Page 298 of 338

•Do 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 engine coolant (antifreeze)
performance, poor gas mileage, and increased emis-
sions.
Charge Air Cooler — Inter-Cooler
The charge air cooler is positioned below 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°F
(10° to 38°C). 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.
Brake System
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 Light” indicates
system failure.
The brake master cylinder has a translucent plastic
reservoir. On the outboard side of the reservoir, there is a
“MAX” mark and a “MIN” mark. 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.
296 MAINTAINING YOUR VEHICLE
Page 308 of 338
Maintenance Log and Service Chart (Diesel Engines)
Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest
to the mileage at which service was performed.
MILES 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000
KILOMETERS 12 000 24 000 36 000 48 000 60 000 72 000 84 000 96 000
Exhaust system-
inspect
Air cleaner assembly-
inspect
ODOMETER
READING
PERFORMED BY
PERFORMED AT
306 MAINTAINING YOUR VEHICLE
Page 309 of 338
Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest
to the mileage at which service was performed.
MILES 67,500 75,000 82,500 90,000 97,500 105,000 112,500 120,000
KILOMETERS 108 000 120 000 132 000 144 000 156 000 168 000 180 000 192 000
Exhaust system-
inspect
Air cleaner
assembly-inspect
ODOMETER READ-
ING
PERFORMED BY
PERFORMED AT
7
MAINTAINING YOUR VEHICLE 307
Page 319 of 338
Maintenance Chart — Cummins Diesel Engine
Mileage or time passed
(whichever comes first):
7,500
15,000
22,500
30,000
37,500
45,000
52,500
60,000
67,500
75,000
82,500
90,000
97,500
105,000 112,500
120,000
127,500
135,000
142,500
150,000
Or Months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
Or Kilometers:
12,000
24,000
36,000
48,000
60,000
72,000
84,000
96,000
108,000
120,000
132,000
144,000
156,000
168,000
180,000
192,000
204,000
216,000
228,000
240,000
Change engine oil every 15,000
miles (24 000 km) or six months
or 500 Hours or sooner if
prompted by the oil change indi-
cator system, whichever comes
first. ** XXXXXXXXXXXXXXXXX X XX
Additional Inspections
Check the Diesel Exhaust Fluid
(DEF) tank, refill if necessary. XXXXXXXXXXXXXXXXX X XX
Rotate the tires. X X X X X X X X X X X X X X X X X X X X
8
MAINTENANCE SCHEDULE 317
Page 320 of 338
Mileage or time passed
(whichever comes first):
7,500
15,000
22,500
30,000
37,500
45,000
52,500
60,000
67,500
75,000
82,500
90,000
97,500
105,000 112,500
120,000
127,500
135,000
142,500
150,000
Or Months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
Or Kilometers:
12,000
24,000
36,000
48,000
60,000
72,000
84,000
96,000
108,000
120,000
132,000
144,000
156,000
168,000
180,000
192,000
204,000
216,000
228,000
240,000
Lubricate front drive shaft fitting
(4x4). XXXXXXXXXXXXXXXXX X XX
Lubricate outer tie rod ends. X X X X X X X X X X X X X X X X X X X X
Inspect engine air filter, replace if
necessary. **** XXXXXXXX X X
Inspect the front suspension, tie
rod ends and boot seals for
cracks or leaks and all parts for
damage, wear, improper loose-
ness or end play; replace if nec-
essary. XXXXXXXX X X
Inspect the brake linings. XXXXX X
Inspect and adjust parking brake. XXXXX X
318 MAINTENANCE SCHEDULE
Page 321 of 338
Mileage or time passed
(whichever comes first):
7,500
15,000
22,500
30,000
37,500
45,000
52,500
60,000
67,500
75,000
82,500
90,000
97,500
105,000 112,500
120,000
127,500
135,000
142,500
150,000
Or Months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
Or Kilometers:
12,000
24,000
36,000
48,000
60,000
72,000
84,000
96,000
108,000
120,000
132,000
144,000
156,000
168,000
180,000
192,000
204,000
216,000
228,000
240,000
Inspect drive belt; replace as nec-
essary. XXXXXX
Inspect wheel bearings. X X X X X
Additional Maintenance
Replace engine fuel filter element. X X X X X X X X X X
Replace chassis mounted fuel
filter element. XXXXXXXX X X
Inspect the front and rear axle
surfaces. If gear oil leakage is
suspected, check the fluid level. If
using your vehicle for police, taxi,
fleet, off-road or frequent trailer
towing change the axle fluid. *
8
MAINTENANCE SCHEDULE 319
Page 322 of 338
Mileage or time passed
(whichever comes first):
7,500
15,000
22,500
30,000
37,500
45,000
52,500
60,000
67,500
75,000
82,500
90,000
97,500
105,000 112,500
120,000
127,500
135,000
142,500
150,000
Or Months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
Or Kilometers:
12,000
24,000
36,000
48,000
60,000
72,000
84,000
96,000
108,000
120,000
132,000
144,000
156,000
168,000
180,000
192,000
204,000
216,000
228,000
240,000
Inspect the transfer case fluid
(4x4), change for any of the fol-
lowing: police, taxi, fleet, or fre-
quent trailer towing. XXXX X
Change the transfer case fluid
(4x4). XX
Change automatic transmission
fluid (AS69RC transmission only). XXXX X
Change the automatic transmis-
sion fluid and sump filter
(AS69RC transmission only). XX
320 MAINTENANCE SCHEDULE
Page 323 of 338
Mileage or time passed
(whichever comes first):
7,500
15,000
22,500
30,000
37,500
45,000
52,500
60,000
67,500
75,000
82,500
90,000
97,500
105,000 112,500
120,000
127,500
135,000
142,500
150,000
Or Months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
Or Kilometers:
12,000
24,000
36,000
48,000
60,000
72,000
84,000
96,000
108,000
120,000
132,000
144,000
156,000
168,000
180,000
192,000
204,000
216,000
228,000
240,000
Change automatic transmission
fluid and filter(s) if using your ve-
hicle for any of the following: po-
lice, fleet, or frequent trailer tow-
ing (68RFE transmission only). XX
Change automatic transmission
fluid and filter(s). X
Change the manual transmission
fluid if using your vehicle for any
of the following: police, fleet, or
frequent trailer towing. XX
Replace Crankcase Ventilation
Filter (CCV). XX
8
MAINTENANCE SCHEDULE 321