Severe Duty All Models
NOTE:Change Engine Oil at 4,000 miles (6,500 km) or 350
hours of engine run time if the vehicle is operated in a
dusty and off road environment or is operated predomi-
nantly at idle, or only very low engine RPM’s. This type of
vehicle use is considered Severe Duty.
Once A Month Or Before A Long Trip:
• Check engine oil level
• Check windshield washer fluid level
• Check tire pressure and look for unusual wear or
damage. Rotate tires at the first sign of irregular wear,
even if it occurs before the oil indicator system turns on.
• Check the fluid levels of the coolant reservoir, brake
master cylinder, power steering (2500/3500 Models
Only) and automatic transmission (six-speed only) and
fill as needed
• Check function of all interior and exterior lightsMaintenance Plan
Required Maintenance
Refer to the Maintenance Plan on the following pages for
required maintenance.
At Every Oil Change Interval As Indicated By Oil
Change Indicator System:
•Change oil and filter.
• Rotate the tires. Rotate at the first sign of irregular
wear, even if it occurs before the oil indicator
system turns on.
• Inspect battery and clean and tighten terminals as
required.
• Inspect automatic transmission fluid if equipped
with dipstick.
• Inspect brake pads, shoes, rotors, drums, hoses and
park brake.
• Inspect engine cooling system protection and hoses.
• Inspect exhaust system.
• Inspect engine air cleaner if using in dusty or
off-road conditions.
• Lube the front drive shaft fitting (2500/3500 (4x4)
models only).
518 SERVICING AND MAINTENANCE
Mileage or time passed (which-ever comes first)
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
100,000
110,000
120,000
130,000
140,000
150,000
Or Years: 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Or Kilometers:
32,000
48,000
64,000
80,000
96,000
112,000
128,000
144,000
160,000
176,000
192,000
208,000
224,000
240,000
Additional Inspections
Inspect the CV/Universal joints. XX X X X
Inspect front suspension, tie rod
ends, and replace if necessary. XXX X X X X
1500 Models:
Inspect the front and rear axle sur-
faces. If gear oil leakage is sus-
pected, check the fluid level. If us-
ing your vehicle for police, taxi,
fleet, off-road or frequent trailer
towing, change axle fluid. XX X X X
2500/3500 Models:
Inspect the front and rear axle sur-
faces. If gear oil leakage is sus-
pected, check the fluid level. If us-
ing your vehicle for police, taxi,
fleet, off-road or frequent trailer
towing, change axle fluid. XXX X X X X
8
SERVICING AND MAINTENANCE 519
Checking Oil Level — Gas Engine
To assure proper lubrication of your vehicle’s engine, the
engine oil must be maintained at the correct level. Check
the oil level at regular intervals, such as every fuel stop.
The best time to check the engine oil level is about five
minutes after a fully warmed up engine is shut off.
Checking the oil while the vehicle is on level ground will
improve the accuracy of the oil level readings. Always
maintain the oil level within the SAFE zone on the dipstick.
Adding one quart of oil when the reading is at the bottom
of the SAFE zone will result in a reading at the top of the
safe zone on these engines.
CAUTION!
Overfilling or underfilling will cause oil aeration or
loss of oil pressure. This could damage your engine.
Adding Washer Fluid
The fluid reservoir is located under the hood and should be
checked for fluid level at regular intervals. Fill the reservoir
with windshield washer solvent only (not radiator anti-
freeze). When refilling the washer fluid reservoir, take
some washer fluid and apply it to a cloth or towel and wipe
the wiper blades clean. This will help blade performance.To prevent freeze-up of your windshield washer system in
cold weather, select a solution or mixture that meets or
exceeds the temperature range of your climate. This rating
information can be found on most washer fluid containers.
WARNING!
Commercially available windshield washer solvents
are flammable. They could ignite and burn you. Care
must be exercised when filling or working around the
washer solution.
After the engine has warmed up, operate the defroster for
a few minutes to reduce the possibility of smearing or
freezing the fluid on the cold windshield. Windshield
washer solution used with water as directed on the con-
tainer, aids cleaning action, reduces the freezing point to
avoid line clogging, and is not harmful to paint or trim.
Maintenance-Free Battery
Your vehicle is equipped with a maintenance-free battery.
You will never have to add water, nor is periodic mainte-
nance required.
526 SERVICING AND MAINTENANCE
3. Run the engine at normal idle speed for at least 60seconds, 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. Remove the dipstick, wipe it clean and reinsert it until seated.
7. 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 And Lubricants for fluid
specifications). After adding any quantity of oil through the dipstick tube, wait a minimum of two minutes for
the oil to fully drain into the transmission before re-
checking 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. 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 transmis-
sion 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.
8. Reinsert the dipstick. Check for leaks. Release the park- ing brake.
8
SERVICING AND MAINTENANCE 555
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 — Eight-Speed
Transmission
Under normal operating conditions, the fluid installed at
the factory will provide satisfactory lubrication for the life
of the vehicle.
Routine fluid and filter changes are not required. However,
change the fluid and filter if the fluid becomes contami-
nated (with water, etc.), or if the transmission is disas-
sembled for any reason.
Fluid And Filter Changes — Six Speed Transmission
Refer to the “Maintenance Plan” for the proper mainte-
nance intervals.
