UNDERBODY MOUNTED FUEL FILTER/WATER SEPARATOR
Draining Fuel/Water Separator
•If the “Water in Fuel” indicator lightis illuminated and an audible chime is
heard five times, you should stop the engine and drain the water from the separator.
• The drain is located on the bottom of the Fuel Filter and Water Separator assembly which is located in front of the rear axle above the drive shaft on pick up models.
The Chassis Cab models second filter location is on the frame behind the front
axle. The best access to this water drain valve is from under the vehicle.
• Turn the drain valve (located on the side of the filter) counterclockwise 1 full turn, then turn the ignition switch to the ON/RUN position to allow any accumulated
water to drain.
• When clean fuel is visible, close the drain and switch the ignition to OFF.
• Refer to the Diesel Supplement on the DVD for further details.
Underbody Fuel Filter Replacement
• With the engine off and a drain pan under the fuel filter drain hose, open the water drain valve 1 full turn counterclockwise and completely drain fuel and water into
the approved container.
• Close the water drain valve and remove the lid using a socket or strap wrench; rotate counterclockwise for removal. Remove the used o-ring and discard it.
• Remove the used filter cartridge from the housing and dispose of according to your local regulations.
• Wipe clean the sealing surfaces of the lid and housing and install the new o-ring into ring groove on the filter housing and lubricate with clean engine oil.
• Install a new filter in the housing. Push down on the cartridge to ensure it is properly seated. Do not pre-fill the filter housing with fuel.
• Start the engine and confirm no leaks are present.
The underbody mounted filter housing will cause the engine not to run if:
1. No filter is installed.
NOTE:
• Using a fuel filter that does not meet the manufacturer's filtration and water separating requirements can severely impact fuel system life and reliability.
• The WIF sensor is re-usable. Service kit comes with new o-ring for filter canister and WIF sensor.
6.7L CUMMINS® DIESEL
160
Hub Caps/Wheel Covers
• The hub caps must be removed before raising the vehicle off the ground.
• For single rear-wheel (SRW) models, use the blade on the end of the lug wrenchto pry the hub cap off. Insert the blade end into the pry-off notch and carefully pop
off the hub cap with a back-and-forth motion.
• On models with dual rear wheels (DRW), you must first remove the hub caps. The jack handle driver has a hook at one end that will fit in the pry off notch of the rear
hub caps. Position the hook and pull out on the ratchet firmly. The hub cap should
pop off. The wheel skins can now be removed. For the front hub cap use the blade
on the end of the lug wrench to pry the caps off. The wheel skin can now be
removed.
• You must use the flat end of the lug wrench to pry off the wheel skins. Insert the flat tip completely and using a back-and-forth motion, loosen the wheel skin.
Repeat this procedure around the tire until the skin pops off.
• Replace the wheel skins first using a rubber mallet. When replacing the hub caps, tilt the cap retainer over the lug nut bolt circle and strike the high side down with
a rubber mallet. Be sure that the hub caps and wheel skins are firmly seated
around the wheel.
Wheel Nuts
All wheel nuts should be tightened occasionally to eliminate the possibility of wheel
studs being sheared or the bolt holes in the wheels becoming elongated. This is
especially important during the first few hundred miles/kilometers of operation to
allow the wheel nuts to become properly set. All wheel nuts should first be firmly
seated against the wheel. The wheel nuts should then be tightened to recommended
torque. Tighten the wheel nuts to final torque in increments. Progress around the bolt
circle, tightening the wheel nut opposite to the wheel nut just previously tightened
until final torque is achieved. Recommended torques are shown in the following
chart.
Disc Wheels
Nut Type Stud Size Hex Size Torque
Ft LbsTorque
Newton Meters
Cone M14 x 1.5 22 mm 120-150 160-200
Flanged M14 x 1.5 22 mm 130-160 190-220
WHAT TO DO IN EMERGENCIES
186
8-Stud — Dual Rear Wheels
• Dual wheels are flat-mounted and center-piloted. The lug nuts are a two-pieceassembly. When the tires are being rotated or replaced, clean these lug nuts and
add two drops of oil at the interface between the hex and the washer.
• Slots in the wheels will assist in prop- erly orienting the inner and outer
wheels. Align these slots when assem-
bling the wheels for best access to the
tire valve on the inner wheel. The tires
of both dual wheels must be com-
pletely off the ground when tightening,
to ensure wheel centering and maxi-
mum wheel clamping.
• Dual wheel models require a special heavy-duty lug nut tightening adapter
(included with the vehicle) to correctly
tighten the lug nuts. Also, when it is necessary to remove and install dual rear
wheels, use a proper vehicle lifting device.
