Dodge 2500 Diesel (2008 year). Manual — part 28

Adding Coolant
Your vehicle has been built with an improved engine
coolant that allows extended maintenance intervals. This
coolant can be used up to 5 Years or 100,000 miles (160
000 km) before replacement. To prevent reducing this
extended maintenance period, it is important that you
use the same coolant throughout the life of your vehicle.
Please review these recommendations for using Hybrid
Organic Additive Technology (HOAT) coolant. When
adding coolant:

• The manufacturer recommends using Mopart

Antifreeze/Coolant 5 Year/100,000 Mile Formula
HOAT (Hybrid Organic Additive Technology).

• Mix a minimum solution of 50% HOAT engine coolant

and distilled water. Use higher concentrations (not to
exceed 70%) if temperatures below -34°F (-37°C) are
anticipated.

• Use only high purity water such as distilled or deion-

ized 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.

Please note that it is the owner’s responsibility to main-
tain the proper level of protection against freezing ac-
cording to the temperatures occurring in the area where
the vehicle is operated.

NOTE:

Mixing coolant types will decrease the life of the

engine coolant and will require more frequent coolant
changes.

Cooling System Pressure Cap
The cap must be fully tightened to prevent loss of coolant
and to ensure that coolant will return to the radiator from
the coolant recovery bottle.

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The cap should be inspected and cleaned if there is any
accumulation of foreign material on the sealing surfaces.

WARNING!

• The warning words “DO NOT OPEN HOT” on

the cooling system pressure cap are a safety pre-
caution. Never add coolant 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 scald-
ing 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 en-
gine damage may result.

Disposal Of Used Engine Coolant
Used ethylene glycol based engine coolant is a regulated
substance requiring proper disposal. Check with your
local authorities to determine the disposal rules for your
community. Do not store ethylene glycol-based engine
coolant in open containers or allow it to remain in
puddles on the ground. Prevent ingestion by animals and
children. If ingested by a child, contact a physician
immediately. Clean up any ground spills immediately.

Coolant Level
The coolant bottle provides a quick visual method for
determining that the coolant level is adequate. With the
engine cold, the level of the coolant in the coolant
recovery bottle should be between the ranges indicated
on the bottle.

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The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking for
coolant freeze point or replacing coolant. 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 coolant is needed to maintain the
proper level, it should be added to the coolant bottle. Do
not overfill.

Points To Remember

NOTE:

When the vehicle is stopped after a few miles (a

few kilometers) 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 vapor-
ized when the thermostat opens, allowing hot coolant 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 recovery bottle.
• Check coolant freeze point in the radiator and in the

coolant recovery bottle. If antifreeze needs to be
added, contents of coolant recovery bottle must also be
protected against freezing.

• If frequent coolant additions are required, or if the

level in the coolant recovery bottle does not drop when
the engine cools, the cooling system should be pres-
sure tested for leaks.

• Maintain coolant concentration at 50% HOAT engine

coolant (minimum) and distilled water for proper
corrosion protection of your engine which contains
aluminum components.

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• Make sure that the radiator and coolant recovery

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 also.

• Do not change the thermostat for summer or winter

operation. If replacement is ever necessary, install
ONLY the correct type thermostat. Other designs may
result in unsatisfactory coolant performance, poor gas
mileage, and increased emissions.

Fan

Inspection
Check the fan for cracks and bent or broken blades. If any
of these conditions exist, you must replace the fan. Make
sure it is securely mounted.

NOTE:

This service procedure must be performed by a

trained service technician. Make arrangements with your
authorized dealer for this inspection.

Charge Air Cooler (Inter-Cooler)

The charge air cooler is positioned between the radiator
and the air conditioner condenser. Air enters the engine
through the air cleaner and passes through the turbo-
charger 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
degrees Fahrenheit. This cooling process enables more
efficient burning of fuel resulting in fewer emissions.

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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.

Hoses And Vacuum/Vapor Harnesses

Inspect surfaces of hoses and nylon tubing for evidence
of heat and mechanical damage. Hard or soft spots,
brittle rubber, cracking, tears, cuts, abrasions, and exces-
sive swelling indicate deterioration of the rubber.

Pay particular attention to those hoses nearest to high
heat sources such as the exhaust manifold. Inspect hose
routing to be sure hoses do not come in contact with any
heat source or moving component that may cause heat
damage or mechanical wear.

Insure nylon tubing in these areas has not melted or
collapsed.

Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.

