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SERVICING AND MAINTENANCE423
Fluid Level Check — Six-Speed
Transmission
It is best to check the fluid level when the
transmission is at normal operating
temperature (158-176°F / 70-80°C). 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 screen
refer to “Instrument Cluster Display” in “Getting
To Know Your Instrument Panel” for further
information.
Use the following procedure to check the
transmission fluid level properly:
1. Monitor the transmission temperature using the instrument cluster display, and
operate the vehicle as required to reach
the normal operating temperature. If the transmission 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. 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
refer to "Fluids And Lubricants" in
“Technical Specifications” for fluid specifi -
cations. 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 rechecking the
fluid level.
NOTE:
If it is necessary to check the transmission
below the 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. 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 a transmission fluid leak occurs, visit an
authorized dealer immediately. Severe
transmission damage may occur. An
authorized dealer has the proper tools to
adjust the fluid level accurately.
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424SERVICING AND MAINTENANCE
8. Reinsert the dipstick. Check for leaks.
Release the parking brake.
NOTE:
If it is necessary to check the transmission
below the operating temperature, the fluid level
should be between the two COLD (lower) holes
on the dipstick with the fluid at 68-86°F /
20-30°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 transmission reaches
normal operating temperature.
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 contaminated (with water,
etc.), or if the transmission is disassembled for
any reason.
Fluid And Filter Changes — Six Speed
Transmission
Refer to the “Maintenance Plan” for the proper
maintenance 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
A
XLE 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 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, 11.5 in
rear axle, and 12.0 in rear axle.
Drain And Refill
Refer to the “Maintenance Plan” for the proper
maintenance intervals.
Lubricant Selection
Refer to “Fluids And Lubricants” in “Technical
Specifications” for further information.
NOTE:
The presence of water in the gear lubricant will
result in corrosion and possible failure of differ -
ential 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 DO REQUIRE limited
slip oil additive (friction modifiers).
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.
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.
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SERVICING AND MAINTENANCE425
NOTE:
Slight noise and mild shuddering may be
evident while turning a vehicle with limited slip
differential on concrete or dry pavement. These
conditions should be considered normal opera -
tion of the limited slip differential.
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” in this section
for the proper maintenance intervals.
NOISE CONTROL SYSTEM REQUIRED
M
AINTENANCE & WARRANTY
All vehicles built over 10,000 lbs. (4,535 kg)
Gross Vehicle Weight Rating and manufactured
for sale and use in the United States are
required to comply with the Federal
Government's Exterior Noise Regulations.
These vehicles can be identified by the Noise
Emission Control Label located in the operator's
compartment.
Required Maintenance For Noise Control
Systems
The following maintenance services must be
performed every six months or 7,500 miles
(12,000 km) whichever comes first, to ensure
proper operation of the noise control systems.
In addition, inspection and service should be
performed anytime a malfunction is observed
or suspected. Proper maintenance of the
entire vehicle will help the effectiveness of the
noise control systems.
Exhaust System
Inspect the entire exhaust system for leaks and
damaged parts. Devices such as hangers,
clamps, and U-bolts should be tight and in good
condition. Damaged components, burned or
blown out mufflers, burned or rusted out
exhaust pipes should be replaced according to
the procedures and specifications outlined in
the appropriate service manual.
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426SERVICING AND MAINTENANCE
Air Cleaner Assembly
Inspect air cleaner housing for proper assembly
and fit. Make certain that the air cleaner is
properly positioned and that the cover is tight.
Check all hoses leading to the air cleaner for
tightness. The air filter element must also be
clean and serviced according to the instructions
outlined in the Scheduled Maintenance section
of this manual.
Tampering With Noise Control System
Prohibited
Federal law prohibits the following acts or the
causing thereof: (1) the removal or rendering
inoperative by any person, other than for
purposes of maintenance, repair, or
replacement, of any device or element of design
incorporated into any new vehicle for the
purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is
in use, or (2) the use of the vehicle after such
device or element of design has been removed
or rendered inoperative by any person. Among those acts presumed to constitute
tampering are the acts listed below.