NOTE:
When installing a spare tire as part of a dual rear wheel end combination, the tire
diameter of the two individual tires must be compared. If there is a significant
difference, the larger tire should be installed in a front location. The correct direction
of rotation for dual tire installations must also be observed.
These dual rear wheels should be tightened as follows:
1. Tighten the wheel nuts in the num- bered sequence to a snug fit.
2. Retighten the wheel nuts in the same sequence to the torques listed in the
table. Go through the sequence a
second time to verify that specific
torque has been achieved. Retighten to
specifications at 100 miles (160 km)
and after 500 miles (800 km).
• It is recommended that wheel stud
nuts be kept torqued to specifications
at all times. Torque wheel stud nuts to specifications at each lubrication interval.
WHAT TO DO IN EMERGENCIES
187
TOWING A DISABLED VEHICLE
Towing
Condition Wheels OFF the
Ground 2WD Models
4WD Models
Flat Tow NONE If transmission is operable:
• Transmission in NEUTRAL
• 30 mph (48 km/h) max
• 15 miles (24 km) max
distance • Auto Transmission
inPARK
• Manual Trans-
mission in gear
(NOT NEUTRAL)
• Transfer Case in
NEUTRAL
• Tow in FORWARD
direction
Wheel Lift or Dolly Tow Front
NOT ALLOWED
Rear OK
NOT ALLOWED
Flatbed ALL
BEST METHOD BEST METHOD
FREEING A STUCK VEHICLE
• If your vehicle becomes stuck in mud, sand or snow, it can often be moved using
a rocking motion. Turn your steering wheel right and left to clear the area around
the front wheels. Then shift back and forth between DRIVE and REVERSE (with
automatic transmission) or 2nd gear and REVERSE (with manual transmission)
while gently pressing the accelerator. Use the least amount of accelerator pedal
pressure that will maintain the rocking motion, without spinning the wheels or
racing the engine.
NOTE:
Press the "ESC Off" switch, to place the Electronic Stability Control (ESC) system in
"Partial Off" mode before rocking the vehicle. Once the vehicle has been freed, press
the "ESC Off" switch again to restore "ESC On" mode.
CAUTION!
• Racing the engine or spinning the wheels may lead to transmission overheating and failure. Allow the engine to idle with the shift lever in NEUTRAL for at least
one minute after every five rocking-motion cycles. This will minimize overheat-
ing and reduce the risk of transmission failure during prolonged efforts to free
a stuck vehicle.
• When “rocking” a stuck vehicle by moving between DRIVE/2nd and REVERSE,
do not spin the wheels faster than 15 mph (24 km/h), or drivetrain damage may
result.
• Revving the engine or spinning the wheels too fast may lead to transmission
overheating and failure. It can also damage the tires. Do not spin the wheels
above 30 mph (48 km/h) while in gear (no transmission shifting occurring).
WHAT TO DO IN EMERGENCIES
196
FLUIDS AND CAPACITIES
Gasoline Versions
ComponentFluid, Lubricant, or
Genuine Part Capacities
Engine Coolant
3.6L Engine We recommend you use
MOPAR
®Antifreeze/
Coolant 10 Year/150,000
Mile Formula OAT (Organic Additive Technology). 14 Quarts (13 Liters)
Engine Coolant
5.7L 1500 Models We recommend you use
MOPAR
®Antifreeze/
Coolant 10 Year/150,000
Mile Formula OAT (Organic Additive Technology). 16 Quarts (15 Liters)
Engine Coolant
5.7L 2500/3500 Models We recommend you use
MOPAR
®Antifreeze/
Coolant 10 Year/150,000
Mile Formula OAT (Organic Additive Technology) . 18.7 Quarts (17.7 Liters)
Engine Coolant
5.7L 2500/3500 Models
w/Heavy Duty We recommend you use
MOPAR
®Antifreeze/
Coolant 10 Year/150,000
Mile Formula OAT (Organic Additive Technology) . 19.2 Quarts (18.2 Liters)
Engine Coolant
6.4L 2500/3500 Models We recommend you use
MOPAR
®Antifreeze/
Coolant 10 Year/150,000
Mile Formula OAT (Organic Additive Technology) . 18.7 Quarts (17.7 Liters)
Engine Coolant
6.4L 2500/3500 Models
w/Heavy Duty We recommend you use
MOPAR
®Antifreeze/
Coolant 10 Year/150,000
