3. Install the dipstick by pushing it back in all the way,wait three seconds, and then pull it back out again.
4. Check both sides of the dipstick and read the lower level. Repeat the check procedure to verify the
reading.
5. Safe operating level is within the HOT cross hatchband on the dipstick. If the fluid level is not within
the HOT band, and the transmission temperature
is between 71°C and 93°C (160°F and 200°F), add
or drain fluid as necessary to bring the level into
the HOT band. If the fluid level is low, add only
enough fluid to bring the level into the HOT band.
It does not take much fluid, generally less than
0.5 Liter (1 Pint). Do not overfill. 6. If the fluid level is in the acceptable range, push
the dipstick back in all the way, then flip the handle
down to lock the dipstick in place.
Consistency of Readings
Always check the fluid level at least twice using the
procedure described previously. Consistency
(repeatable readings) is important to maintaining proper
fluid level. If readings are still inconsistent, contact your
dealer.
Cooling System
If your vehicle has the DURAMAX®Diesel engine, see
the DURAMAX®Diesel manual for more information.
The Cooling System allows the engine to maintain the
correct working temperature.
6-29
Notice:After driving in the overheated engine
protection operating mode, to avoid engine damage,
allow the engine to cool before attempting any
repair. The engine oil will be severely degraded.
Repair the cause of coolant loss, change the oil and
reset the oil life system. See Engine Oil
on
page 6‑18.
Engine Fan Noise
If the vehicle has a clutched engine cooling fan, when
the clutch is engaged, the fan spins faster to provide
more air to cool the engine. In most everyday driving
conditions, the fan is spinning slower and the clutch is
not fully engaged. This improves fuel economy and
reduces fan noise. Under heavy vehicle loading, trailer
towing, and/or high outside temperatures, the fan speed
increases as the clutch more fully engages, so you may
hear an increase in fan noise. This is normal and should
not be mistaken as the transmission slipping or making
extra shifts. It is merely the cooling system functioning
properly. The fan will slow down when additional cooling
is not required and the clutch disengages.
You may also hear this fan noise when you start the
engine. It will go away as the fan clutch partially
disengages.
If the vehicle has electric cooling fans, you may hear
the fans spinning at low speed during most everyday
driving. The fans may turn off if no cooling is required. Under heavy vehicle loading, trailer towing, and/or high
outside temperatures, or if you are operating the air
conditioning system, the fans may change to high
speed and you may hear an increase in fan noise. This
is normal and indicates that the cooling system is
functioning properly. The fans will change to low speed
when additional cooling is no longer required.
Power Steering Fluid
See
Engine Compartment
Overviewon page 6‑16for reservoir location.
When to Check Power Steering Fluid
It is not necessary to regularly check power steering
fluid unless you suspect there is a leak in the system or
you hear an unusual noise. A fluid loss in this system
could indicate a problem. Have the system inspected
and repaired.
6-37
ApplicationCapacities
English Metric
Fuel Tank
1500 Series Standard and Short Box 26.0 gal 98.0 L
1500 Series Long Box 34.0 gal 128.7 L
2500 Series Standard Box 26.0 gal 98.0 L
2500 Series and 3500 Series Long Box 34.0 gal 128.7 L
3500 Series Chassis Cab 50.0 gal 189.0 L
3500 Chassis Cab –Front Tank 27.0 gal 102.0 L
3500 Chassis Cab –Rear Tank (if equipped) 23.0 gal 87.0 L
Transmission Fluid (Pan Removal and Filter Replacement) Auto 4-Speed Transmission 4L60-E Electronic Transmission 5.0 qt 4.7 L
Auto 6-Speed Transmission 6L80-E 6.0 qt 5.7 L
Auto 6-Speed Transmission 6L90-E 6.3 qt 6.0 L
Auto 6-Speed Transmission Allison 7.4 qt 7.0 L
Transfer Case Fluid 1.6 qt 1.5 L
Wheel Nut Torque 140 ft lb 190 Y
All capacities are approximate. When adding, be sure to fill to the approximate level, as recommended in this manual.
Recheck fluid level after filling.
6-127
MaintenanceI
.Change engine oil and filter. See Engine Oilon
page 6‑18. An Emission Control Service.
