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MAINTAINING YOUR VEHICLE
CONTENTS
ENGINE COMPARTMENT — 6.7L DIESEL —
SIX-SPEED 68RFE (2500/3500 Models) .........174
ENGINE COMPARTMENT — 6.7L DIESEL —
SIX-SPEED AS69RC HD (3500/CHASSIS CAB
MODELS) ............................ .175
MAINTENANCE PROCEDURES .............176
▫ Engine Oil .......................... .176
▫ Engine Air Cleaner Filter .................180
▫ Draining Fuel/Water Separator Filter ........184
▫ Engine Mounted Fuel Filter Replacement ......185
▫ Underbody Mounted Fuel Filter Replacement . . .186
▫ Priming If The Engine Has Run Out Of Fuel . . .188
▫ Intervention Regeneration Strategy — Message
Process Flow ......................... .189
▫ Diesel Exhaust Fluid .....................190 ▫
Maintenance-Free Batteries ................190
▫ Cooling System ....................... .191
▫ Charge Air Cooler — Inter-Cooler ...........195
▫ Brake System ........................ .195
▫ Clutch Hydraulic System .................196
▫ Transfer Case — If Equipped ..............197
▫ Manual Transmission — If Equipped .........197
▫ Automatic Transmission — If Equipped .......197
▫ Noise Control System Required Maintenance &
Warranty ........................... .200
FLUID CAPACITIES ..................... .204
FLUIDS, LUBRICANTS AND GENUINE PARTS . .205
▫ Engine ............................. .205
▫ Chassis ............................ .207
7
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ENGINE COMPARTMENT — 6.7L DIESEL — SIX-SPEED 68RFE (2500/3500 Models)
1 — Battery7 — Washer Fluid Reservoir
2 — Engine Coolant Reservoir 8 — Power Steering Fluid Reservoir
3 — Automatic Transmission Dipstick 9 — Power Distribution Center
4 — Brake Fluid Reservoir 10 — Engine Oil Dipstick
5 — Battery 11 — Engine Oil Fill
6 — Aux Power Distribution Center 12 — Air Cleaner Filter
174 MAINTAINING YOUR VEHICLE
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ENGINE COMPARTMENT — 6.7L DIESEL — SIX-SPEED AS69RC HD (3500/CHASSIS CAB MODELS)
1 — Battery7 — Washer Fluid Reservoir
2 — Engine Coolant Reservoir 8 — Power Steering Fluid Reservoir
3 — Automatic Transmission Dipstick 9 — Power Distribution Center
4 — Brake Fluid Reservoir 10 — Engine Oil Dipstick
5 — Battery 11 — Engine Oil Fill
6 — Aux Power Distribution Center 12 — Air Cleaner Filter
7
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Engine oil not designated by the FCA or Cummins Material
Standards and API CJ-4 should not be used, as engine and
exhaust system durability may be compromised. The en-
gine oil filler cap also shows the recommended engine oil
viscosity for your engine. For information on engine oil
filler cap location, refer to “Engine Compartment” in
“Maintaining Your Vehicle” for further information.
Synthetic Engine Oils
You may use synthetic engine oils if the recommended oil
quality requirements are met and the recommended main-
tenance intervals for oil and filter changes are followed.
Materials Added To Engine Oil
The manufacturer strongly recommends against the addi-
tion of any additives (other than leak detection dyes) to the
engine oil. Engine oil is an engineered product and its
performance may be impaired by supplemental additives.
Engine Oil Filter
Refer to “Fluids, Lubricants, And Genuine Parts” in “Main-
taining Your Vehicle” for further information. The engine
oil filter should be changed at every engine oil change.
Disposing Of Used Engine Oil And Oil Filters
Care should be taken in disposing of used engine oil and
oil filters from your vehicle. Used oil and oil filters,
indiscriminately discarded, can present a problem to the
environment. Contact your authorized dealer, service sta-
tion or governmental agency for advice on how and where
used oil and oil filters can be safely discarded in your area.7
MAINTAINING YOUR VEHICLE 179
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CAUTION!
•Diesel fuel will damage blacktop paving surfaces.
Drain the filter into an appropriate container.
• Do not prefill the fuel filter when installing a new
fuel filter. There is a possibility debris could be
introduced into the fuel filter during this action. It is
best to install the filter dry and allow the in-tank lift
pump to prime the fuel system.
1. Ensure engine is turned off.
2. Place drain pan under the fuel filter drain hose.
3. Open the water drain valve 1/4 turn counterclockwise and completely drain fuel and water into the approved
container.
4. Close the water drain valve.
5. Remove lid using a socket or strap wrench. Rotate counterclockwise for removal. Remove used o-ring and
discard it.
6. Remove the used filter cartridge from the housing and dispose of according to your local regulations.
7. Wipe clean the sealing surfaces of the lid and housing. 8. Install new o-ring back into ring groove on the filter
housing and lubricate with clean engine oil.
