Dodge 2500 Diesel (2005 year). Manual — part 26

Once a Month

• Check tire pressure and look for unusual wear or

damage.

• Inspect the batteries and clean and tighten the termi-

nals as required.

• Check the fluid levels of coolant reservoir, brake

master cylinder, and transmission and transfer case (if
equipped), add as needed.

• Check Filter Minder™. Replace air cleaner filter

element if necessary.

• Check all lights and all other electrical items for correct

operation.

At Each Oil Change

• Change the engine oil filter.
• Inspect the exhaust system.
• Inspect the brake hoses.
• Inspect the CV joints (if equipped) and front suspen-

sion components.

• Check the automatic transmission fluid level.
• Check the manual transmission fluid level.
• Check the coolant level, hoses, and clamps.

404

MAINTENANCE SCHEDULES

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Schedule “B”
Follow schedule “B” if you usually operate your vehicle
under one or more of the following conditions.

• Frequent short trips where the engine does not achieve

full operating temperature (operating temperature de-
fined as 190° F (66° C) coolant temperature).

• Extensive engine idling (over 10 minutes per hour of

operation) at ambient temperatures less than 32° F (0°
C).

• Driving in dusty conditions.

• Frequent trailer towing.
• Taxi, police, or delivery service (commercial service).
• Off-road or desert operation.
• Extensive operation at high engine speeds (greater

than 2900 rpm) and loads (greater than 70% throttle).

NOTE:

If ANY of these apply to you then change your

coolant every 102,000 miles (163 000 km) or 60 months,
whichever comes first and follow schedule “B” of the

⬙Maintenance Schedules⬙ section of this manual.

SCHEDULE “B”

405

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

3,750

7,500

11,250

15,000

18,750

(Kilometers)

(6 000)

(12 000)

(18 000)

(24 000)

(30 000)

Change engine oil and engine oil filter.

X

X

Lubricate Front Drive Shaft Fitting (2500/3500,
4X4).

X

X

X

X

X

Rotate tires.

X

X

Lubricate outer tie rod ends 2500/3500 (4X4) mod-
els only.

X

X

Inspect water pump weep hole for blockage.

X

Replace fuel filter element. Clean the water in fuel
sensor.

X

Change rear axle fluid.

X

Change front axle fluid (4X4).

X

Inspect brake linings.

X

Inspect and adjust parking brake if necessary.

X

406

SCHEDULE “B”

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

22,500

26,250

30,000

33,750

37,500

(Kilometers)

(36 000)

(42 000)

(48 000)

(54 000)

(60 000)

Change engine oil and engine oil filter.

X

X

X

Lubricate Front Drive Shaft Fitting (2500/3500, 4X4).

X

X

X

X

X

Rotate tires.

X

X

X

Lubricate outer tie rod ends 2500/3500 (4X4) models only.

X

X

X

Inspect drive belt, replace as required.

X

Inspect fan hub.

X

Inspect damper.

X

Inspect water pump weep hole for blockage.

X

Replace fuel filter element. Clean the water in fuel sensor.

X

Change rear axle fluid.

X

Change front axle fluid (4X4).

X

Check transfer case fluid level (4X4).

X

Drain and refill automatic transmission fluid. Replace filter
and adjust bands (48RE only).

X

SCHEDULE “B”

407

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

41,250

45,000

48,750

52,500

56,250

(Kilometers)

(66 000)

(72 000)

(78 000)

(84 000)

(90 000)

Change engine oil and engine oil filter.

X

X

Lubricate Front Drive Shaft Fitting (2500/3500,
4X4).

X

X

X

X

X

Rotate tires.

X

X

Lubricate outer tie rod ends 2500/3500 (4X4) mod-
els only.

X

X

Inspect drive belt, replace as required.

X

Inspect water pump weep hole for blockage.

X

Replace fuel filter element. Clean the water in fuel
sensor.

X

Inspect brake linings.

X

Inspect and adjust parking brake if necessary.

X

Change rear axle fluid.

X

Change front axle fluid (4X4).

X

408

SCHEDULE “B”

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

60,000

63,750

67,500

71,250

75,000

(Kilometers)

(96 000)

(102 000)

(108 000)

(114 000)

(120 000)

Change engine oil and engine oil filter.