.Engine coolant level check. See Engine Coolanton page 6‑31.
.Windshield washer fluid level check. See
Windshield Washer Fluid on page 6‑38.
.Tire inflation check. SeeInflation - Tire Pressureon page 6‑73.
.Tire wear inspection. See Tire Inspection and
Rotation on page 6‑80.
.Rotate tires. See Tire Inspection and Rotationon
page 6‑80.
.Fluids visual leak check (or every 12 months,
whichever occurs first). A leak in any system must
be repaired and the fluid level checked.
.Engine air cleaner filter inspection (vehicles driven
in dusty conditions only). See Engine Air Cleaner/
Filter on page 6‑21.
.Brake system inspection (or every 12 months,
whichever occurs first).
.For vehicles with Allison Transmission®only: At
the first engine oil change only, replace external
transmission filter.
Maintenance II
.Perform all services described in Maintenance I.
.Steering and suspension inspection. Visual
inspection for damaged, loose, or missing parts or
signs of wear.
.Lubricate the front suspension, steering linkage,
and parking brake cable guides. Control arm ball
joints on 2500/3500 series vehicles require
lubrication but should not be lubricated unless their
temperature is−12°C (10°F) or higher, or they
could be damaged. Control arm ball joints on
1500 series vehicles are maintenance‐free.
Vehicles used under severe commercial operating
conditions require lubrication on a regular basis
every 5 000 km/3,000 miles.
.Engine cooling system inspection. Visual
inspection of hoses, pipes, fittings, and clamps and
replacement, if needed.
.Windshield wiper blade inspection for wear,
cracking, or contamination and windshield and
wiper blade cleaning, if contaminated. See
Windshield and Wiper Blades
on page 6‑114. Worn
or damaged wiper blade replacement. See
Windshield Wiper Blade Replacement
on
page 6‑63.
7-4
.Body hinges and latches, key lock cylinders,
folding seat hardware, and tailgate hinges, linkage,
and handle pivot points lubrication. See
Recommended Fluids and Lubricants
on
page 7‑13. More frequent lubrication may be
required when vehicle is exposed to a corrosive
environment. Applying silicone grease on
weatherstrips with a clean cloth makes them last
longer, seal better, and not stick or squeak.
.Restraint system component check. See Checking
the Restraint Systems on page 2‑94.
.Automatic transmission fluid level check and
adding fluid, if needed. See Automatic
Transmission Fluid (4-Speed Transmission)
on
page 6‑23or Automatic Transmission Fluid
(6-Speed Transmission) on page 6‑26.
.Four‐wheel drive vehicles: Transfer case fluid level
check and adding fluid, if needed.
.Engine air cleaner filter inspection. See Engine Air
Cleaner/Filter on page 6‑21.
.Vehicles with diesel engine or GVWR above
4 536 kg (10,000 lbs) only: Shields inspection for
damage or looseness. Adjust or replace as
required. This is a Noise Emission Control Service.
Applicable to vehicles sold in the United States
and recommended for vehicles sold in Canada.
Additional Required Services
At the First 160 km/100 Miles,
1 600 km/1,000 Miles, and
10 000 km/6,000 Miles
.For vehicles with dual wheels: Check dual wheel
nut torque. For proper torque, see Capacities and
Specifications on page 6‑126.
At Each Fuel Stop
.Engine oil level check. See Engine Oilon
page 6‑18.
.Engine coolant level check. See Engine Coolanton page 6‑31.
.Windshield washer fluid level check. See
Windshield Washer Fluid on page 6‑38.
Once a Month
.Tire inflation check. SeeInflation - Tire Pressureon page 6‑73.
.Tire wear inspection. See Tire Inspection and
Rotation on page 6‑80.
7-5
Once a Year
.Starter switch check. SeeOwner Checks and
Services on page 7‑11.
.Parking brake and automatic transmission P (Park)
mechanism check. See Owner Checks and
Services on page 7‑11.
.Automatic transmission shiftlock control system
check. See Owner Checks and Serviceson
page 7‑11.
.Ignition transmission lock check. See Owner
Checks and Services on page 7‑11.
