2004 DODGE RAM 2500 DIESEL service

²Highway Driving Ð
reduce your speed.
²Up Steep Hills Ð
select a lower transmission gear, but try and keep the
torque converter locked.
²Air Conditioning Ð
turn it off temporarily.
Do Not Operate The Engine With Low Oil
Pressure
When the engine is at normal operating temperature, the
minimum oil pressures required are:
Idle 700 to 800 RPM............... 10psi(69kPa)
Full speed and load.............. 30psi(207 kPa)
CAUTION!
If oil pressure falls to less than normal readings, shut
the engine off immediately. Failure to do so could
result in immediate and severe engine damage.
Do Not Operate The Engine With Failed Parts
Practically all failures give some warning before the parts
fail. Be on the alert for changes in performance, sounds,
and visual evidence that the engine requires service.
Some important clues are:
²engine misfiring or vibrating severely
²sudden loss of power
²unusual engine noises
²fuel, oil or coolant leaks
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NOTE:Before retrying a selection, make certain that all
the necessary requirements for selecting a new transfer
case position have been met. To retry the selection, turn
the control knob back to the current position, wait five (5)
seconds, and retry selection. To find the shift require-
ments, refer to the9Shifting Procedure9for your transfer
case, located in this section of the owner's manual.
The ªSERVICE 4WDº warning light monitors the electric
shift 4WD system. If this light remains on after engine
start up or illuminates during driving, it means that the
4WD system is not functioning properly and that service
is required.
WARNING!
Always engage the parking brake when powering
down the vehicle if the(Service 4WD(light is illu-
minated. Not engaging the parking brake may allow
the vehicle to roll which may cause personal injury.
NOTE:Do not attempt to make a shift while only the
front or rear wheels are spinning. The transfer case is not
equipped with a synchronizer and therefore the front and
rear driveshaft speeds must be equal for the shift to take
place. Shifting while only the front or rear wheels are
spinning can cause damage to the transfer case.
When operating your vehicle in 4LO, the engine speed is
approximately three times that of the 2WD/AWD or 4HI
positions at a given road speed. Take care not to over-
speed the engine and do not exceed 25 mph (40 km/h).
Proper operation of 4 wheel drive vehicles depends on
tires of equal size, type and circumference on each wheel.
Any difference in tire size can cause damage to the
transfer case.
Because 4 wheel drive provides improved traction, there
is a tendency to exceed safe turning and stopping speeds.
Do not go faster than road conditions permit.
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EXAMPLE:
Service Description:
95= Load Index
ÐA numerical code associated with the maximum load a tire can carry.
H= Speed Symbol
ÐA symbol indicating the range of speeds at which a tire can carry a load corresponding
to its load index under certain operating conditions.
ÐThe maximum speed corresponding to the Speed Symbol should only be achieved un-
der specified operating conditions. (ie. tire pressure, vehicle loading, road conditions and
posted speed limits).
Load Identification:
(....blank....(= Absence of any text on sidewall of the tire indicates a Standard Load (SL) Tire
Extra Load (XL)= Extra Load (or Reinforced) Tire
Light Load= Light Load Tire
C,D,E= Load range associated with the maximum load a tire can carry at a specified pressure
Maximum LoadÐ Maximum Load indicates the maximum load this tire is designed to carry.
Maximum PressureÐ
Maximum Pressure indicates the maximum permissible cold tire inflation pressure for this tire.
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Tread Wear Indicators
Tread wear indicators are in the original equipment tires
to help you in determining when your tires should be
replaced.
These indicators are molded into the bottom of the tread
grooves and will appear as bands when the tread depth
becomes 1/16 inch (2 mm). When the indicators appear
in 2 or more adjacent grooves, the tire should be replaced.Many states have laws requiring tire replacement at this
point.