Mile Formula OAT (Organic Additive Technology) . 19.2 Quarts (18.2 Liters)
Engine Oil with Filter
3.6L, 5.7L We recommend you use
API Certified SAE 5W-20 Engine Oil, meeting the
requirements of Chrysler Material Standard
MS-6395 such as
MOPAR
®, Pennzoil®,and
Shell Helix®. Refer to your
engine oil filler cap for correct SAE grade. 3.6L Engine - 6 Quarts
(5.7 Liters)
5.7L Engine - 7 Quarts (6.6 Liters)
MAINTAINING YOUR VEHICLE
205
ComponentFluid, Lubricant, or
Genuine Part Capacities
Automatic Transmission –
Eight-Speed Automatic Use only MOPAR
®ZF
8&9 Speed ATF™ Auto-
matic Transmission Fluid, or equivalent. Failure to
use the correct fluid may affect the function orperformance of your transmission. —
Automatic Transmission –
Six-Speed Automatic with
Gasoline Engine We recommend you use
only ATF+4
®Automatic
Transmission Fluid. Failure to use ATF+4
®fluid may
affect the function or
performance of your trans- mission. We recommendMOPAR
®ATF+4®fluid. —
Transfer Case We recommend you use
MOPAR
®BW44–44
Transfer Case Fluid. —
Front Axle 1500
Four-Wheel Drive Models We recommend you use
MOPAR
®GL-5 Synthetic
Axle Lubricant SAE 75W-85. —
Rear Axle 1500 Models We recommend you use
MOPAR
®Synthetic Gear
Lubricant SAE 75W-140
(MS-8985). Limited-Slip Rear Axles require the
addition of 5 oz. (148 ml) MOPAR
®Limited Slip
Additive (MS-10111). —
Front and Rear Axle –
2500/3500 Models We recommend you
use Synthetic, GL-5
SAE 75W-85. Limited slip
additive is not required for Limited-Slip Rear Axles. —
Brake Master Cylinder We recommend you use
MOPAR
®DOT 3 and
SAE J1703. If DOT 3 is
not available, then DOT 4 is acceptable. —
MAINTAINING YOUR VEHICLE
207
ComponentFluid, Lubricant, or
Genuine Part Capacities
Power Steering Reservoir –
2500/3500 Models We recommend you use
MOPAR
®Power Steering
Fluid +4 or MOPAR®
ATF+4®Automatic
Transmission Fluid. —
Fuel Selection 3.6L 87 Octane1500 Regular Cab
Shortbed/Crew Quad Cab - 26 Gallons (98 Liters) (Approximate)
1500 Regular Cab
Longbed/Crew Quad Cab (Optional) - 32 Gallons
(121 Liters) (Approximate) 2500/3500 Shortbed -
34 Gallons (129 Liters) (Approximate)
2500/3500 Longbed -
35 Gallons (132 Liters) (Approximate)
Fuel Selection 5.7L 87 Octane Acceptable.
89 Octane Recommended. 1500 Regular Cab
Shortbed/Crew Quad Cab - 26 Gallons (98 Liters) (Approximate)
1500 Regular Cab
Longbed/Crew Quad Cab (Optional) - 32 Gallons
(121 Liters) (Approximate) 2500/3500 Shortbed -
31 Gallons (117 Liters) (Approximate)
2500/3500 Longbed -
32 Gallons (121 Liters) (Approximate)
Fuel Selection 6.4L 87 Octane2500/3500 Shortbed -
34 Gallons (129 Liters)
(Approximate) 2500/3500 Longbed - 35 Gallons
(132 Liters) (Approximate)
MAINTAINING YOUR VEHICLE
208
Diesel Versions
ComponentFluid, Lubricant, or
Genuine Part Capacities
Engine Coolant
3.0 L Turbo Diesel Engine –
1500 Models Only
We recommend you use MOPAR®Antifreeze/
Coolant Ten Year/150,000
Mile Formula OAT (Organic Additive Technology). 11.6 Quarts (11 Liters)
Engine Coolant
6.7L Turbo Diesel Engine We recommend you use
MOPAR
®Antifreeze/
Coolant Ten Year/150,000
Mile Formula OAT (Organic Additive Technology). 5.7 Gallons (21.4 Liters)
Engine Oil with Filter
3.0L Turbo Diesel Engine –
1500 Models Only
We recommend you use
ACEA C3 5W-30 engine oil meeting Chrysler material standard MS-11106 or
Pennzoil Ultra Euro L full
synthetic 5W-30 motor oil. 10.5 Quarts (10 Liters)
Engine Oil with Filter
6.7L Turbo Diesel Engine In ambient temperatures
below 0°F (-18°C),
We recommend you use
5W-40 synthetic engine oil that meets Chrysler Materials Standard
MS-10902 and the API
CJ-4 engine oil category is
required such as MOPAR
®,
Shell Rotella®and
Shell Rimula®.
In ambient temperatures above 0°F (-18°C),
We recommend you use 15W-40 engine oil that
meets Chrysler Materials
Standard MS-10902 and the API CJ-4 engine oil
category is required such
as MOPAR
®, Shell Rotella®
and Shell Rimula®. 12 Quarts (11.4 Liters)
MAINTAINING YOUR VEHICLE
209