6
REFUELING THE VEHICLE —
DIESEL ENGINE ................................................. 269 Fuel Filler Cap ............................................269
Avoid Using Contaminated Fuel ................269Bulk Fuel Storage — Diesel Fuel ...............269
Diesel Exhaust Fluid ..................................270Diesel Exhaust Fluid Storage ....................270
Adding Diesel Exhaust Fluid (DEF) ........... 271
VEHICLE LOADING .......................................... 273
Gross Vehicle Weight Rating (GVWR) ......273Payload .......................................................273Gross Axle Weight Rating (GAWR) ............273
Tire Size ......................................................273
Rim Size......................................................273
Inflation Pressure ......................................273
Curb Weight................................................273
Loading .......................................................273
TRAILER TOWING ............................................ 274
Common Towing Definitions .....................274Trailer Hitch Type and Maximum
Trailer Weight .............................................278 Trailer Towing Weights (Maximum Trailer
Weight Ratings) .......................................279 Trailer And Tongue Weight .......................279
Towing Requirements ...............................279
Towing Tips ................................................284 SNOWPLOW ....................................................... 286
Before Plowing ........................................... 286
Snowplow Prep Package Model
Availability .................................................. 286 Over The Road Operation With Snowplow
Attached ..................................................... 287 Operating Tips ............................................ 287General Maintenance................................ 287
RECREATIONAL TOWING (BEHIND
MOTORHOME, ETC.) .......................................... 288
Towing This Vehicle Behind Another
Vehicle ........................................................ 288 Recreational Towing — Two-Wheel Drive
Models ........................................................ 289 Recreational Towing — Four-Wheel Drive
Models ........................................................ 289
DRIVING TIPS ...................................................... 292
Driving On Slippery Surfaces ................... 292
Driving Through Water .............................. 292
IN CASE OF EMERGENCY
HAZARD WARNING FLASHERS .................... 294
ASSIST AND SOS SYSTEM — IF EQUIPPED..... 294General Information .................................. 299
BULB REPLACEMENT ......................................300
Replacement Bulbs .............................. 300
Replacing Exterior Bulbs ........................... 301
FUSES ..................................................................305
Power Distribution Center ......................... 306 JACKING AND TIRE CHANGING ...................... 314
4500/5500 Models .................................. 315
Preparations For Jacking .......................... 315
Jacking Instructions 4500 And
5500 Series ............................................... 315 To Stow The Flat Or Spare —
If Equipped ................................................ 318 Hub Caps/Wheel Covers —
If Equipped ............................................... 318
JUMP STARTING ............................................... 319
Preparations For Jump Start ..................... 320
Jump Starting Procedure .......................... 320
IF YOUR ENGINE OVERHEATS ......................... 321
GEAR SELECTOR OVERRIDE — 6–SPEED
TRANSMISSION ................................................ 322
MANUAL PARK RELEASE — 8 – SPEED
TRANSMISSION ................................................ 323
FREEING A STUCK VEHICLE ............................ 324
TOWING A DISABLED VEHICLE ...................... 326
Two-Wheel Drive Models ........................... 327
Four-Wheel Drive Models .......................... 327
Emergency Tow Hooks — If Equipped ...... 328
ENHANCED ACCIDENT RESPONSE SYSTEM
(EARS) ................................................................ 328
EVENT DATA RECORDER (EDR) ....................... 328
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7
SERVICING AND MAINTENANCE
SCHEDULED SERVICING — GAS ENGINE ....... 329Maintenance Plan......................................330
Heavy Duty Use Of The Vehicle ................. 333
SCHEDULED SERVICING — DIESEL ENGINE .. 334
Oil Change Indicator System —
Cummins Diesel .........................................335 Perform Service Indicator —
Cummins Diesel ........................................335 Maintenance Plan — Cummins
Diesel Engine ............................................336
ENGINE COMPARTMENT ................................ 343
6.4L Engine ...............................................3436.7L Engine ................................................344
Checking Oil Level — Gas Engine .............345
Checking Oil Level — Diesel Engine ..........345
Adding Washer Fluid ................................345Maintenance-Free Battery .......................346
Pressure Washing ......................................346
DEALER SERVICE .............................................. 347
Engine Oil .................................................. 347Engine Oil Filter ........................................349
Engine Air Cleaner Filter .........................349
Air Conditioner Maintenance ................. 351
Accessory Drive Belt Inspection................354Draining Fuel/Water Separator Filter .....354
Engine Mounted Fuel Filter
Replacement ..............................................356 Underbody Mounted Fuel Filter
Replacement ..............................................357 Priming If The Engine Has Run