9. Remove new filter cartridge from plastic bag and install into housing.
NOTE: Do not remove cartridge from bag until you reach
this step in order to keep cartridge clean.
10. Push down on the cartridge to ensure it is properly seated. Do not pre-fill the filter housing with fuel.
11. Install lid onto housing and tighten to 22.5 ft lbs (30.5 N.m). Do not overtighten the lid.
12. Prime the engine using the procedure in “Priming If The Engine Has Run Out Of Fuel.” Then start the
engine and confirm there are no leaks.
Underbody Mounted Fuel Filter Replacement
NOTE:
•Using a fuel filter that does not meet the manufacturer’s
filtration and water separating requirements can se-
verely impact fuel system life and reliability.
• The underbody mounted filter housing will cause the
engine not to run if:
186 MAINTAINING YOUR VEHICLE
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1. No filter is installed.
CAUTION!
•Diesel fuel will damage blacktop paving surfaces.
Drain the filter into an appropriate container.
(Continued)
CAUTION! (Continued)
•Do not prefill the fuel filter when installing a new
fuel filter. There is a possibility debris could be
introduced into the fuel filter during this action. It is
best to install the filter dry and allow the in-tank lift
pump to prime the fuel system.
1. Ensure engine is turned off.
2. Place drain pan under the fuel filter drain hose.
3. Open the water drain valve 1 full turn counterclockwise and completely drain fuel and water into the approved
container.
4. Close the water drain valve.
5. Remove lid using a socket or strap wrench. Rotate counterclockwise for removal. Remove used o-ring and
discard it.
6. Remove the used filter cartridge from the housing and dispose of according to your local regulations.
7. Wipe clean the sealing surfaces of the lid and housing.
8. Install new o-ring back into ring groove on the filter housing and lubricate with clean engine oil.
Underbody Mounted Fuel Filter Assembly
1 — Drain Valve 2 — WIF Sensor
7
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7. Remove the dipstick again and note the fluid level onboth sides. The fluid level reading is only valid if there
is a solid coating of oil on both sides of the dipstick.
Note that the holes in the dipstick will be full of fluid if
the actual level is at or above the hole. The fluid level
should be between the “HOT” (upper) reference holes
on the dipstick at normal operating temperature. If the
fluid level is low, add fluid through the dipstick tube to
bring it to the proper level. Do not overfill.Use ONLY
the specified fluid (see Fluids, Lubricants, and Genuine
Parts for fluid specifications). After adding any quan-
tity of oil through the dipstick tube, wait a minimum of
two minutes for the oil to fully drain into the transmis-
sion before rechecking the fluid level.
NOTE: If it is necessary to check the transmission below
the operating temperature, the fluid level should be be-
tween the two “COLD” (lower) holes on the dipstick with
the fluid at 60-70°F / 16-21°C for 68RFE transmission, or
68-86°F / 20-30°C for AS69RC transmission. Only use the
COLD region of the dipstick as a rough reference when
setting the fluid level after a transmission service or fluid
change. Re-check the fluid level, and adjust as required,
once the transmission reaches normal operating tempera-
ture.CAUTION!
If the fluid temperature is below 50°F (10°C) it may not
register on the dipstick. Do not add fluid until the
temperature is elevated enough to produce an accurate
reading. Run the engine at idle, in PARK, to warm the
fluid.
8. Reinsert the dipstick. Check for leaks. Release the park- ing brake.
NOTE: To prevent dirt and water from entering the
transmission after checking or replenishing fluid, make
sure that the dipstick cap is properly reseated. It is normal
for the dipstick cap to spring back slightly from its fully
seated position, as long as its seal remains engaged in the
dipstick tube.
Fluid And Filter Changes
Refer to the “Maintenance Schedule” for the proper main-
tenance intervals.
In addition, change the fluid and filter(s) if the fluid
becomes contaminated (with water, etc.), or if the transmis-
sion is disassembled for any reason.
7
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FLUID CAPACITIES
U.S.Metric
Fuel (Approximate)
2500/3500 Standard Cab Longbed Models 28 Gallons106 Liters
2500/3500 Crew/Mega Cab Shortbed Models 31 Gallons129 Liters
2500/3500 Crew Cab Longbed Models 32 Gallons132 Liters
Standard Rear Tank – Chassis Cab Only 52 Gallons197 Liters
Optional Midship Tank – Chassis Cab Only 22 Gallons83 Liters
Diesel Exhaust Fluid Tank (Approximate) –
2500/3500 Models 5.5 Gallons
21 Liters
Diesel Exhaust Fluid Tank (Approximate) –
Chassis Cab 9 Gallons
34 Liters
Engine Oil With Filter
6.7L Turbo Diesel Engine 12 Quarts11.4 Liters
Cooling System
6.7L Turbo Diesel Engine (MOPAR Engine
Coolant/Antifreeze 10 Year/150,000 Mile
Formula) 5.7 Gallons
21.4 Liters
204 MAINTAINING YOUR VEHICLE