Components should be replaced immediately if there is
any evidence of wear or damage that could cause failure.

Brake System

Power Disc Brakes (Front and Rear)
Disc brakes do not require adjustment; however, several
hard stops during the break-in period are recommended
to seat the linings and wear off any foreign material.

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Brake Master Cylinder
The fluid level of the master cylinder should be checked
when performing under the hood service, or immedi-
ately if the brake system warning lamp indicates system
failure.

The brake master cylinder has a translucent plastic
reservoir. On the outboard side of the reservoir there is a

“FULL” dot and an “ADD” dot. The fluid level must be
kept within these two dots. Do not add fluid above the
full mark because leakage may occur at the 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 correct fluid type, refer to ”Brake Master Cylinder”
under “Fluids, Lubricants and Genuine Parts” in this
section.

WARNING!

Use of a brake fluid that may have a lower initial
boiling point, or unidentified as to specification, may
result in sudden brake failure during hard prolonged
braking. You could have an accident.

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WARNING!

Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts and the
brake fluid catching fire.

Use only brake fluid that has been in a tightly closed
container to avoid contamination from foreign matter or
moisture.

CAUTION!

Do not allow a petroleum-base fluid to contaminate
the brake fluid. Seal damage and loss of brake
performance may result.

Brake Hoses
Inspection should be performed whenever the brake
system is serviced or at intervals specified. Inspect hy-
draulic brake hoses for surface cracking, scuffing or worn
spots. If there is any evidence of cracking, scuffing, or
worn spots, the hose should be replaced immediately!
Eventual deterioration of the hose can take place with
possible burst failure.

Clutch Linkage

If the clutch pedal linkage begins to squeak or grunt, the
clutch pedal pivot bushings should be lubricated. Refer
to Fluids, Lubricants and Genuine Parts for the correct
lubricant type. Multipurpose Grease, NLGI Grade 2 E.P.

Clutch Hydraulic System

The clutch hydraulic system is a sealed maintenance-free
system. In the event of leakage or other malfunction, the
system must be replaced.

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Rear Axle And 4x4 Front Driving Axle Fluid Level

For Model 9.25 Front Axles and 10.5”/11.5” Rear Axles
refer to Fluids, Lubricants and Genuine Parts for the
correct lubricant type. For normal service, periodic fluid
level checks are not required. When the vehicle is ser-
viced 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 should be 1/4” ± 1/4” (6.4
mm ± 6.4 mm) below the fill hole on the 9.25” Front Axle.
The fluid level should be 3/4” ± 1/4” (19 mm ± 6.4 mm)
below the fill hole on all 10.5” and 1/4” ± 1/4” (6.4 mm
± 6.4 mm) on 11.5” Rear Axles.

Drain And Refill
Follow the Maintenance Schedule for recommended fron
and rear axle fluid change intervals.

Lubricant Selection
Refer to Fluids, Lubricants and Genuine Parts for the
correct lubricant type.

NOTE:

The presence of water in the gear lubricant will

result in corrosion and possible failure of differential
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

in vehicles equipped with

10.5”/11.5” Axles DO NOT REQUIRE any limited slip
oil additive (friction modifiers).

Transfer Case — If Equipped

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.

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Drain And Refill
Follow the Maintenance Schedule for recommended
transfer case fluid change intervals.

Lubricant Selection
Refer to Fluids, Lubricants and Genuine Parts for the
correct lubricant type.

Manual Transmission — If Equipped

Fluid Level Check
This fluid level can be checked by removing the filler
plug. If the level of the lubricant is more than 1/4” below
the bottom of the filler hole while the vehicle is on level
ground, enough lubricant should be added to bring the
level to the bottom of the filler hole.

Lubricant Selection for 6-Speed Manual
Transmission — If Equipped
If it becomes necessary to add fluid or change the fluid,
be sure to use the same lubricant or equivalent. Refer to
Fluids, Lubricants and Genuine Parts for the correct
lubricant type.

Automatic Transmission

Selection Of Lubricant
It is important that the proper lubricant is used in the
transmission to assure optimum transmission perfor-
mance. Use only manufacturer’s recommended transmis-
sion fluid; refer to “Automatic Transmission” under
“Fluids, Lubricants and Genuine Parts” in this section

Refer to Fluids, Lubricants and Genuine Parts for correct
fluid type. It is important that the transmission fluid be
maintained at the prescribed level using the recom-
mended fluid.

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CAUTION!

