2005 DODGE POWER WAGON suspension

High-Pressure Monotube Shocks/New Front and
Rear Springs
The new variable-rate shocks and revised springs help to
create a suitable on-road ride without compromising
off-road competency. The shocks are designed to provide
improved stability, durability, and suspension articula-
tion.
Off-Road Tires
These tires are specifically designed for extreme off-road
use, while also maintaining quite on-road operation.The
tires utilize long-life compounds for increased durability,
and a deep-groove tread for extra traction. The LT285/
70R17 used provides a large contact patch for better
traction, two full-width steel belts for improved strength,
as well as a reinforced sidewall to help protect against
bruising and shredding.
Skid Plates And Underbody Protection
Steel skid plates protect the major driveline components
of the truck including the fuel tank, transfer case and
steering damper. In addition the Power Wagon is
equipped with boxed cross membes and fore/aft rails.
This additional protection allows the vehicle to be uti-
lized in severe off-road situations that would be consid-
ered impassable by a normal truck.
Wheel Flares
Not just for looks, the wheel flares on the Power Wagon
were designed to help cover its new larger off-road tires.
The larger flares also help to reduce the amount of debris
that can be flung up by the more aggressive tread pattern
on the tires.
82 UNDERSTANDING THE FEATURES OF YOUR VEHICLE

•Off-Road Tuned Suspension And Shocks - improves
mobility, ground clearance and ride comfort.
•Heavy Duty Thermally Protected and Sealed Electric
Winch With Roller Fairlead - Useful for work and
vehicle recovery.
•17 Inch Forged Aluminum Wheels With 33 Inch Tires
- improves traction and differential ground clearance.
Mopar Options:
•
Rock Rails - protects the door sills from impingement
damage and provides a vehicle jacking point.
•Winch accessory kit - Contents include:
•Snatch Block/Pulley
•Clevis
•Tree strap
•Tow Strap
•Gloves
•“Power Wagon embossed”storage bag
•Bed Liner - protects the bed from impingement dam-
age
NOTE:These Mopar options have been specially de-
signed and tested for the Power Wagon to meet the
vigorous off-road conditions.
MIRRORS
Inside Mirror
The mirror should be adjusted to center on the view
through the rear window.
Annoying headlight glare can be reduced by moving the
small control under the mirror to the night position
(toward rear of vehicle). The mirror should be adjusted
while set in the day position (toward windshield).
84 UNDERSTANDING THE FEATURES OF YOUR VEHICLE

Stabilizer/Sway Bar System
Power Wagon vehicles are equipped with an electronic
disconnecting stabilizer/sway bar. This system allows
greater front suspension travel in off-road situations.
This system is controlled by the electronic control sway
bar switch located on the instrument panel.The switch has two positions, on-road and off-road. The
system is normally in on-road mode, indicated by a solid
green light. The stabilizer/sway bar should remain in
on-road mode during normal driving conditions.
To disconnect the stabilizer/sway bar, shift to either 4HI
or 4LO as shown in Four Wheel Drive Operation and
press the top of the stabilizer/sway bar button to obtain
the off-road position. The amber indicator light will flash
until the stabilizer/sway bar has been fully disconnected.
(See page 277 for more information.)
NOTE:The stabilizer/sway bar may be torque locked
due to left and right suspension height differences. This
condition is due to driving surface differences or vehicle
loading. In order for the stabilizer/sway bar to
disconnect/reconnect, the right and left halves of the bar
must be aligned. This alignment may require that the
vehicle be driven onto level ground or rocked from side
to side.
Electronic Control Sway Bar Switch
STARTING AND OPERATING 223
5

WARNING!
Winch cables are under high tension when in use
and can become a projectile if they fail. Never stand
over or straddle the winch cable. Never jerk or
overload the winch cable. Never stand in front of the
vehicle while winching. Failure to follow these in-
structions can result in serious or fatal injury.
After Driving Off-Road
Off-road operation puts more stress on your vehicle than
does most on-road driving. After driving off-road, it is
always a good idea to check for damage.
•Completely inspect the underbody of your vehicle.
Check tires, body structure, steering, suspension, and
exhaust system for damage.
•Check threaded fasteners for looseness, particularly on
the chassis, drivetrain components, steering, and sus-
pension. Retighten them, if required, and torque to the
values specified in the Service Manual.
•Check for accumulations of plants or brush. These
things could be a fire hazard, or they might hide
damage to fuel lines, brake hoses, axle pinion seals,
and propeller shafts.
•After extended operation in mud, sand, water, or
similar dirty conditions, have brake drums and rotors,
brake linings, and axle yokes inspected and cleaned as
soon as possible.
•If you experience unusual vibration after driving in
mud, slush or similar conditions, check the wheels for
packed material. Packed foreign material can cause a
wheel imbalance and cleaning the wheels will correct
the situation.
STARTING AND OPERATING 245
5

