the correct type thermostat. Other designs may result in
unsatisfactory engine coolant (antifreeze) performance,
poor gas mileage, and increased emissions.
Brake System
In order to assure brake system performance, all brake
system components should be inspected periodically. Refer
to the “Maintenance Schedule” for the proper maintenance
intervals.
WARNING!
Riding the brakes can lead to brake failure and possi-
bly a collision. Driving with your foot resting or riding
on the brake pedal can result in abnormally high brake
temperatures, excessive lining wear, and possible
brake damage. You would not have your full braking
capacity in an emergency.
Brake Fluid Level Check
The fluid level of the master cylinder should be checked
when performing under the hood service or immediately if
the brake system warning lamp indicates system failure.
The brake master cylinder has a translucent plastic reser-
voir. 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
MAX 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.
Use only the manufacturer’s recommended brake fluid.
Refer to “Fluids, Lubricants, And Genuine Parts” in “Main-
taining Your Vehicle” for further information.
WARNING!
•
Use only manufacturer’s recommended brake fluid.
Refer to “Fluids, Lubricants, And Genuine Parts” in
“Maintaining Your Vehicle” for further information.
Using the wrong type of brake fluid can severely
damage your brake system and/or impair its perfor-
mance. The proper type of brake fluid for your
vehicle is also identified on the original factory
installed hydraulic master cylinder reservoir.
(Continued)
7
MAINTAINING YOUR VEHICLE 481
WARNING!(Continued)
•To avoid contamination from foreign matter or mois-
ture, use only new brake fluid or fluid that has been
in a tightly closed container. Keep the master cylin-
der reservoir cap secured at all times. Brake fluid in
a open container absorbs moisture from the air
resulting in a lower boiling point. This may cause it
to boil unexpectedly during hard or prolonged brak-
ing, resulting in sudden brake failure. This could
result in a collision.
• Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts, causing the
brake fluid to catch fire. Brake fluid can also damage
painted and vinyl surfaces, care should be taken to
avoid its contact with these surfaces.
• Do not allow petroleum based fluid to contaminate
the brake fluid. Brake seal components could be
damaged, causing partial or complete brake failure.
This could result in a collision.
Rear Axle And 4x4 Front Driving Axle Fluid Level
For models with 9.25 in Front Axles and 11.5 in Rear Axles,
refer to “Fluids, Lubricants, And Genuine Parts” in “Main-
taining Your Vehicle” for further information. For normal
service, periodic fluid level checks are not required. When
the vehicle is serviced for other reasons, the exterior
surfaces of the axle assembly should be inspected.
When checking the fluid level (4500/5500 only), the vehicle
should be in a level position. The fluid level should be ¼ in
± ¼ in (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.
482 MAINTAINING YOUR VEHICLE
Fluid Level Check
This fluid level can be checked by removing the filler plug.
The fluid level should be to the bottom edge of the filler
plug hole with the vehicle in a level position.
Automatic Transmission — If Equipped
Selection Of Lubricant
It is important to use the proper transmission fluid to
ensure optimum transmission performance and life. Use
only the manufacturer ’s specified transmission fluid. Refer
to “Fluids, Lubricants, And Genuine Parts” in this section
for fluid specifications. It is important to maintain the
transmission fluid at the correct level using the recom-
mended fluid. No chemical flushes should be used in any
transmission; only the approved lubricant should be used.
CAUTION!
Using a transmission fluid other than the manufactur-
er ’s recommended fluid may cause deterioration in
transmission shift quality and/or torque converter
shudder, and will require more frequent fluid and
filter changes. Refer to “Fluids, Lubricants, And Genu-
ine Parts” in this section for fluid specifications.
Special Additives
The manufacturer strongly recommends against using any
special additives in the transmission. Automatic Transmis-
sion Fluid (ATF) is an engineered product and its perfor-
mance may be impaired by supplemental additives. There-
fore, do not add any fluid additives to the transmission.
Avoid using transmission sealers as they may adversely
affect seals.
CAUTION!
Do not use chemical flushes in your transmission as
the chemicals can damage your transmission compo-
nents. Such damage is not covered by the New Vehicle
Limited Warranty.
Fluid Level Check
Check the fluid level when the engine is fully warmed up
and the transmission fluid is at normal operating tempera-
ture. Driving with an improper fluid level will greatly
reduce the life of the transmission and of the fluid. Check
the fluid level whenever the vehicle is serviced.
484 MAINTAINING YOUR VEHICLE
Fluid Level Check — Procedure
It is best to check the fluid level when the transmission is
at normal operating temperature (170-180°F / 77-82°C for
66RFE transmission, or 158–176°F / 70–80°C for AS66RC
transmission). This normally occurs after at least 15 miles
(25 km) of driving. At normal operating temperature the
fluid cannot be held comfortably between the fingertips.
You can read the transmission sump temperature in the
instrument cluster display (refer toInstrument Cluster
Display” in “Understanding Your Instrument Panel” for
further information).
Use the following procedure to check the transmission
fluid level properly:
1. Monitor the transmission temperature using the instru- ment cluster display, and operate the vehicle as required
to reach the normal operating temperature. If the trans-
mission is not functioning properly, or the vehicle
cannot be driven, see the NOTE and CAUTION below
about checking the fluid level at colder temperatures.