In addition, change the fluid and filters if the fluid becomes
contaminated (with water, etc.), or if the transmission is
disassembled for any reason.
Rear Axle And 4x4 Front Driving Axle Fluid Level
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.
If gear oil leakage is suspected inspect the fluid level. Refer
to “Fluids And Lubricants” in “Technical Specifications”
for further information. This inspection should be made
with the vehicle in a level position.
For 1500 Model axles, the fluid level should be even with
the bottom of the fill hole (within 1/4 in (6.4 mm) of edge
of hole) for the FDU215 HD front axle and C235FE rear
axle.
For all 2500/3500 Model axles, the fluid level should be 1/4
in ± 1/4 in (6.4 mm ± 6.4 mm) below the fill hole on the 9.25
in front and 3/4 in ± 1/4 in (19 mm ± 6.4 mm) on 10.5 in
rear axles. The 11.5 in rear axle level should be 1/4 in ± 1/4
in (6.4 mm ± 6.4 mm) below the fill hole.
Lubricant Selection
Refer to “Fluids And Lubricants” in “Technical Specifica-
tion” for further information.
556 SERVICING AND MAINTENANCE
NOTE:The presence of water in the gear lubricant will
result in corrosion and possible failure of differential
components. Operation of the vehicle in water, as may be
encountered in some off-highway types of service, will
require draining and refilling the axle to avoid damage.
Limited-Slip Differentials
1500 Model rear axles equipped with a Limited Slip
Differential require that 5 oz. (148 ml) Mopar Limited Slip
Additive be added to the gear lubricant. Refer to “Fluids
And Lubricants” in “Technical Specification” for further
information. The Mopar Limited Slip Additive should be
added to the gear lubricant whenever a fluid change is
made to an axle equipped with a Limited Slip Differential.
2500/3500 Model axles DO NOT REQUIREany limited
slip oil additive (friction modifiers).
NOTE: When refilling an axle with a Limited Slip Differ-
ential, (which requires a Limited Slip Additive), the Lim-
ited Slip Additive should be added before the gear lubri-
cant is added to insure proper additive fill.
Drain And Refill
Refer to the “Maintenance Plan” for the proper mainte-
nance intervals.
Transfer Case
Selection Of Lubricant
Use only the manufacturer’s recommended fluid. Refer to
“Fluids And Lubricants” in “Technical Specifications” for
further information.
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.
Drain And Refill
Refer to the “Maintenance Plan” for the proper mainte-
nance intervals.8
SERVICING AND MAINTENANCE 557
Stain Repel Fabric Cleaning Procedure — If
Equipped
Stain Repel seats may be cleaned in the following manner:
•Remove as much of the stain as possible by blotting with
a clean, dry towel.
• Blot any remaining stain with a clean, damp towel.
• For tough stains, apply Mopar Total Clean, or a mild
soap solution to a clean, damp cloth and remove stain.
Use a fresh, damp towel to remove soap residue.
• For grease stains, apply Mopar Multi-Purpose Cleaner
to a clean, damp cloth and remove stain. Use a fresh,
damp towel to remove soap residue.
• Do not use any harsh solvents or any other form of
protectants on Stain Repel products.
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.).
Plastic And Coated Parts
Use Mopar Total Clean to clean vinyl upholstery.
CAUTION!
• Direct contact of air fresheners, insect repellents,
suntan lotions, or hand sanitizers to the plastic,
(Continued)
588 SERVICING AND MAINTENANCE
Fluid Level Check.....................553, 554
Fluid Type ..........................553, 607
Shifting ............................306, 315
Special Additives ........................ .553
Automatic Transmission Limp Home Mode ........304
Axle Fluid ............................556, 607
Axle Lubrication .......................... .556
Back-Up .................................410
Back-Up Camera .......................... .410
Bar, Stabilizer/Sway System ...................361
Battery ...............................191, 526
Charging System Light ....................191
Keyless Key Fob Replacement ................24
Belts, Seat ............................... .279
Body Builders Guide ..........................7
Body Mechanism Lubrication ..................541
B-Pillar Location .......................... .564
Brake Assist System ........................ .206
Brake Control System, Electronic ................205
Brake Fluid .......................... .552, 607
Brake System ..........................552, 593
Fluid Check ............................552
Master Cylinder ........................ .552
Parking ...............................295 Warning Light
.......................... .190
Brake/Transmission Interlock ..................299
Bulb Replacement ..........................452
Bulbs, Light .......................... .281, 452
Cab Top Clearance Lights .....................458
Camera .................................410
Camera, Rear ............................ .410
Camper .................................152
Capacities, Fluid .......................... .603
Caps, Filler Oil (Engine) ..................... .523, 529, 530
Power Steering ..........................394
Radiator (Coolant
Pressure).................549
Carbon Monoxide Warning ................279, 600
Cargo Light ...............................79
Car Washes ...............................585
Cellular Phone ............................654
Center High Mounted Stop Light ...............457
Center Seat Storage Compartment ...............123
Changing A Flat Tire ........................468
Chart, Tire Sizing .......................... .560
Check Engine Light (Malfunction Indicator Light). . . .201
Checking Your Vehicle For Safety ...............278
Checks, Safety ............................ .278
12
INDEX 683