Page 376 of 496

▫Front Axle Universal Drive Joints And Pivot
Bearings ............................398
▫ Body Lubrication .....................399
▫ Windshield Wiper Blades ................399
▫ Windshield Washers ...................399
▫ Exhaust System ......................400
▫ Cooling System .......................401
▫ Fan ...............................407
▫ Charge Air Cooler (Inter-Cooler) ..........408
▫ Hoses And Vacuum/Vapor Harnesses .......408
▫ Brake System ........................409
▫ Clutch Linkage .......................411
▫ Clutch Hydraulic System ................411 ▫
Rear Axle And 4X4 Front Driving
Axle Fluid Level ......................411
▫ Transfer Case — If Equipped .............412
▫ Manual Transmission — If Equipped .......412
▫ Automatic Transmission ................413
▫ Front Wheel Bearings ..................415
▫ Selection Of Lubricating Grease ...........416
▫ Noise Control System Required Maintenance &
Warranty ...........................417
▫ Appearance Care And Protection
From Corrosion ......................422
Fuses (Integrated Power Module) ...........426
Vehicle Storage ........................431
Replacement Light Bulbs .................432
376 MAINTAINING YOUR VEHICLE
Page 402 of 496

accumulation of bugs, leaves, etc. If dirty, clean by gently
spraying water from a garden hose vertically down the
face of the condenser.
Check the coolant recovery bottle tubing for brittle rub-
ber, cracking, tears, cuts and tightness of the connection
at the bottle and radiator. Inspect the entire system for
leaks.
Extremely cold ambient temperature may require the
addition of a “winter front” for effective operation of the
cab heating/cooling system. Make certain that a percent-
age of the radiator is exposed for adequate air flow
through the charge air cooler and automatic transmission
oil cooler. The percentage of opening must be increased
with the increasing ambient air temperature and/or
engine load. If the cooling fan can be heard cycling
frequently, increase the size of the opening in the winter
front.Coolant bottle level check
The coolant reserve system provides a quick visual
method of determining that the coolant level is adequate.
With the engine idling, and warmed to the normal
operating temperature, the level of the coolant on the
coolant bottle should be between the fluid level marks.
Check the coolant level whenever the hood is raised.
The radiator normally remains completely full, so there is
no longer a need to remove the coolant pressure cap
except for checking coolant freeze point or replacement
with new antifreeze coolant.
402 MAINTAINING YOUR VEHICLE
Page 413 of 496

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
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.
Procedure For Checking Fluid Level
To properly check the automatic transmission fluid level,
the following procedure must be used: 1. The vehicle must be on level ground.
2. The engine should be running at curb idle speed for a
minimum of 60 seconds.
3. Fully apply parking brake.
4. Place the gear selector briefly in each gear position
ending with the lever in N (Neutral).
5. Remove the dipstick and determine if the fluid is hot
or warm. Hot fluid is approximately 180°F (82°C) which
is the normal operating temperature after the vehicle has
been driven at least 15 miles. The fluid can not be
comfortably held between the finger tips. Warm is when
fluid is between 85° - 125°F (29° - 52°C).
6. Wipe the dipstick clean and reinsert until seated.
Remove dipstick and note reading.
a. If the fluid is hot, the reading should be in the
crosshatched area marked “OK”.
MAINTAINING YOUR VEHICLE 413
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b. If the fluid is warm, the reading should be between
the two holes. If the fluid level indicates low, add
sufficient fluid to bring to the proper level.
Fluid is added through the dipstick tube.
NOTE: To prevent dirt and water from entering the
transmission after checking or replenishing fluid, make
certain that the dipstick cap is properly seated.
Selection Of Lubricant
Refer to Fluids, Lubricants and Genuine Parts for the
correct lubricant type. It is important that the transmis-
sion 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
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 the
transmission be adjusted periodically, the fluid main-
tained at the correct level, and that it be drained and
refilled as specified.
414 MAINTAINING YOUR VEHICLE
Page 447 of 496
Chassis
Component Fluids, Lubricants and Genuine Parts.
Automatic Transmission Mopar ATF+4, Automatic Transmission Fluid.
Transfer Case Mopar ATF+4, Automatic Transmission Fluid.
Manual Transmission Fluid G-56 Mopar ATF+4, Automatic Transmission Fluid.
Clutch Linkage Multipurpose Grease, NLGI Grade 2 E.P. or equivalent.
Front and Rear Axle Fluid 2500/3500
Models GL-5 SAE 75W-90 Synthetic or equivalent. 2500/3500 axels do not require
limited slip additive.
Brake Master Cylinder Mopar DOT 3 and SAE J1703 should be used or equivalent. If DOT 3
brake fluid is not available, then DOT 4 is acceptable. Use only recom-
mended brake fluids.
Power Steering Reservoir Mopar ATF+4, Automatic Transmission Fluid.
MAINTAINING YOUR VEHICLE 447
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Page 452 of 496
Once a Month
•Check tire pressure and look for unusual wear or
damage.
•Inspect the batteries and clean and tighten the termi-
nals as required.
•Check the fluid levels of coolant reservoir, brake
master cylinder, and transmission and transfer case (if
equipped), add as needed.
•Check Filter Minder™. Replace air cleaner filter
element if necessary.
•Check all lights and all other electrical items for correct
operation.
•Drain water from the fuel filter. At Each Oil Change
•Change the engine oil filter.
•Inspect the exhaust system.
•Inspect the brake hoses.
•Inspect the U-Joints ( if equipped) and front suspen-
sion components.
•Check the automatic transmission fluid level.
•Check the manual transmission fluid level.
•Check the coolant level, hoses, and clamps.
•Lubricate outer tie rod ends.
•Lubricate Front Drive Shaft Fittin
452 MAINTENANCE SCHEDULES
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Page 455 of 496
Miles 22,500 26,250 30,000 33,750 37,500
(Kilometers) (36 000) (42 000) (48 000) (54 000) (60 000)
Change engine oil and engine oil filter. X X X
Lubricate Front Drive Shaft Fitting (2500/3500,
4X4). X X XXX
Rotate tires. X X X
Check spare tire for proper pressure and correct
stowage. XXX
Lubricate outer tie rod ends 2500/3500 (4X4) mod-
els. XXX
Inspect drive belt, replace as required. X
Replace fuel filter element. X
Change rear axle fluid. X
Change front axle fluid (4X4). X
Check transfer case fluid level (4X4). X
Drain and refill automatic transmission fluid. Re-
place filter and adjust bands (48RE only). X
SCHEDULE “B” 455
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Page 458 of 496
Miles 60,000 63,750 67,500 71,250 75,000
(Kilometers) (96 000) (102 000) (108 000) (114 000) (120 000)
Change 6-spd manual transmission (G-56) fluid
2500/3500. X
Inspect brake linings. X X
Inspect and adjust parking brake if necessary. X X
Drain and refill transfer case fluid (4X4). X
Drain and refill automatic transmission fluid and
change main sump filter (545 RFE only). X
Drain and refill automatic transmission fluid. Re-
place filter and adjust bands (48RE only). X
458 SCHEDULE “B”
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