2004 DODGE RAM 2500 DIESEL maintenance

TABLE OF CONTENTSSECTIONPAGE
1INTRODUCTION.............................................................3
2THINGS TO KNOW BEFORE STARTING YOUR VEHICLE..............................9
3UNDERSTANDING THE FEATURES OF YOUR VEHICLE..............................71
4UNDERSTANDING YOUR INSTRUMENT PANEL...................................137
5STARTING AND OPERATING.................................................199
6WHAT TO DO IN EMERGENCIES..............................................295
7MAINTAINING YOUR VEHICLE...............................................317
8MAINTENANCE SCHEDULES..................................................383
9IF YOU NEED CONSUMER ASSISTANCE.........................................401
10INDEX....................................................................411
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INTRODUCTION
This manual has been prepared with the assistance of
service and engineering specialists to acquaint you with
the operation and maintenance of your new vehicle. It is
supplemented by a Warranty Information Booklet and
various customer oriented documents. You are urged to
read these publications carefully. Following the instruc-
tions and recommendations in this manual will help
assure safe and enjoyable operation of your vehicle.
NOTE: After you read the manual, it should be stored
in the vehicle for convenient reference and remain with
the vehicle when sold, so that the new owner will be
aware of all safety warnings.
When it comes to service, remember that your dealer
knows your vehicle best, has the factory-trained techni-
cians and genuine Mopartparts, and is interested in
your satisfaction.WARNING!
Engine exhaust, some of its constituents, and certain
vehicle components contain or emit chemicals
known to the State of California to cause cancer and
birth defects or other reproductive harm. In addition,
certain fluids contained in vehicles and certain prod-
ucts of component wear contain or emit chemicals
known to the State of California to cause cancer and
birth defects or other reproductive harm.
A MESSAGE FROM DAIMLERCHRYSLER
CORPORATION
DaimlerChrysler Corporation and Cummins welcome
you as a new Dodge Ram Cummins Turbo Diesel-
powered truck owner.
4 INTRODUCTION

Almost 100% of the heavy duty trucks in the United
States are diesel powered because of the fuel economy,
rugged durability, and high torque which permits pulling
heavy loads. Cummins engines power well over half of
these trucks. Now this same technology and proven
performance is yours in your new Dodge Ram truck
equipped with the Cummins 5.9 liter, Turbocharged,
Charge Air Cooled, Diesel engine.
Your diesel truck will sound, feel, drive, and operate
differently from a gasoline-powered truck. It is important
that you read and understand this manual. You may find
that some of the starting, operating, and maintenance
procedures are different. However, they are simple to
follow and careful adherence to them will ensure that
you take full advantage of the features of this engine.
Thank you for choosing the Dodge Ram truck with
Cummins Turbo Diesel power.HOW TO USE THIS MANUAL
Consult the table of contents to determine which section
contains the information you desire.
The detailed index, at the rear of this manual, contains a
complete listing of all subjects.
WARNINGS AND CAUTIONS
This manual containsWARNINGSagainst operating
procedures which could result in an accident or bodily
injury. It also containsCAUTIONSagainst procedures
which could result in damage to your vehicle. If you do
not read this entire manual you may miss important
information. Observe all Warnings and Cautions.
INTRODUCTION 5
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Airbag Light
You will want to have the airbags ready to inflate for your
protection in an impact. While the airbag system is
designed to be maintenance free, if any of the following
occurs, have an authorized dealer service the system
promptly:
²The airbag light does not come on or flickers during
the 6 to 8 seconds when the ignition switch is first
turned on.
²The light remains on or flickers after the 6 to 8 second
interval.
²The light flickers or comes on and remains on while
driving.NOTE:If the speedometer, tachometer or any engine
related gauges are not working, the airbag control mod-
ule may also be disabled. The airbags may not be ready
to inflate for your protection. Promptly check fuse num-
bers 52 and 53 in the fuse and relay center. See your
dealer if the fuse is good.
Child Restraint
Everyone in your vehicle needs to be buckled up all the
time Ð babies and children, too. Every state in the United
States and all Canadian provinces require that small
children ride in proper restraint systems. This is the law,
and you can be prosecuted for ignoring it.
Children 12 years and under should ride properly buck-
led up in a rear seat, if available. According to crash
statistics, children are safer when properly restrained in
the rear seats rather than in the front.
THINGS TO KNOW BEFORE STARTING YOUR VEHICLE 55
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mRemote Sound System Controls Ð If Equipped . . 181
NRadio Operation......................182
NTape Player.........................182
NCD Player..........................182
mCassette Tape And Player Maintenance.......183
mCompact Disc Maintenance................184
mRadio Operation And Cellular Phones........184
mClimate Controls.......................185NHeater Only Ð Fleet Vehicles.............185
NAir ConditioningÐIf Equipped...........187
NElectric Rear Window Defroster And Heated
Sideview Mirrors Ð If Equipped..........191
NAir Conditioning With Dual Zone Temperature
Control Ð If Equipped.................191
NOperating Tips.......................196
NOperating Tips Chart...................198
140 UNDERSTANDING YOUR INSTRUMENT PANEL

