Dodge 2500 Diesel (2005 year). Manual — part 21

models use the blade on the end of the lug wrench to pry
the caps off. The wheel skin can now be removed.

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

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

8-Stud — Dual Rear Wheels
Dual wheels are flat mounted, center piloted. The lug
nuts are a two piece assembly. When the tires are being
rotated or replaced, clean these lug nuts and add 2 drops
of oil at the interface between the hex and the washer.

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

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WHAT TO DO IN EMERGENCIES

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

NOTE:

When installing a spare tire as part of a dual rear

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

These dual rear wheels should be tightened as follows:

WHAT TO DO IN EMERGENCIES

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

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

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

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

wheel. The nuts should then be tightened to recom-
mended torque. Tighten the nuts to final torque in
increments. Progress around the bolt circle, tightening
the nut opposite to the nut just previously tightened until
final torque is achieved. Recommended torques are
shown in the following chart.

Disc
Wheels

Type Nut Stud Size Torque

Ft. Lbs.

Torque
Newton
Meters

Cone

9/16-18

120-150

160-200

Flanged

9/16-18

130-160

190-220

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

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

326

WHAT TO DO IN EMERGENCIES

Attach the wheel wrench to the extension tube. Rotate the
winch mechanism until the wheel is drawn into place
against the underside of the vehicle. Continue to rotate
until you feel the winch mechanism slip or click 3 or 4
times. It cannot be overtightened. Push against the tire
several times to be sure it is firmly in place.

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

CAUTION!

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

JUMP-STARTING

WARNING!

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

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

NOTE:

Replacement batteries should both be of equal

size to prevent damage to the vehicles charging system.

WHAT TO DO IN EMERGENCIES

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6

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

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

CAUTION!

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

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

328

WHAT TO DO IN EMERGENCIES

WARNING!

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

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

WARNING!

• Do not connect the cable to the negative post of

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

• During cold weather when temperatures are be-

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

WHAT TO DO IN EMERGENCIES

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6

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

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

a. Disconnect the negative cable at the engine ground.

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

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

WARNING!

Any procedure other than above could result in:

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

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

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

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

330

WHAT TO DO IN EMERGENCIES

CAUTION!

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

FREEING A STUCK VEHICLE
If vehicle becomes stuck in snow, sand, or mud, it can
often be moved by a rocking motion. Move the gear
selector rhythmically between DRIVE and REVERSE,
while applying slight pressure to the accelerator.

In general, the least amount of accelerator pedal pressure
to maintain the rocking motion without spinning the
wheels or racing the engine is most effective. Racing the
engine or spinning the wheels, due to the frustration of
not freeing the vehicle, may lead to transmission over-
heating and failure. Allow the engine to idle with the

transmission selector in NEUTRAL for at least one
minute after every five rocking-motion cycles. This will
minimize overheating and reduce the risk of transmis-
sion failure during prolonged efforts to free a stuck
vehicle.

EMERGENCY TOW HOOKS — IF EQUIPPED
Your vehicle may be equipped with emergency tow
hooks.

WARNING!

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

WHAT TO DO IN EMERGENCIES

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6

WARNING!

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

CAUTION!

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

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

4-Wheel- Drive Vehicles

CAUTION!

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

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WHAT TO DO IN EMERGENCIES

The manufacturer recommends towing with all wheels
OFF

the ground. Acceptable methods are to tow vehicle

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

2–Wheel- Drive Vehicles
Provided that the transmission is operable, tow with the
transmission in Neutral and the ignition key in the OFF
position along with the front wheels raised and the rear
wheels on the ground. Speed must not exceed 30 mph (50
km/h) and distance must not exceed 15 miles (25 km).

CAUTION!

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

If the vehicle is to be towed more than 15 miles (25 km)
the vehicle must be towed with the rear wheels raised
and the front wheels on the ground. It may also be towed
on a flatbed or with the front wheels raised and the rear
wheels on a dolly.

