2008 DODGE RAM 3500 CHASSIS CAB service

WARNING!
Fluid level should be checked on a level surface and
with the engine off to prevent injury from moving
parts and to insure accurate fluid level reading. Do
not overfill. Use only manufacturers recommended
power steering fluid.
If necessary, add fluid to restore to the proper indicated
level. With a clean cloth, wipe any spilled fluid from all
surfaces. Refer to Fluids, Lubricants, and Genuine Parts
for correct fluid type.
Front Suspension Ball Joints
The ball joints originally supplied with the vehicle are
permanently lubricated at the factory and do not require
service. The ball joints and seals should be inspected
whenever the vehicle is serviced for other reasons.
Steering Linkage Ð Inspection
Whenever the vehicle is hoisted, all steering linkage
joints should be inspected for evidence of damage. If
seals are damaged, parts should be replaced to prevent
leakage or contamination of the grease.
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Front Prop Shaft Lubrication
Lubricate the front driveshaft grease fitting at each oil
change listed in the appropriate Maintenance Schedule
for your vehicle. Use Moparttype MS-6560 (lithium
based grease), or equivalent.
Front Axle Universal Drive Joints And Ball Joints
The front axle universal joint and ball joints are perma-
nently lubricated and do not require servicing.
Body Lubrication
Locks and all body pivot points, including such items as
seat tracks, doors, liftgate and hood hinges, should be
lubricated periodically to assure quiet, easy operation
and to protect against rust and wear. Prior to the appli-
cation of any lubricant, the parts concerned should be
wiped clean to remove dust and grit; after lubricating
excess oil and grease should be removed. Particular
attention should also be given to hood latching compo-
nents to insure proper function. When performing other
underhood services, the hood latch, release mechanism
and safety catch should be cleaned and lubricated.
The external lock cylinders should be lubricated twice a
year, preferably in the fall and spring. Apply a small
Front Driveshaft Grease Fitting
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WARNING!
²The warning words ªDO NOT OPEN HOTº on
the cooling system pressure cap are a safety pre-
caution. Never add coolant when the engine is
overheated. Do not loosen or remove the cap to
cool an overheated engine. Heat causes pressure to
build up in the cooling system. To prevent scald-
ing or injury, do not remove the pressure cap while
the system is hot or under pressure.
²Do not use a pressure cap other than the one
specified for your vehicle. Personal injury or en-
gine damage may result.
Disposal Of Used Engine Coolant
Used ethylene glycol based engine coolant is a regulated
substance requiring proper disposal. Check with your
local authorities to determine the disposal rules for yourcommunity. Do not store ethylene glycol-based engine
coolant in open containers or allow it to remain in
puddles on the ground. Prevent ingestion by animals and
children. If ingested by a child, contact a physician
immediately. Clean up any ground spills immediately.
Coolant Level
The coolant bottle provides a quick visual method for
determining that the coolant level is adequate. With the
engine cold, the level of the coolant in the coolant
recovery bottle should be between the ranges indicated
on the bottle.
The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking for
coolant freeze point or replacing coolant. Advise your
service attendant of this. As long as the engine operating
temperature is satisfactory, the coolant bottle need only
be checked once a month.
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²Do not change the thermostat for summer or winter
operation. If replacement is ever necessary, install
ONLY the correct type thermostat. Other designs may
result in unsatisfactory coolant performance, poor gas
mileage, and increased emissions.
Fan
Inspection
Check the fan for cracks and bent or broken blades. If any
of these conditions exist, you must replace the fan. Make
sure it is securely mounted.
NOTE:This service procedure must be performed by a
trained service technician. Make arrangements with your
authorized Dodge Truck Dealer for this inspection.
Charge Air Cooler Ð Inter-Cooler (Diesel
Engines)
The charge air cooler is positioned between the radiator
and the air conditioner condenser. Air enters the engine
through the air cleaner and passes through the turbo-
charger where it is pressurized. This pressurized air
rapidly reaches high temperature. The air is then directed
through a hose to the charge air cooler and through
another hose to the intake manifold of the engine. The air
entering the engine has been cooled by about 50 to 100
degrees Fahrenheit. This cooling process enables more
efficient burning of fuel resulting in fewer emissions.
To guarantee optimum performance of the system, keep
the surfaces of the charge air cooler, condenser and
radiator clean and free of debris. Periodically check the
hoses leading to and from the charge air cooler for cracks
or loose clamps resulting in loss of pressure and reduced
engine performance.