NOTE:If the gauge pointer moves to either extreme of
the gauge, the ªCheck Gagesº indicator will illuminate
and a single chime will sound.
14. Security
The light will flash rapidly for approximately 16 seconds
when the vehicle theft alarm is arming. The light will
flash at a slower rate after the alarm is set. The security
light will also come on for about two seconds when the
ignition is first turned ON.
15. Transmission Range Indicator (Automatic
Tranmissions Only)
When the gear selector lever is moved, this indicator
shows the automatic transmission gear range selected.
16. CRUISE Light
This indicator lights when the electronic speed control
system is turned on.17. Water In Fuel Indicator
Indicates there is water detected in the fuel
filter bowl. Refer to the Maintenance section,
Draining Fuel/Water Separator Filter, for water
drain procedure.
18. Brake System Warning Light
This light illuminates when the ignition key is turned to
the ON position and remains on for a few seconds. If the
light stays on longer, it may be an indication that the
parking brake has not been released. This light will
illuminate if the brake fluid is low, especially when
braking or accelerating hard. This light will illuminate if
the ABS indicator light has a malfunction. This light will
flash if the engine is running and the parking brake is on.
If the light remains on when the parking brake is
released, it indicates a possible brake hydraulic system
malfunction. In this case, the light will remain on until
the cause is corrected.
UNDERSTANDING YOUR INSTRUMENT PANEL 147
4

If you press the switch up or down twice it plays the
second track, three times, it will play the third, etc.
The button in the center of the left hand switch has no
function in this mode.
CASSETTE TAPE AND PLAYER MAINTENANCE
To keep the cassette tapes and player in good condition,
take the following precautions:
1. Do not use cassette tapes longer than C-90; otherwise,
sound quality and tape durability will be greatly dimin-
ished.
2. Keep the cassette tape in its case to protect from
slackness and dust when it is not in use.
3. Keep the cassette tape away from direct sunlight, heat
and magnetic fields such as the radio speakers.
4. Before inserting a tape, make sure that the label is
adhering flatly to the cassette.5. A loose tape should be corrected before use. To rewind
a loose tape, insert the eraser end of a pencil into the tape
drive gear and twist the pencil in the required directions.
Maintain your cassette tape player. The head and capstan
shaft in the cassette player can pick up dirt or tape
deposits each time a cassette is played. The result of
deposits on the capstan shaft may cause the tape to wrap
around and become lodged in the tape transport. The
other adverse condition is low or ªmuddyº sound from
one or both channels, as if the treble tone control were
turned all the way down. To prevent this, you should
periodically clean the head with a commercially available
WET cleaning cassette.
As preventive maintenance, clean the head about every
30 hours of use. If you wait until the head becomes very
dirty (noticeably poor sound), it may not be possible to
remove all deposits with a simple WET cleaning cassette.
UNDERSTANDING YOUR INSTRUMENT PANEL 183
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COMPACT DISC MAINTENANCE
To keep the compact discs in good condition, take the
following precautions:
1. Handle the disc by its edge; avoid touching the
surface.
2. If the disc is stained, clean the surface with a soft cloth,
wiping from center to edge.
3. Do not apply paper or tape to the disc; avoid scratch-
ing the disc.
4. Do not use solvents such as benzene, thinner, cleaners,
or antistatic sprays.
5. Store the disc in its case after playing.
6. Do not expose the disc to direct sunlight.
7. Do not store the disc where temperatures may become
too high.NOTE:If you experience difficulty in playing a particu-
lar disc, it may be damaged, oversized, or have theft
protection encoding. Try a known good disc before
considering disc player service.
RADIO OPERATION AND CELLULAR PHONES
Under certain conditions, the operation of a cellular
phone in your vehicle can cause erratic or noisy perfor-
mance from your radio. This condition may be lessened
or eliminated by relocating the cellular phone antenna.
This condition is not harmful to the radio. If your radio
performance does not satisfactorily ªclearº by the repo-
sitioning of the antenna, it is recommended that the radio
volume be turned down or off during cellular phone
operation.
184 UNDERSTANDING YOUR INSTRUMENT PANEL