AIR CLEANER
Removal of the air cleaner.
Removal of the air cleaner filter element from
the air cleaner housing.
Removal of the air ducting.
EXHAUST SYSTEM
Removal or rendering inoperative exhaust
system components including the muffler or
tailpipe.
ENGINE COOLING SYSTEM
Removal or rendering inoperative the fan
clutch.
Removal of the fan shroud.
Noise Emission Warranty
The manufacturer warrants that this vehicle as
manufactured by the manufacturer, was
designed, built and equipped to conform at the
time it left the manufacturer's control with all
applicable U.S. EPA Noise Control Regulations.
This warranty covers this vehicle as designed,
built and equipped by the manufacturer, and is
not limited to any particular part, component or
system of the vehicle manufactured by the
manufacturer. Defects in design, assembly or in
any part, component or system of the vehicle as
manufactured by the manufacturer, which, at
the time it left the manufacturer's control,
caused noise emissions to exceed Federal
standards, are covered by this warranty for the
life of the vehicle.
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SERVICING AND MAINTENANCE427
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.
MILES7,500 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
7
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428SERVICING AND MAINTENANCE
MILES67,500 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
READING
PERFORMED BY
PERFORMED AT
Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest to the mileage at which
service was performed.
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SERVICING AND MAINTENANCE429
HOISTING
A conventional floor jack may be used at the
jacking locations. However, a floor jack or frame
hoist must never be used on any other parts of
the underbody.
TIRES
TIRE SAFETY INFORMATION
Tire safety information will cover aspects of the
following information: Tire Markings, Tire
Identification Numbers, Tire Terminology and
Definitions, Tire Pressures, and Tire Loading.
Tire Markings
Tire Markings
NOTE:
P (Passenger) — Metric tire sizing is based on
US design standards. P-Metric tires have the
letter “P” molded into the sidewall preceding
the size designation. Example: P215/65R15
95H.
European — Metric tire sizing is based on
European design standards. Tires designed
to this standard have the tire size molded
into the sidewall beginning with the section
width. The letter "P" is absent from this tire
size designation. Example: 215/65R15 96H.
LT (Light Truck) — Metric tire sizing is based
on US design standards. The size designation
for LT-Metric tires is the same as for P-Metric
tires except for the letters “LT” that are
molded into the sidewall preceding the size
designation. Example: LT235/85R16.
Temporary spare tires are designed for
temporary emergency use only. Temporary
high pressure compact spare tires have the
letter “T” or “S” molded into the sidewall
preceding the size designation. Example:
T145/80D18 103M.
High flotation tire sizing is based on US
design standards and it begins with the tire
diameter molded into the sidewall. Example:
31x10.5 R15 LT.
CAUTION!
Never use a floor jack directly under the
differential housing of a loaded truck or
damage to your vehicle may result.
1 — US DOT Safety Standards Code
(TIN)
2 — Size Designation
3 — Service Description
4 — Maximum Load
5 — Maximum Pressure
6 — Treadwear, Traction and Tempera -
ture Grades
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430SERVICING AND MAINTENANCE
Tire Sizing Chart
EXAMPLE:
Example Size Designation: P215/65R15XL 95H, 215/65R15 96H, LT235/85R16C, T145/80D18 103M, 31x10.5 R15 LT
P = Passenger car tire size based on US design standards, or
"....blank...." = Passenger car tire based on European design standards, or
LT = Light truck tire based on US design standards, or
T or S = Temporary spare tire or
31 = Overall diameter in inches (in)
215, 235, 145 = Section width in millimeters (mm)
65, 85, 80 = Aspect ratio in percent (%)
Ratio of section height to section width of tire, or
10.5 = Section width in inches (in)
R = Construction code
"R" means radial construction, or
"D" means diagonal or bias construction
15, 16, 18 = Rim diameter in inches (in)
Service Description:
95 = Load Index
A numerical code associated with the maximum load a tire can carry
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