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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
MAINTAINING YOUR VEHICLE 187
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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.
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)
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 accident.
• 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 an accident.
Clutch Hydraulic System
The clutch hydraulic system is a sealed maintenance-free
system. In the event of leakage or other malfunction, the
system must be replaced.
196 MAINTAINING YOUR VEHICLE
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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
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FLUIDS, LUBRICANTS AND GENUINE PARTS
Engine
ComponentFluid, Lubricant, or Genuine Part
Engine Coolant We recommend you use MOPAR Antifreeze/Coolant 10 Year/150,000 Mile Formula OAT (Organic Additive Technology).
Engine Oil In ambient temperatures above 0°F (-18°C), we recommend you use 15W-40 engine oil such as
MOPAR, Shell Rotella and Shell Rimula that meets FCA Material Standard MS-10902 and the
API CJ-4 engine oil category is required. Products meeting Cummins CES 20081 may also be
used. The identification of these engine oils is typically located on the back of the oil container.
In ambient temperatures below 0°F (-18°C), we recommend you use 5W-40 syntheticengine oil
such as MOPAR, Shell Rotella and Shell Rimula that meets FCA Material Standard MS-10902
and the API CJ-4 engine oil category is required.
Engine Oil Filter We recommend you use MOPAR Engine Oil Filters.
Fuel Filters We recommend you use MOPAR Fuel Filter. Must meet 3 micron rating. Using a fuel filter that
does not meet the manufacturers filtration and water separating requirements can severely
impact fuel system life and reliability.
Crankcase Ventilation
Filter We recommend you use MOPAR CCV Filter.
7
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MAINTENANCE SCHEDULE
CONTENTS
MAINTENANCE SCHEDULE — DIESEL
ENGINE ............................. .210
▫ Oil Change Indicator System — Cummins
Diesel ............................. .210▫
Perform Service Indicator — Cummins
Diesel ...............................211
▫ Maintenance Chart — Cummins Diesel
Engine ............................. .212
8
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MAINTENANCE SCHEDULE — DIESEL ENGINE
CAUTION!
Failure to perform the required maintenance items
may result in damage to the vehicle.
At Each Stop For Fuel
Check the engine oil level at least 30 minutes after a fully
warmed engine is shut off. Checking the oil level while the
vehicle is on level ground will improve the accuracy of the
oil level reading. Add oil only when the level is at or below
the ADD or MIN mark.
Once A Month
• Inspect the batteries, and clean and tighten the terminals
as required.
• Check the fluid levels of the coolant reservoir, brake
master cylinder, and automatic transmission (if
equipped), and add as needed.
At Each Oil Change
• Change the engine oil filter.
• Inspect the exhaust system.
• Inspect engine air filter. •
Check the coolant level, hoses, and clamps.
• Lubricate outer tie rod ends.
Inspection and service should also be performed anytime a
malfunction is observed or suspected. Retain all receipts.
Oil Change Indicator System — Cummins Diesel
Your vehicle is equipped with an engine oil change indi-
cator system. This system will alert you when it is time to
change your engine oil by displaying the words “Oil
Change Due” in your instrument cluster display. The oil
change reminder will remind the owner to change the
engine oil every 15,000 miles or 500 hours, whichever
comes first, except for the Chassis Cab models and Pickup
models configured with optional B20 capability that are
using B20 biodiesel, which are 12,500 miles or 400 hours,
whichever comes first. Failure to change the engine oil per
the maintenance schedule can result in internal engine
damage.
Your authorized dealer will reset the oil change indicator
message after completing the scheduled oil change. If a
scheduled oil change is performed by someone other than
your authorized dealer, the message can be reset by
210 MAINTENANCE SCHEDULE