Out Of Fuel ................................................ 358 Intervention Regeneration Strategy —
Message Process Flow ............................. 359 Diesel Exhaust Fluid .................................. 359Body Lubrication ...................................... 360
Windshield Wiper Blades ........................ 360
Exhaust System ........................................ 362
Cooling System ......................................... 363
Charge Air Cooler — Inter-Cooler .............. 366
Brake System ............................................ 367Automatic Transmission............................ 368
Rear Axle And 4x4 Front Driving Axle Fluid
Level ....................................................... 370 Transfer Case ............................................ 371Noise Control System Required
Maintenance & Warranty ......................... 371
HOISTING ............................................................374
TIRES....................................................................374
Tire Safety Information ........................... 374
Tires — General Information .................... 382
Tire Types ................................................... 386
Spare Tires — If Equipped ....................... 387
Wheel And Wheel Trim Care .................. 389Tire Chains and Traction Devices ............ 390
Tire Rotation Recommendations .............. 391 DEPARTMENT OF TRANSPORTATION UNIFORM
TIRE QUALITY GRADES .................................... 392
Treadwear .................................................. 392
Traction Grades ......................................... 392Temperature Grades ................................. 393
STORING THE VEHICLE .................................. 393
BODYWORK ........................................................ 393 Protection From Atmospheric Agents ..... 393
Body And Underbody Maintenance .......... 394Preserving The Bodywork.......................... 394
INTERIORS ......................................................... 395
Seats And Fabric Parts .............................. 395
Plastic And Coated Parts........................... 396
Leather Parts ............................................. 396
Glass Surfaces .......................................... 396
TECHNICAL SPECIFICATIONS
IDENTIFICATION DATA ...................................... 397Vehicle Identification Number ................. 397
BRAKE SYSTEM ................................................ 397
Hydraulic Brake Assist — If Equipped....... 397
WHEEL AND TIRE TORQUE
SPECIFICATIONS .............................................. 397
Torque Specifications .............................. 398
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182SAFETY
Periodic Safety Checks You Should Make
Outside The Vehicle
Tires
Examine tires for excessive tread wear and
uneven wear patterns. Check for stones, nails,
glass, or other objects lodged in the tread or
sidewall. Inspect the tread for cuts and cracks.
Inspect sidewalls for cuts, cracks, and bulges.
Check the wheel bolts for tightness. Check the
tires (including spare) for proper cold inflation
pressure.
Lights
Have someone observe the operation of brake
lights and exterior lights while you work the
controls. Check turn signal and high beam indi -
cator lights on the instrument panel.
Door Latches
Check for proper closing, latching, and locking.
Fluid Leaks
Check area under the vehicle after overnight
parking for fuel, coolant, oil, or other fluid leaks.
Also, if gasoline fumes are detected or if fuel, or
brake fluid leaks are suspected, the cause
should be located and corrected immediately.
ALWAYS make sure objects cannot fall or
slide into the driver’s side floor area when
the vehicle is moving. Objects can become
trapped under accelerator, brake, or clutch
pedals and could cause a loss of vehicle
control.
NEVER place any objects under the floor
mat (e.g., towels, keys, etc.). These objects
could change the position of the floor mat
and may cause interference with the accel -
erator, brake, or clutch pedals.
If the vehicle carpet has been removed and
re-installed, always properly attach carpet
to the floor and check the floor mat
fasteners are secure to the vehicle carpet.
Fully depress each pedal to check for inter -
ference with the accelerator, brake, or
clutch pedals then re-install the floor mats.
It is recommended to only use mild soap
and water to clean your floor mats. After
cleaning, always check your floor mat has
been properly installed and is secured to
your vehicle using the floor mat fasteners
by lightly pulling mat.
WARNING! (Continued)
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240STARTING AND OPERATING
Adaptive Cruise Control Set
When the RES (+) or the SET(-) button (located
on the steering wheel) is pushed, the display will
read “ACC SET.”
When ACC is set, the set speed will show in the
instrument cluster display.
The ACC screen may display once again if any
ACC activity occurs, which may include any of
the following:
System Cancel
Driver Override
System Off
ACC Proximity Warning
ACC Unavailable Warning
The instrument cluster display will return to
the last display selected after five seconds of
no ACC display activity
Display Warnings And Maintenance
“Wipe Front Radar Sensor In Front Of
Vehicle” Warning
The “ACC/FCW Unavailable Wipe Front Radar
Sensor” warning will display and also a chime
will indicate when conditions temporarily limit
system performance. This most often occurs at times of poor visibility,
such as in snow or heavy rain. The ACC system
may also become temporarily blinded due to
obstructions, such as mud, dirt or ice. In these
cases, the instrument cluster display will display
“ACC/FCW Unavailable Wipe Front Radar
Sensor” and the system will deactivate.
