Dodge Diesel (2004 year). Manual — part 20

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

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WHAT TO DO IN EMERGENCIES

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.

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.

WHAT TO DO IN EMERGENCIES

309

6

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.

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.

310

WHAT TO DO IN EMERGENCIES

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.

WARNING!

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

WHAT TO DO IN EMERGENCIES

311

6

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.

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.

312

WHAT TO DO IN EMERGENCIES

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.

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

WHAT TO DO IN EMERGENCIES

313

6

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.

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.

314

WHAT TO DO IN EMERGENCIES

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.

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).

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

315

6

MAINTAINING YOUR VEHICLE

CONTENTS

m Engine Compartment . . . . . . . . . . . . . . . . . . . . 320

▫ 5.9L/5.9L HO Cummins Turbo Diesel . . . . . . . 320

m Onboard Diagnostic System (OBD II) . . . . . . . . . 321
m Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 322
m Dealer Service . . . . . . . . . . . . . . . . . . . . . . . . . 322
m Service Information . . . . . . . . . . . . . . . . . . . . . 322
m Maintenance Procedures . . . . . . . . . . . . . . . . . . 325

▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 325
▫ Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

▫ Engine Air Cleaner Filter . . . . . . . . . . . . . . . . 331
▫ Draining Fuel/Water Separator Filter . . . . . . . 334
▫ Maintenance Free Batteries . . . . . . . . . . . . . . . 336
▫ Air Conditioner Maintenance . . . . . . . . . . . . . 338
▫ Power Steering — Fluid Check . . . . . . . . . . . . 339
▫ Front Suspension Ball Joints . . . . . . . . . . . . . . 340
▫ Steering Linkage — Inspection . . . . . . . . . . . . 340
▫ Front Axle Universal Drive Joints And Pivot

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

7

▫ Body Lubrication . . . . . . . . . . . . . . . . . . . . . 340
▫ Windshield Wiper Blades . . . . . . . . . . . . . . . . 341
▫ Windshield Washers . . . . . . . . . . . . . . . . . . . 341
▫ Exhaust System . . . . . . . . . . . . . . . . . . . . . . 342
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . . . 343
▫ Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
▫ Charge Air Cooler (Inter-Cooler) . . . . . . . . . . 347
▫ Hoses And Vacuum/Vapor Harnesses . . . . . . . 348
▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . . 348
▫ Clutch Linkage . . . . . . . . . . . . . . . . . . . . . . . 350
▫ Clutch Hydraulic System . . . . . . . . . . . . . . . . 351
▫ Propeller Shaft Universal Joints . . . . . . . . . . . 351

▫ Rear Axle And 4X4 Front Driving Axle Fluid

Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

▫ Transfer Case — If Equipped . . . . . . . . . . . . . 352
▫ Manual Transmission — If Equipped . . . . . . . 352
▫ Automatic Transmission . . . . . . . . . . . . . . . . 353
▫ Front Wheel Bearings . . . . . . . . . . . . . . . . . . 355
▫ Selection Of Lubricating Grease . . . . . . . . . . . 356
▫ Noise Control System Required

Maintenance & Warranty . . . . . . . . . . . . . . . . 357

▫ Appearance Care And Protection From

Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

m Fuse And Relay Center . . . . . . . . . . . . . . . . . . . 366
m Vehicle Storage . . . . . . . . . . . . . . . . . . . . . . . . 366

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MAINTAINING YOUR VEHICLE

m Replacement Light Bulbs . . . . . . . . . . . . . . . . . 367
m Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . 367

▫ Headlight (Halogen)/Front Park And Turn

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

▫ Tail, Stop, Turn And Backup Lights . . . . . . . . . 371
▫ Center High-Mounted Stoplight With Cargo

Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

▫ Cab Top Clearance Lights — If Equipped . . . . 375
▫ Tailgate ID Lights (Dual Rear Wheels) . . . . . . . 376

▫ Side Marker Lights (Dual Rear Wheels) . . . . . . 378
▫ Fog Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 378

m Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . 379
m Recommended Fluids, Lubricants And Genuine

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380

▫ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
▫ Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381

MAINTAINING YOUR VEHICLE

319

7

ENGINE COMPARTMENT

5.9L/5.9L HO CUMMINS TURBO DIESEL

320

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.

MAINTAINING YOUR VEHICLE

321

7

REPLACEMENT PARTS

Use of genuine Mopar

t 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.

DEALER SERVICE

Your dealer has the qualified service personnel, special
tools and equipment to perform all service operations in
an expert manner. Service manuals are available which
include detailed service information for your vehicle.
Refer to these manuals before attempting any procedure
yourself.

NOTE:

Intentional tampering with emissions control

systems can result in civil penalties being assessed
against you.

WARNING!

You can be badly injured working on or around a
motor vehicle. Do only that service work for which
you have the knowledge and the proper equipment.
If you have any doubt about your ability to perform
a service job, take your vehicle to a competent
mechanic.

SERVICE INFORMATION

Mopar Fluids, Lubricants and Parts are available from
your dealer and will help you keep your vehicle operat-
ing at its best. Your dealer also has the qualified service
personnel, special tools and equipment to perform all
service operations in an expert manner. Service manuals
are available which include detailed service information
for your vehicle. Refer to these manuals before attempt-
ing any procedure yourself. See Service Publications
information at the back of this manual.

322

MAINTAINING YOUR VEHICLE

NOTE:

Failure to perform maintenance service at the

specified intervals as outlined in the Maintenance
Schedules

may void provisions of your Vehicle Warranty.

CAUTION!

To maintain your vehicle safely follow these guide-
lines:

• Watch your vehicle’s mileage and check your Mainte-

nance Schedules

regularly for required servicing. Ex-

cessive wear or damage to certain vehicle components
can result if required services are not performed.

• If you have your vehicle undercoated, inspect for

undercoating material on the propeller shafts. Such
material could cause the shafts to become unbalanced
and result in drivetrain vibrations. Remove any under-
coating with solvent.

• If you have your vehicle undercoated, make sure no

undercoating material is sprayed on the exhaust sys-
tem or components of the seat belt system.

NOTE:

It is not possible for the manufacturer and

Cummins, Inc. to anticipate every possible circumstance
that can involve a potential hazard.

WARNING!

To maintain your vehicle safely and avoid personal
injury, follow these guidelines:

• Never spray or pour diesel fuel, flammable liquid or

starting fluids (ether) into the air cleaner canister, air
intake piping or turbocharger inlet in an attempt to
start the vehicle.

MAINTAINING YOUR VEHICLE

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