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Hoses And Vacuum/Vapor Harnesses
Inspect surfaces of hoses and nylon tubing for evidence
of heat and mechanical damage. Hard or soft spots,
brittle rubber, cracking, tears, cuts, abrasions, and exces-
sive swelling indicate deterioration of the rubber.
Pay particular attention to those hoses nearest to high
heat sources such as the exhaust manifold. Inspect hose
routing to be sure hoses do not come in contact with any
heat source or moving component which may cause heat
damage or mechanical wear.
Insure nylon tubing in these areas has not melted or
collapsed.
Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.
Components should be replaced immediately if there is
any evidence of wear or damage that could cause failure.
Fuel System Connections
Electronic Fuel Injection high pressure fuel systems are
designed with tubes and special connects, connections
and clamps which have unique material characteristics to
provide adequate sealing and resist attack by deterio-
rated gasoline.
You are urged to use only the manufactures-specified
tubes, connections and clamps, or their equivalent in
material and specification, in any fuel system servicing.
Brake System
Power Disc Brakes (Front and Rear)
Disc brakes do not require adjustment; however, several
hard stops during the break-in period are recommended
to seat the linings and wear off any foreign material.
Brake And Power Steering Hoses
When the vehicle is serviced for scheduled maintenance,
inspect surface of hoses and nylon tubing for evidence of
440 MAINTAINING YOUR VEHICLE

heat and mechanical damage. Hard and brittle rubber,
cracking, tears, cuts, abrasion, and excessive swelling
indicate deterioration of the rubber. Particular attention
should be made to examining those hose surfaces nearest
to high heat sources, such as the exhaust manifold.
Insure nylon tubing in these areas has not melted or
collapsed.
Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.
NOTE:Often, fluid such as oil, power steering fluid,
and brake fluid are used during assembly plant opera-
tions to facilitate the assembly of hoses to couplings.
Therefore, oil wetness at the hose-coupling area is not
necessarily an indication of leakage. Actual dripping of
hot fluid when systems are under pressure (during
vehicle operation), should be noted before hose is re-
placed based on leakage.NOTE:Inspection of brake hoses should be performed
whenever the brake system is serviced and every engine
oil change. Inspect hydraulic 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 resulting in a possibility of a burst failure.
WARNING!
Worn brake hoses can burst and cause brake failure.
You could have an accident. If you see any signs of
cracking, scuffing, or worn spots, have the brake
hoses replaced immediately.
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Brake Master Cylinder ± Brake Fluid Level Check
The fluid level of the master cylinder should be checked
when performing under the hood service, or immedi-
ately if the brake system warning lamp indicates system
failure.
The brake master cylinder has a translucent plastic
reservoir. On the outboard side of the reservoir, there is a
ªMAXº mark and an ªMINº mark (3500 vehicles only)
and a ªFULLº and ªADDº mark (4500/5500 vehicles
only). The fluid level must be kept within these two
marks. Do not add fluid above the full mark because
leakage may occur at the cap.
With disc brakes the fluid level can be expected to fall as
the brake linings wear. However, an unexpected drop in
fluid level may be caused by a leak and a system check
should be conducted.
Refer to Fluids, Lubricants and Genuine Parts for the
correct Fluid type.WARNING!
Use of a brake fluid that may have a lower initial
boiling point, or 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.
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CAUTION!
Do not allow a petroleum-base fluid to contaminate
the brake fluid. Seal damage and loss of brake
performance may result.
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.
Clutch Linkage
If the clutch pedal linkage begins to squeak or grunt, the
clutch pedal pivot bushings should be lubricated. Refer
to Fluids, Lubricants and Genuine Parts for the correct
lubricant type. Multipurpose Grease, NLGI Grade 2 E.P.
Rear Axle And 4x4 Front Driving Axle Fluid Level
For Models with 9.25 Front Axles and 11.5º Rear Axles
refer to Fluids, Lubricants and Genuine Parts for the
correct lubricant type. For normal service, periodic fluid
level checks are not required. When the vehicle is ser-
viced for other reasons, the exterior surfaces of the axle
assembly should be inspected.
When checking the fluid level (3500 only), the vehicle
should be in a level position. The fluid level should be
1/4º   1/4º (6.4 mm   6.4 mm) below the fill hole on the
front axle. The fluid level should be 1/4º   1/4º (6.4 mm
  6.4 mm) below the fill hole on the rear axle.
When checking the fluid level (4500/5500 only), the
vehicle should be in a level position. The fluid level
should be 1/4º   1/4º (6.4 mm   6.4 mm) below the fill
hole on the front axle. The fluid level should be level with
the bottom of the fill hole on the rear axle.
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