X

X

X

Lubricate Front Drive Shaft Fitting (2500/3500,
4X4).

X

X

X

X

X

Flush and replace engine coolant at 60 months, if
not replaced at 102,000 miles (163 000 km).

X

Rotate tires.

X

X

X

Lubricate outer tie rod ends 2500/3500 (4X4) mod-
els only.

X

X

X

Inspect drive belt, replace as required.

X

Inspect fan hub.

X

Inspect damper.

X

Inspect water pump weep hole for blockage.

X

X

Replace fuel filter element. Clean the water in fuel
sensor.

X

X

Inspect front wheel bearings.

X

Change rear axle fluid.

X

X

SCHEDULE “B”

409

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

60,000

63,750

67,500

71,250

75,000

(Kilometers)

(96 000)

(102 000)

(108 000)

(114 000)

(120 000)

Change front axle fluid (4X4).

X

X

Change 6-spd manual transmission (G-56) fluid
2500/3500 models only.

X

Inspect brake linings.

X

X

Inspect and adjust parking brake if necessary.

X

X

Drain and refill transfer case fluid (4X4).

X

Drain and refill automatic transmission fluid and
change main sump filter (545 RFE only).

X

Drain and refill automatic transmission fluid. Re-
place filter and adjust bands (48RE only).

X

410

SCHEDULE “B”

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

78,750

82,500

86,250

90,000

93,750

(Kilometers)

(126 000)

(132 000)

(138 000)

(144 000)

(150 000)

Change engine oil and engine oil filter.

X

X

Lubricate Front Drive Shaft Fitting (2500/3500,
4X4).

X

X

X

X

X

Rotate tires.

X

X

Lubricate outer tie rod ends 2500/3500 (4X4) mod-
els only.

X

X

Inspect drive belt, replace as required.

X

Change rear axle fluid.

X

Change front axle fluid (4X4).

X

Check transfer case fluid level (4X4).

X

Inspect fan hub.

X

Inspect damper.

X

Inspect water pump weep hole for blockage.

X

Replace fuel filter element. Clean the water in fuel
sensor.

X

SCHEDULE “B”

411

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

78,750

82,500

86,250

90,000

93,750

(Kilometers)

(126 000)

(132 000)

(138 000)

(144 000)

(150 000)

Inspect front wheel bearings.

X

Inspect brake linings.

X

Inspect and adjust parking brake if necessary.

X

Drain and refill automatic transmission fluid. Re-
place filter and adjust bands (48RE only).

X

412

SCHEDULE “B”

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

97,500

100,000

101,250

105,000

108,750

112,500

(Kilometers)

(156 000)

(160 000) (162 000) (168 000) (174 000) (180 000)

Change engine oil and engine oil filter.

X

X

X

Lubricate Front Drive Shaft Fitting (2500/3500, 4X4).

X

X

X

X

X

X

Flush and replace engine coolant, if not replaced

at 60 months.

X

Rotate tires.

X

X

X

Lubricate outer tie rod ends 2500/3500 (4X4)

models only.

X

X

X

Flush and replace engine coolant.

X

Inspect drive belt, replace as required.

X

Inspect water pump weep hole for blockage.

X

Replace fuel filter element. Clean the water in fuel

sensor.

X

Change rear axle fluid.

X

Change front axle fluid (4X4).

X

Inspect brake linings.

X

Inspect and adjust parking brake if necessary.

X

SCHEDULE “B”

413

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

116,250

120,000

123,750

127,500

131,250

135,000

(Kilometers)

(186 000)

(192 000)

(198 000) (204 000) (210 000) (216 000)

Change engine oil and engine oil filter.

X

X

X

Lubricate Front Drive Shaft Fitting (2500/
3500, 4X4).

X

X

X

X

X

X

Rotate tires.

X

X

X

Flush and replace engine coolant at 120
months, if not replaced at 102,000 miles (163
000 km).

X

Lubricate outer tie rod ends 2500/3500 (4X4)
models only.

X

X

X

Clean engine air filter canister.

X

Adjust valve lash clearance.

X

Inspect drive belts, replace as required.

X

Drain and refill transfer case fluid (4X4).

X

Inspect fan hub.

X

Inspect damper.

X

Inspect water pump weep hole for blockage.