WHAT TO DO IN EMERGENCIES

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6

MAINTAINING YOUR VEHICLE

CONTENTS

䡵 Engine Compartment . . . . . . . . . . . . . . . . . . . . 338

▫ 5.9L HO Cummins Turbo Diesel . . . . . . . . . . . 338

䡵 Onboard Diagnostic System (OBD II) . . . . . . . . . 339
䡵 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 339
䡵 Dealer Service . . . . . . . . . . . . . . . . . . . . . . . . . 340
䡵 Service Information . . . . . . . . . . . . . . . . . . . . . 340
䡵 Maintenance Procedures . . . . . . . . . . . . . . . . . . 343

▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 343
▫ Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

▫ Engine Air Cleaner Filter . . . . . . . . . . . . . . . . 349
▫ Draining Fuel/Water Separator Filter . . . . . . . 351
▫ Maintenance Free Batteries . . . . . . . . . . . . . . . 354
▫ Air Conditioner Maintenance . . . . . . . . . . . . . 355
▫ Power Steering — Fluid Check . . . . . . . . . . . . 356
▫ Front Suspension Ball Joints . . . . . . . . . . . . . . 357
▫ Steering Linkage — Inspection . . . . . . . . . . . . 357
▫ Front Prop Shaft Lubrication . . . . . . . . . . . . . 358

7

▫ Front Axle Universal Drive Joints And Pivot

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

▫ Body Lubrication . . . . . . . . . . . . . . . . . . . . . 358
▫ Windshield Wiper Blades . . . . . . . . . . . . . . . . 359
▫ Windshield Washers . . . . . . . . . . . . . . . . . . . 359
▫ Exhaust System . . . . . . . . . . . . . . . . . . . . . . 360
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . . . 361
▫ Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
▫ Charge Air Cooler (Inter-Cooler) . . . . . . . . . . 365
▫ Hoses And Vacuum/Vapor Harnesses . . . . . . . 366
▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . . 366
▫ Clutch Linkage . . . . . . . . . . . . . . . . . . . . . . . 368
▫ Clutch Hydraulic System . . . . . . . . . . . . . . . . 369

▫ Rear Axle And 4X4 Front Driving Axle Fluid

Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

▫ Transfer Case — If Equipped . . . . . . . . . . . . . 370
▫ Manual Transmission — If Equipped . . . . . . . 370
▫ Automatic Transmission . . . . . . . . . . . . . . . . 370
▫ Front Wheel Bearings . . . . . . . . . . . . . . . . . . 373
▫ Selection Of Lubricating Grease . . . . . . . . . . . 373
▫ Noise Control System Required Maintenance

& Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 374

▫ Appearance Care And Protection From

Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

䡵 Fuse And Relay Center . . . . . . . . . . . . . . . . . . . 383
䡵 Vehicle Storage . . . . . . . . . . . . . . . . . . . . . . . . 384
䡵 Replacement Light Bulbs . . . . . . . . . . . . . . . . . 384

336

MAINTAINING YOUR VEHICLE

䡵 Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . 385

▫ Headlight (Halogen)/Front Park And Turn

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385

▫ Tail, Stop, Turn And Backup Lights . . . . . . . . . 389
▫ Center High-Mounted Stoplight With Cargo

Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

▫ Cab Top Clearance Lights — If Equipped . . . . 393
▫ Tailgate ID Lights (Dual Rear Wheels) . . . . . . . 394

▫ Side Marker Lights (Dual Rear Wheels) . . . . . . 396
▫ Fog Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 396

䡵 Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . 397
䡵 Recommended Fluids, Lubricants And Genuine

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398

▫ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
▫ Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

MAINTAINING YOUR VEHICLE

337

7

ENGINE COMPARTMENT

5.9L HO CUMMINS TURBO DIESEL

338

MAINTAINING YOUR VEHICLE

ONBOARD DIAGNOSTIC SYSTEM (OBD II)
CARB emission control vehicles are equipped with a
sophisticated onboard diagnostic system called OBDII.
This system monitors the performance of the emissions,
engine, and automatic transmission control systems.
When these systems are operating properly, your vehicle
will provide excellent performance and fuel economy, as
well as engine emissions well within current government
regulations.

If any of these systems require service, the OBD II system
will turn on the “Malfunction Indicator Light.” It will
also store diagnostic codes and other information to
assist your service technician in making repairs. Al-
though your vehicle will usually be driveable and not
need towing, see your dealer for service as soon as
possible.

CAUTION!

Prolonged driving with the “Malfunction Indicator
Light” on could cause further damage to the emis-
sion control system. It could also affect fuel economy
and driveability. The vehicle must be serviced before
any emissions tests can be performed.

If the “Malfunction Indicator Light” is flashing,
severe catalytic converter damage and power loss
will soon occur. Immediate service is required.

REPLACEMENT PARTS
Use of genuine Mopar

威 parts for normal/scheduled

maintenance and repairs is highly recommended to in-
sure the designed performance. Damage or failures
caused by the use of non-Mopar parts for maintenance
and repairs will not be covered by the manufacturer’s
warranty.

MAINTAINING YOUR VEHICLE

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