Using a transmission fluid other than the manufac-
turers recommended fluid may cause deterioration in
transmission shift quality and/or torque converter
shudder. Using a transmission fluid other than the
manufacturers recommended fluid will result in
more frequent fluid and filter changes. Refer to
Fluids, Lubricants and Genuine Parts for correct
fluid type.

Fluid Level Check
If equipped with a dipstick, use the following procedure.
If your vehicle has a capped dipstick tube, it is sealed and
should not be tampered with. Your authorized dealer has
the proper tools to ensure that the fluid level is set
properly. The fluid level should be checked when the

engine is fully warmed up and the fluid in the transmis-
sion is at normal operating temperature. Operation of the
transmission with an improper fluid level will greatly
reduce the life of the transmission and of the fluid. Check
the fluid level whenever the vehicle is serviced.

Procedure For Checking Fluid Level
To properly check the automatic transmission fluid level,
the following procedure must be used:

1. Operate the engine at idle speed and normal operating
temperature.

2. The vehicle must be on level ground.

3. Fully apply the parking brake and press the brake
pedal.

4. Place the gear selector momentarily in each gear
position ending with the lever in PARK.

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5. Remove the dipstick, wipe it clean and reinsert it until
seated.

6. Remove the dipstick again and note the fluid level on
both sides. The fluid level should be between the “HOT”
(upper) reference holes on the dipstick at normal operat-
ing temperature. Verify that a solid coating of oil is seen
on both sides of the dipstick. If the fluid is low, add as
required into the dipstick tube. Do not overfill. After
adding any quantity of oil through the oil fill 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 approximately 70°F (21°C) (room tem-
perature). If the fluid level is correctly established at
room temperature, it should be between the “HOT”

(upper) reference holes when the transmission reaches
180°F (82°C). Remember it is best to check the level at the
normal operating temperature.

CAUTION!

Be aware that 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.

7. Check for leaks. Release parking brake.

To prevent dirt and water from entering the transmission
after checking or replenishing fluid, make certain that the
dipstick cap is properly reseated. It is normal for the
dipstick cap to spring back slightly from its fully seated
position, as long as its seal remains engaged in the
dipstick tube.

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Automatic Transmission Fluid and Filter Change
To obtain best performance and long life for automatic
transmissions, the manufacturer recommends that they
be given regular maintenance service by an authorized
dealer or Service Center. It is important that the trans-
mission fluid is maintained at the correct level, and that
it is drained and refilled as specified.

Use only manufacturer’s recommended transmission
fluid; for correct fluid type, refer to “Automatic Trans-
mission” under “Fluids, Lubricants and Genuine Parts”
in this section. It is important that the transmission fluid
be maintained at the prescribed level using the recom-
mended fluid..

The fluid and filter(s) should be changed as specified in
the Maintenance Schedule (Section 8).

NOTE:

If the transmission is disassembled for any

reason, the fluid and filter should be changed.

Special Additives
Automatic Transmission Fluid (ATF) is an engineered
product and its performance may be impaired by supple-
mental additives. Therefore, do not add any fluid addi-
tives to the transmission. The only exception to this
policy is the use of special dyes to aid in detecting fluid
leaks. In addition, avoid using transmission sealers as
they may adversely affect seals.

Front Wheel Bearings

Front wheel bearings for your vehicle are sealed-for-life.
They do not require greasing or seal replacement. In
some instances, these bearings will “purge” excess grease
and the bearing housing will look slightly wet. This is
normal.

• Periodic inspection for excess play is recommended.
• If a bearing assembly is accidentally separated when

servicing the brake rotors, it should be replaced.

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Rear Wheel Bearings
Clean and repack when brake linings are replaced or
rotors resurfaced.

Noise Control System Required Maintenance &
Warranty

For 3500 Two-Wheel Drive and Four-Wheel Drive mod-
els over 10,000 lbs. (4 535 kg) Gross Vehicle Weight
Rating.

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.

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Required Maintenance For Noise Control Systems
The following maintenance services must be performed
every 6 months or 6,000 miles (9 600 km), whichever
comes first, to assure 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 compo-
nents, 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 out-
lined in the Maintenance Schedule 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 incorpo-
rated 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.

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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 manufac-
tured 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 Regu-
lations.

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.

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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

84,000

105,00

112,500

KILOMETERS

108 000 120 000 132 000 144 000 126 000 156 000 168 000 181 000

Exhaust system-inspect
Air cleaner assembly-inspect
ODOMETER READING
PERFORMED BY
PERFORMED AT

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