Replacement Tires
The tires on your new vehicle provide a balance of many
characteristics. They should be inspected regularly for
wear and correct cold tire inflation pressure. The manu-
facturer strongly recommends that you use tires equiva-
lent to the originals in size, quality and performance
when replacement is needed (see the paragraph on tread
wear indicators). Refer to the Tire and Loading Informa-
tion placard for the size designation of your tire. The
service description and load identification will be found
on the original equipment tire. Failure to use equivalent
replacement tires may adversely affect the safety, han-
dling, and ride of your vehicle. We recommend that you
contact your original equipment or an authorized tire
dealer with any questions you may have on tire specifi-
cations or capability.
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ENGINE RUNAWAY
WARNING!
In case of engine runaway due to flammable fumes
from gasoline spills or turbocharger oil leaks being
sucked into the engine do the following to help
avoid personal injury and/or vehicle damage:
1. Shut off engine ignition switch.
2. Using a CO
2or dry chemical type fire extin-
guisher, direct the spray from the fire extinguisher
into the grille on the passenger side so that the spray
enters the engine air intake.
The inlet for the engine air intake is located behind the
passenger side headlamp and receives air through the
grille
FUEL REQUIREMENTS
Use good quality diesel fuel from a reputable supplier in
your Dodge truck. For most year-round service, No. 2
diesel fuel meeting ASTM specification D-975 will pro-
vide good performance. If the vehicle is exposed to
extreme cold (below 20ÉF or -7ÉC), or is required to
operate at colder-than-normal conditions for prolonged
periods, use climatized No. 2 diesel fuel or dilute the No.
2 diesel fuel with 50% No. 1 diesel fuel. This will provide
better protection from fuel gelling or wax-plugging of the
fuel filters.
WARNING!
Do not use alcohol or gasoline as a fuel blending
agent. They can be unstable under certain conditions
and hazardous or explosive when mixed with diesel
fuel.
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Improper weight distributions can have an adverse effect
on the way your vehicle steers and handles and the way
the brakes operate.
CAUTION!
Do not load your vehicle any heavier than the
GVWR or the maximum front and rear GAWR. If
you do, parts on your vehicle can break, or it can
change the way your vehicle handles. This could
cause you to lose control. Also overloading can
shorten the life of your vehicle.
An EXAMPLE of a loaded vehicle is shown in the
following chart. Note that neither GVWR nor GAWR
capabilities are exceeded. Overloading can cause poten-
tial safety hazards and shorten service life.NOTE: The weights shown in this chart are not
necessarily the weights for your vehicle. Also, the
amount of load added to both the front and rear axles
can be computed after the vehicle has been weighed
both in its(curb weight(condition, and in its(loaded
and ready for operation(condition.
Gross Vehicle Weight Rating (GVWR) 6500 LBS.
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²Highway DrivingÐreduce your speed.
²Air ConditioningÐturn it off temporarily.
²Hilly TerrainÐTurn overdrive off.
See Cooling System Operating information in the Service
and Maintenance section of this manual for more infor-
mation.
Automatic Transmission Oil Temperature Warning
Light
All vehicles with heavy duty transmission oil cooling are
equipped with a transmission sump oil temperature
sensor and warning light. If elevated transmission tem-
peratures are encountered, the engine controller will
select the most desirable gear until the transmission
temperatures are reduced. If transmission oil tempera-
tures continue to rise, a warning light located in theinstrument cluster will illuminate. If this should occur,
stop the vehicle, shift to Neutral, and run the engine at
idle or faster until the light goes off.
Towing With An Automatic Transmission
Vehicles equipped with an automatic transmission may
shift into and out of Overdrive, or a lower gear, when
driving in hilly areas, when heavily loaded, or when
towing into heavy winds.
When this condition occurs, press the ªTOW/HAULº
button or shift into a lower gear to prevent excessive
transmission wear and/or overheating, and to provide
better engine braking.
NOTE:Do not exceed the following RPM while manu-
ally downshifting:
²5.9L Diesel Engines 3200 RPM.
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3. Replace tires when tread wear indicators first become
visible.
4. Keep tires properly inflated.
5. Maintain sufficient distance between your vehicle and
the car in front to avoid a collision in a sudden stop.ENGINE DATA PLATE
Use the information from the engine data plate when
discussing service or sourcing parts for your engine. The
engine data plate is located on the intake side of the
breather cover.
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