2005 DODGE POWER WAGON Owners Manual

WARNING!
Use of a brake fluid that may have a lower initial
boiling point, or is unidentified as to specification,
may result in sudden brake failure during hard
prolonged braking. You could have an accident.
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 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 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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Clutch Linkage
If the clutch pedal linkage begins to squeak or grunt, the
clutch pedal pivot bushings should be lubricated. Refer
to Recommended Fluids, Lubricants and Genuine Parts
for the correct lubricant type.
Rear Axle And 4x4 Front Driving Axle Fluid Level
Refer to Recommended Fluids, Lubricants and Genuine
Parts for the correct Fluid type. For normal service,
periodic fluid level checks are not required. When the
vehicle is serviced for other reasons the exterior surfaces
of the axle assembly should be inspected. If gear oil
leakage is suspected inspect the fluid level.
This inspection should be made with the vehicle in a level
position. The fluid level should be even with the bottom
of the fill hole for the Manufacturer’s C205F HD Front
Axles. The fluid level should be 5/8”(16 mm) below on
9 1/4”Manufacturer’s Rear Axles.For all 2500 Model axles, the fluid level should be 1/4”±
1/4”(6.4 mm ± 6.4 mm) below the fill hole on the 9.25”
Front and 3/4”± 1/4”(19 mm ± 6.4 mm) on 10.5”Rear
axles. The 11.5”Rear Axle level should be 1/4”± 1/4”
(6.4 mm ± 6.4 mm) below the fill hole.
Drain and Refill
Vehicles operated in normal service do not have regularly
scheduled oil changes. If fluid has become contaminated
with water or to provide the correct viscosity grade, drain
and refill.
Lubricant Selection
Refer to Recommended Fluids, Lubricants and Genuine
Parts for correct fluid 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.
378 MAINTAINING YOUR VEHICLE

Limited-Slip Differentials
Power Wagon AxlesDO NOT REQUIREany limited slip
oil additive (friction modifiers).
Transfer Case
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.
Lubricant Selection
Refer to Recommended Fluids, Lubricants and Genuine
Parts for correct fluid type.
Front Drive Shaft
The front drive shaft contains a grease fitting which
should be serviced at every oil change (see maintenance
schedule A/B).
Manual Transmission
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”(6.4
mm) 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 G56 (6–Speed Manual
Transmission—If Equipped)
This transmission does not require periodic changing. If
it becomes necessary to add or change the fluid in this
transmission, refer to Recommended Fluids, Lubricants
and Genuine Parts for correct fluid type.
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Automatic Transmission
Fluid Level Check
The fluid level should be checked when the engine is
fully warmed up and the fluid in the transmission is at
normal operating temperature. Operation of the trans-
mission 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.
Fluid Level Check–545RFE
Check the fluid level while the transmission is at normal
operating temperature 82°C (180°F). This occurs after at
least 15 miles (25 km) of driving. At normal operating
temperature the fluid cannot be held comfortably be-
tween the fingertips.
To check the automatic transmission fluid level properly,
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 P (Park).
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 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
380 MAINTAINING YOUR VEHICLE

a minimum of two (2) minutes for the oil to fully drain
into the transmission before rechecking the fluid level.
NOTE:If it is necessary to check the transmissionbelow
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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Selection Of Lubricant
Refer to Recommended Fluids, Lubricants and Genuine
Parts for correct fluid type. It is important that the
transmission fluid be maintained at the prescribed level
using the recommended fluid.
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
Recommended Fluids, Lubricants and Genuine Parts
for correct fluid type.
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
Dodge Dealer or Service Center.
It is important that proper lubricant is used in the
transmission. Refer to Recommended Fluids, Lubricants
and Genuine Parts for correct fluid type.
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(s) should be changed.
382 MAINTAINING YOUR VEHICLE

Special Additives
The manufacturer strongly recommends against the ad-
dition of any additives to the transmission. Exception to
this policy is the use of special dyes to aid in detecting
fluid leaks. The use of transmission sealers should be
avoided, since they may adversely affect seals.
Front Wheel Bearings
Front wheel bearings for all Dodge Ram Trucks are
sealed-for-life. They do not require greasing or seal
replacement. In some instances, these bearings will
“purge”excess grease and the bearing will look slightly
wet. This is normal. Periodic inspection for excess play is
recommended.
Rear Wheel Bearings—Manufacturer’s Axles
These bearings are normally considered permanently
lubricated. Cleaning and repacking is required only
when axle shafts are removed or in case of extreme water
or dust contamination.
Selection of Lubricating Grease
The National Lubricating Grease Institute (NLGI) has
developed a symbol (Certification Mark) to aid the
vehicle owner in the proper selection of grease for the
lubrication of wheel bearings and chassis components.
This symbol (an example is shown below) is located on
the grease container and identifies the application and
quality of the grease.
There are two groups
identified, those for wheel
bearings (Letter“G”) and
those for chassis (Letter
“L”) lubrication. Perfor-
mance categories within
these groups result in dual
letter designations for
each group. The letter des-
ignations shown in the ex-
ample are the highest
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7

quality level available and when combined as shown can
be used for both wheel bearing and chassis lubrication.
Use only those greases that have the NLGI symbol on the
container along with the proper quality level for your
application.
Noise Control System Required Maintenance &
Warranty
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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