2. Park the vehicle on level ground.
3. Run the engine at normal idle speed for at least 60 seconds, and leave the engine running for the rest of this
procedure. 4. Fully apply the parking brake and press the brake pedal.
5. Place the gear selector momentarily into each gear
position (allowing time for the transmission to fully
engage in each position), ending with the transmission
in PARK.
6. Wipe the area around the dipstick clean to prevent dirt from entering the transmission.
7. Remove the dipstick, wipe it clean and reinsert it until seated.
8. Remove the dipstick again and note the fluid level on both 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.
7
MAINTAINING YOUR VEHICLE 485
NOTE:If it is necessary to check the transmissionbelowthe
operating temperature, the fluid level should be between the
two “COLD” (lower) holes on the dipstick with the fluid at
60-70°F / 16-21°C for 66RFE transmission, or 68-86°F /
20-30°C for AS66RC 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 temperature.
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.
9. Reinsert the dipstick. Check for leaks. Release the park- ing brake.
NOTE: To prevent dirt and water from entering the trans-
mission 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 — Six Speed Transmission
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.
Appearance Care And Protection From Corrosion
Protection Of Body And Paint From Corrosion
Vehicle body care requirements vary according to geographic
locations and usage. Chemicals that make roads passable in
snow and ice, and chemicals that are sprayed on trees and
road surfaces during other seasons, are highly corrosive to
the metal in your vehicle. Outside parking, which exposes
your vehicle to airborne contaminants, road surfaces on
which the vehicle is operated, extreme hot or cold weather
and other extreme conditions will have an adverse effect on
paint, metal trim, and underbody protection.
486 MAINTAINING YOUR VEHICLE
Seat Belt Maintenance
Do not bleach, dye or clean the belts with chemical solvents
or abrasive cleaners. This will weaken the fabric. Sun
damage can also weaken the fabric.
If the belts need cleaning, use a mild soap solution or
lukewarm water. Do not remove the belts from the vehicle
to wash them. Dry with a soft cloth.
Replace the belts if they appear frayed or worn or if the
buckles do not work properly.
NOTE:If the belts retract slowly, inspect the upper turning
loop for soiling. If soiling is present, clean with a wet soft
cloth until all residue is removed.
WARNING!
A frayed or torn belt could rip apart in a collision and
leave you with no protection. Inspect the belt system
periodically, checking for cuts, frays, or loose parts.
Damaged parts must be replaced immediately. Do not
disassemble or modify the system. Seat belt assemblies
must be replaced after a collision if they have been
damaged (i.e., bent retractor, torn webbing, etc.).
FUSES
WARNING!
• When replacing a blown fuse, always use an appro-
priate replacement fuse with the same amp rating as
the original fuse. Never replace a fuse with another
fuse of higher amp rating. Never replace a blown
fuse with metal wires or any other material. Failure
to use proper fuses may result in serious personal
injury, fire and/or property damage.
• Before replacing a fuse, make sure that the ignition is
off and that all the other services are switched off
and/or disengaged.
• If the replaced fuse blows again, contact an autho-
rized dealer.
• If a general protection fuse for safety systems (air
bag system, braking system), power unit systems
(engine system, gearbox system) or steering system
blows, contact an authorized dealer.
492 MAINTAINING YOUR VEHICLE
Power Distribution Center
The Power Distribution Center is located in the engine
compartment near the battery. This center contains car-
tridge fuses, micro fuses, relays, and circuit breakers. A
description of each fuse and component may be stamped
on the inside cover, otherwise the cavity number of each
fuse is stamped on the inside cover that corresponds to the
following chart.
CavityCartridge Fuse Micro Fuse Description
F01 80 Amp Black –Rad Fan Control Module – If Equipped
F03 60 Amp Yellow –Rad Fan – If Equipped
F05 40 Amp Green –Compressor for Air Suspension – If
Equipped
F06 40 Amp Green –Antilock Brakes/Electronic Stability Control
Pump
F07 40 Amp Green –Starter Solenoid
Power Distribution Center Location
7
MAINTAINING YOUR VEHICLE 493
CavityCartridge Fuse Micro Fuse Description
F22 20 Amp Blue
30 Amp Pink
(Cummins Diesel) –
Engine Control Module
F23 30 Amp Pink –Body Controller #1 / Interior Lighting
F24 30 Amp Pink –Driver Door Module
F25 30 Amp Pink – Front Wiper
F26 30 Amp Pink –Antilock Brakes / Stability Control Module /
Valves
F28 20 Amp Blue –Trailer Tow Backup Lights – If Equipped
F29 20 Amp Blue –Trailer Tow Parking Lights – If Equipped
F30 30 Amp Pink –Trailer Tow Receptacle
F31 30 Amp Pink
(1500 LD Diesel) –
Urea Heater Control – If Equipped
F32 –– Spare Fuse
F33 20 Amp Blue –Special Services Vehicle Only
F34 30 Amp Pink –Vehicle System Interface Module #2 – If
Equipped
F35 30 Amp Pink –Sunroof – If Equipped
F36 30 Amp Pink –Rear Defroster – If Equipped
F37 30 Amp Pink –Cummins Diesel Fuel Heater #2 – If
Equipped
7
MAINTAINING YOUR VEHICLE 495