WARNING!
•Do not use a tire, wheel size or rating other than that
specified for your vehicle. Some combinations of
unapproved tires and wheels may change suspen-
sion dimensions and performance characteristics,
resulting in changes to steering, handling, and brak-
ing of your vehicle. This can cause unpredictable
handling and stress to steering and suspension com-
ponents. You could lose control and have an accident
resulting in serious injury or death. Use only the tire
and wheel sizes with load ratings approved for your
vehicle.
•Never use a tire with a smaller load index or capacity,
other than what was originally equipped on your
vehicle. Using a tire with a smaller load index could
result in tire overloading and failure. You could lose
control and have an accident.
•Failure to equip your vehicle with tires having
adequate speed capability can result in sudden tire
failure and loss of vehicle control.
CAUTION!
Replacing original tires with tires of a different size
may result in false speedometer and odometer read-
ings.
Alignment And Balance
Poor suspension alignment may result in:
•Fast tire wear.
•Uneven tire wear, such as feathering and one-sided
wear.
•Vehicle pull to right or left.
Tires may also cause the vehicle to pull to the left or right.
Alignment will not correct this condition. See your dealer
for proper diagnosis.
STARTING AND OPERATING 303
5

Improper alignment will not cause vehicle vibration.
Vibration may be a result of tire and wheel out-of-
balance. Proper balancing will reduce vibration and
avoid tire cupping and spotty wear.
SUPPLEMENTAL TIRE PRESSURE INFORMATION
A light load vehicle condition is defined as two passen-
gers {150 lbs (68 kg) each} plus 200 lbs (91kg) of cargo.
Cold tire inflation pressures for a lightly loaded vehicle
will be found on a“Supplemental Tire Pressure Inflation”
label located on the face of the driver’s door or in the Tire
Information Pressures pamphlet in the glove box.
TIRE CHAINS
Use“Class U”chains on Power Wagon models, or other
traction aids that meet SAE Type“U”specifications.
NOTE:Chains must be the proper size for the vehicle,
as recommended by the chain manufacturer.
CAUTION!
To avoid damage to your vehicle, tires or chains, observe the
following precautions:
•Because of limited chain clearance between tires and other
suspension components, it is important that only chains in
good condition are used. Broken chains can cause serious
vehicle damage. Stop the vehicle immediately if noise
occurs that could suggest chain breakage. Remove the
damaged parts of the chain before further use.
•Install chains as tightly as possible and then retighten after
driving about 1/2 mile (0.8 km).
•Do not exceed 45 mph (72 km/h).
•Drive cautiously and avoid severe turns and large bumps,
especially with a loaded vehicle.
•Do not install tire chains on front wheels of 4x2 vehicles.
•Do not drive for a prolonged period on dry pavement.
•Observe the tire chain manufacturer’s instructions on
method of installation, operating speed, and conditions for
usage. Always use the lower suggested operating speed of
the chain manufacturer if different than the speed recom-
mended by the manufacturer.
304 STARTING AND OPERATING

VEHICLE LOADING
Certification Label
As required by National Highway Traffic Safety Admin-
istration Regulations, your vehicle has a certification
label affixed to the driver’s side door or pillar.
This label contains the month and year of manufacture,
Gross Vehicle Weight Rating (GVWR), Gross Axle Weight
Rating (GAWR) front and rear, and Vehicle Identification
Number (VIN). A Month-Day-Hour (MDH) number is
included on this label and indicates the Month, Day and
Hour of manufacture. The bar code that appears on the
bottom of the label is your Vehicle Identification Number
(VIN).
Gross Vehicle Weight Rating (GVWR)
The GVWR is the total permissible weight of your vehicle
including driver, passengers, vehicle, options and cargo.
The label also specifies maximum capacities of front andrear axle systems (GAWR). Total load must be limited so
GVWR and front and rear GAWR are not exceeded.
Payload
The payload of a vehicle is defined as the allowable load
weight a truck can carry, including the weight of the
driver, all passengers, options and cargo.
Gross Axle Weight Rating (GAWR)
The GAWR is the maximum permissible load on the front
and rear axles. The load must be distributed in the cargo
area so that the GAWR of each axle is not exceeded.
Each axle GAWR is determined by the components in the
system with the lowest load carrying capacity (axle,
springs, tires or wheels). Heavier axles or suspension
components sometimes specified by purchasers for in-
creased durability does not necessarily increase the vehi-
cle’s GVWR.
STARTING AND OPERATING 315
5

▫Power Steering—Fluid Check............367
▫Front Suspension Ball Joints..............367
▫Steering Linkage—Inspection............368
▫Front Prop Shaft Lubrication.............368
▫Body Lubrication.....................369
▫Windshield Wiper Blades................369
▫Windshield Washers...................369
▫Exhaust System......................370
▫Cooling System.......................371
▫Hoses And Vacuum/Vapor Harnesses.......375
▫Brake System........................376
▫Clutch Hydraulic System................377
▫Clutch Linkage.......................378▫Rear Axle And 4X4 Front Driving Axle Fluid
Level..............................378
▫Transfer Case........................379
▫Front Drive Shaft.....................379
▫Manual Transmission..................379
▫Automatic Transmission................380
▫Front Wheel Bearings..................383
▫Selection Of Lubricating Grease...........383
▫Noise Control System Required Maintenance
& Warranty.........................384
▫Appearance Care And Protection From
Corrosion...........................388

Fuse And Relay Center...................393

Vehicle Storage........................393
350 MAINTAINING YOUR VEHICLE