organic Additive Technology (OAT) engine

coolant that meets the requirements of FCA

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

FCA Material Standard MS.90032.



Mix a minimum solution of 50% OAT engine

coolant that meets the requirements of FCA

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 corro

-

sion 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 autho

-

rized 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 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.

8

386

SERVICING AND MAINTENANCE

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/

kilometers of operation, you may observe vapor

coming from the front of the engine compart

-

ment. This is normally a result of moisture from

rain, snow, or high humidity accumulating on

the radiator and being vaporized when the ther

-

mostat opens, allowing hot engine coolant (anti

-

freeze) 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 pres

-

sure tested for leaks.



Maintain engine coolant concentration at a

minimum of 50% OAT coolant (conforming to

MS.90032) and distilled water for proper

corrosion 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

necessary, install ONLY the correct type ther

-

mostat. Other designs may result in unsatis

-

factory 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.

SERVICING AND MAINTENANCE

387

(Continued)

B

RAKE

S

YSTEM

In order to ensure brake system performance,

all brake system components should be

inspected periodically

Ú

page 354.

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 lamp 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 444.

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 six-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 444. Using the wrong

type of brake fluid can severely damage

your brake system and/or impair its perfor

-

mance. 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 a 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

contaminate the brake fluid. Brake seal

components could be damaged, causing

partial or complete brake failure. This could

result in a collision.

WARNING!

(Continued)

8

388

SERVICING AND MAINTENANCE

Fluid Level Check — Eight-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 — Six-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 90.

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.

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.

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.

SERVICING AND MAINTENANCE

389

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 444. 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 refer

-

ence when setting the fluid level after a transmis

-

sion service or fluid change. Re-check the fluid level,

and adjust as required, once the transmission

reaches normal operating temperature.

8. Reinsert the dipstick. Check for leaks.

Release the parking brake.

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 transmission

service or fluid change. Re-check the fluid level, and

adjust as required, once the transmission reaches

normal operating temperature.

Fluid And Filter Changes — Eight-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 — Six Speed

Transmission

For the proper maintenance intervals

Ú

page 354.

In addition, change the fluid and filters if the

fluid becomes contaminated (with water, etc.),

or if the transmission is disassembled for any

reason.

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!

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

390

SERVICING AND MAINTENANCE

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 444. 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 models with 9.25 in Front Axles and 11.5 in

Rear Axles

Ú

page 444. 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.
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.

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 354.

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 six-speed

transmissions) will require more frequent fluid

and filter changes

Ú

page 444.

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

SERVICING AND MAINTENANCE

391

Lubricant Selection

For further information

Ú

page 444.

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 354.

Selection Of Lubricant

Use only the manufacturer's recommended

fluid

Ú

page 444.

N

OISE

C

ONTROL

S

YSTEM

R

EQUIRED

M

AINTENANCE

& W

ARRANTY

All vehicles built over 10,000 lbs. (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.
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.

8

392

SERVICING AND MAINTENANCE

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

tailpipe.

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 U.S. 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.

SERVICING AND MAINTENANCE

393

Maintenance Log and Service Chart (Diesel Engines)

Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest to the mileage at which

service was performed.

MILES

7,500

15,000

22,500

30,000

37,500

45,000

52,500

60,000

KILOMETERS

12,000

24 ,000

36,000

48,000

60,000

72,000

84,000

96,000

Exhaust

system-inspect
Air cleaner

assembly-inspect
ODOMETER

READING
PERFORMED BY
PERFORMED AT

MILES

67,500

75,000

82,500

90,000

97,500

105,000

112,500

120,000

KILOMETERS

108,000

120,000

132,000

144,000

156,000

168,000

180,000

192,000

Exhaust

system-inspect
Air cleaner

assembly-inspect
ODOMETER

READING

8