X

X

414

SCHEDULE “B”

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

116,250

120,000

123,750

127,500

131,250

135,000

(Kilometers)

(186 000)

(192 000)

(198 000) (204 000) (210 000) (216 000)

Replace fuel filter element. Clean the water in
fuel sensor.

X

X

Inspect front wheel bearings.

X

Change rear axle fluid.

X

X

Change front axle fluid (4X4).

X

X

Change 6-spd manual transmission (G-56)
fluid 2500/3500 models only.

X

Inspect brake linings.

X

X

Inspect and adjust parking brake if necessary.

X

X

Drain and refill automatic transmission fluid
and change main sump and spin-on cooler
return filter (if equipped) (545 RFE only).

X

Drain and refill automatic transmission fluid.
Replace filter and adjust bands (48RE only).

X

Inspection and service should also be performed anytime a
malfunction is observed or suspected. Retain all receipts.

SCHEDULE “B”

415

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Schedule “A”

Miles

7,500

15,000

22,500

30,000

37,500

(Kilometers)

(12 000)

(24 000)

(36 000)

(48 000)

(60 000)

[Months]

[6]

[12]

[18]

[24]

[30]

Change engine oil and engine oil filter.

X

X

Lubricate Front Drive Shaft Fitting (2500/3500, 4X4).

X

X

X

X

X

Rotate tires.

X

X

X

X

X

Lubricate outer tie rod ends 2500/3500 (4X4) models only.

X

X

X

X

X

Check transfer case fluid level (4X4).

X

Inspect water pump weep hole for blockage

X

X

Replace fuel filter element. Clean the water in fuel sensor.

X

X

Inspect drive belts, replace as necessary.

X

Inspect brake linings.

X

Inspect and adjust parking brake if necessary.

X

Inspect fan hub.

X

Inspect damper.

X

Inspect front wheel bearings.

X

416

SCHEDULE “A”

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

45,000

52,500

60,000

67,500

75,000

(Kilometers)

(72 000)

(84 000)

(96 000)

(108 000)

(120 000)

[Months]

[36]

[42]

[48]

[54]

[60]

Change engine oil and engine oil filter.

X

X

X

Lubricate Front Drive Shaft Fitting (2500/3500,
4X4).

X

X

X

X

X

Rotate tires.

X

X

X

X

X

Lubricate outer tie rod ends 2500/3500 (4X4) mod-
els only.

X

X

X

X

X

Check transfer case fluid level.

X

Flush and replace engine coolant at 60 months, if
not replaced at 102,000 miles (163 000 km).

X

Inspect drive belts, replace as necessary.

X

X

Inspect water pump weep hole for blockage

X

X

X

Replace fuel filter element. Clean the water in fuel
sensor.

X

X

X

Inspect brake linings.

X

X

Inspect and adjust parking brake if necessary.

X

X

SCHEDULE “A”

417

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

45,000

52,500

60,000

67,500

75,000

(Kilometers)

(72 000)

(84 000)

(96 000)

(108 000)

(120 000)

[Months]

[36]

[42]

[48]

[54]

[60]

Inspect fan hub.

X

Inspect damper.

X

Inspect front wheel bearings.

X

Replace fuel filter element. Clean the water in fuel
sensor

X

418

SCHEDULE “A”

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S

Miles

82,500

90,000

97,500

100,000

105,000

(Kilometers)

(132 000)

(144 000)

(156 000)

(160 000)

(168 000)

[Months]

[66]

[72]

[78]

[84]

Change engine oil and engine oil filter.

X

X

Lubricate Front Drive Shaft Fitting (2500/3500,
4X4).

X

X

X

X

X

Rotate tires.

X

X

X

X

X

Lubricate outer tie rod ends 2500/3500 (4X4) mod-
els only.

X

X

X

X

X

Flush and replace engine coolant, if not replaced at
60 mos.

X

Check transfer case fluid level (4X4).

X

Inspect drive belt, replace as required.

X

Inspect fan hub.

X

Inspect damper.

X

Inspect water pump weep hole for blockage.

X

X

Replace fuel filter element. Clean the water in fuel
sensor.

X

X

SCHEDULE “A”

419

8

M

A

I

N

T
E

N
A
N
C

E

S
C
H
E
D
U
L
E
S