.Engine cooling system and pressure cap pressure
check. Radiator and air conditioning condenser
outside cleaning. See Cooling System
on
page 6‑29.
.Exhaust system and nearby heat shields
inspection for loose or damaged components.
.Accelerator pedal check for damage, high effort,
or binding. Replace if needed.
First Engine Oil Change After Every
40 000 km/25,000 Miles
.Fuel system inspection for damage or leaks.
.Four‐wheel drive only: Transfer case fluid change
(extreme duty service) for vehicles mainly driven
off‐road in four‐wheel drive. Vehicles used for
farming, mining, forestry, Department of Natural
Resources (DNR), and snow plowing occupations
meet this definition. Check vent hose at transfer
case for kinks and proper installation. Check to be
sure vent hose is unobstructed, clear, and free of
debris. During any maintenance, if a power washer
is used to clean mud and dirt from the underbody,
care should be taken to not directly spray the
transfer case output seals. High pressure water
can overcome the seals and contaminate the
transfer case fluid. Contaminated fluid will
decrease the life of the transfer case and should
be replaced.
7-6
First Engine Oil Change After Every
80 000 km/50,000 Miles
.Engine air cleaner filter replacement. SeeEngine
Air Cleaner/Filter on page 6‑21.
.Automatic transmission fluid change (severe
service) for vehicles with Gross Vehicle Weight
Rating (GVWR) over 3 901 kg (8,600 lbs) or mainly
driven in heavy city traffic in hot weather, in hilly or
mountainous terrain, when frequently towing a
trailer, or used for taxi, police, or delivery service.
See Automatic Transmission Fluid (4-Speed
Transmission)
on page 6‑23or Automatic
Transmission Fluid (6-Speed Transmission)on
page 6‑26.
.Four‐wheel drive only: Transfer case fluid change
(severe service) for vehicles mainly driven when
frequently towing a trailer, or used for taxi, police,
or delivery service. Check vent hose at transfer
case for kinks and proper installation. Check to be
sure vent hose is unobstructed, clear, and free of
debris. During any maintenance, if a power washer is used to clean mud and dirt from the underbody,
care should be taken to not directly spray the
transfer case output seals. High pressure water
can overcome the seals and contaminate the
transfer case fluid. Contaminated fluid will
decrease the life of the transfer case and should
be replaced.
.Evaporative control system inspection. Check all
fuel and vapor lines and hoses for proper hook‐up,
routing, and condition. Check that the purge valve,
if the vehicle has one, works properly. Replace as
needed.
An Emission Control Service. The U.S.
Environmental Protection Agency or the California
Air Resources Board has determined that the
failure to perform this maintenance item will not
nullify the emission warranty or limit recall liability
prior to the completion of the vehicle's useful life.
We, however, urge that all recommended
maintenance services be performed at the
indicated intervals and the maintenance be
recorded.
7-7
First Engine Oil Change After Every
160 000 km/100,000 Miles
.Automatic transmission fluid change (normal
service). SeeAutomatic Transmission Fluid
(4-Speed Transmission)
on page 6‑23or
Automatic Transmission Fluid (6-Speed
Transmission) on page 6‑26.
.Four‐wheel drive only: Transfer case fluid change
(normal service). Check vent hose at transfer case
for kinks and proper installation. Check to be sure
vent hose is unobstructed, clear, and free of
debris. During any maintenance, if a power washer
is used to clean mud and dirt from the underbody,
care should be taken to not directly spray the
transfer case output seals. High pressure water
can overcome the seals and contaminate the
transfer case fluid. Contaminated fluid will
decrease the life of the transfer case and should
be replaced.
.Spark plug replacement and spark plug wires
inspection. An Emission Control Service.
First Engine Oil Change After Every
240 000 km/150,000 Miles
.Engine cooling system drain, flush, and refill,
cooling system and cap pressure check, and
cleaning of outside of radiator and air conditioning
condenser (or every 5 years, whichever occurs
first). SeeEngine Coolant
on page 6‑31.An
Emission Control Service.
.Engine accessory drive belt inspection for fraying,
excessive cracks, or obvious damage and
replacement, if needed. An Emission Control
Service.
7-8