The “ACC/FCW Unavailable Wipe Front Radar
Sensor” message can sometimes be displayed
while driving in highly reflective areas (i.e.
tunnels with reflective tiles, or ice and snow).
The ACC system will recover after the vehicle
has left these areas. Under rare conditions,
when the radar is not tracking any vehicles or
objects in its path this warning may temporarily
occur.
NOTE:
If the “ACC/FCW Unavailable Wipe Front Radar
Sensor” warning is active Normal (Fixed Speed)
Cruise Control is still available. For additional
information refer to “Normal (Fixed Speed)
Cruise Control Mode” in this section.
If weather conditions are not a factor, the driver
should examine the sensor. It may require
cleaning or removal of an obstruction. The
sensor is located in the camera in the center of
the windshield, on the forward side of the rear
-
view mirror. To keep the ACC System operating properly, it is
important to note the following maintenance
items:
Always keep the sensor clean. Carefully clear
the windshield.
Do not remove any screws from the sensor.
Doing so could cause an ACC system
malfunction or failure and require a sensor
realignment.
Do not attach or install any accessories near
the sensor, including transparent material or
aftermarket grilles. Doing so could cause an
ACC system failure or malfunction.
When the condition that deactivated the system
is no longer present, the system will return to
the “Adaptive Cruise Control Off” state and will
resume function by simply reactivating it.
NOTE:
If the “ACC/FCW Unavailable Wipe Front
Radar Sensor” message occurs frequently
(e.g. more than once on every trip) without
any snow, rain, mud, or other obstruction,
have the radar sensor realigned at your
authorized dealer.
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280STARTING AND OPERATING
(Continued)
Towing Requirements — Tires
Do not attempt to tow a trailer while using a
compact spare tire.
Do not drive more than 50 mph (80 km/h) when towing while using a full size spare tire.
Proper tire inflation pressures are essential
to the safe and satisfactory operation of your
vehicle. Refer to “Tires” in “Servicing And
Maintenance” for proper tire inflation proce -
dures.
Check the trailer tires for proper tire inflation
pressures before trailer usage.
Check for signs of tire wear or visible tire
damage before towing a trailer. Refer to
“Tires” in “Servicing And Maintenance” for
the proper inspection procedure.
When replacing tires, refer to “Tires” in
“Servicing And Maintenance” for the proper
tire replacement procedures. Replacing tires
with a higher load carrying capacity will not
increase the vehicle's GVWR and GAWR
limits.
Towing Requirements — Trailer Brakes
Do not interconnect the hydraulic brake
system or vacuum system of your vehicle
with that of the trailer. This could cause inad -
equate braking and possible personal injury.
WARNING!
Make certain that the load is secured in the
trailer and will not shift during travel. When
trailering cargo that is not fully secured,
dynamic load shifts can occur that may be
difficult for the driver to control. You could
lose control of your vehicle and have a colli -
sion.
When hauling cargo or towing a trailer, do
not overload your vehicle or trailer. Over -
loading can cause a loss of control, poor
performance or damage to brakes, axle,
engine, transmission, steering, suspension,
chassis structure or tires.
Safety chains must always be used
between your vehicle and trailer. Always
connect the chains to the hook retainers of
the vehicle hitch. Cross the chains under
the trailer tongue and allow enough slack
for turning corners.
Vehicles with trailers should not be parked
on a grade. When parking, apply the
parking brake on the tow vehicle. Put the
tow vehicle transmission in PARK. For
four-wheel drive vehicles, make sure the
transfer case is not in NEUTRAL. Always,
block or "chock" the trailer wheels.
GCWR must not be exceeded.
Total weight must be distributed between
the tow vehicle and the trailer such that the
following four ratings are not exceeded :
GVWR
GTW
GAWR
Tongue weight rating for the trailer
hitch utilized.
WARNING! (Continued)
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IN CASE OF EMERGENCY309
F3630 Amp Pink –Electric Back Light – If Equipped
F37 30 Amp Pink –Fuel Heater #2, Aux Relay 2 – If Equipped (HD Only)
SSV (DS 1500 Only)
F38 30 Amp Pink –Integrated Trailer Brake Module – If Equipped (HD Only)
Power Inverter 115 Volt AC – If Equipped (DS 1500 Only)
F39 20 Amp Blue –Power Outlet – SSV Only
F40 –10 Amp Red Ventilated Seats – If Equipped (HD Only)
F41 –10 Amp Red Active Grille Shutter / Active Air Dam – If Equipped
F42 –20 Amp Yellow Horn
F43 –15 Amp Blue Heated Steering Wheel – If Equipped (HD Only)
F44 –10 Amp Red Diagnostic Port
F46 –10 Amp RedUpfitters Relay Coil – If Equipped (HD Only)
Spare (DS 1500 Only)
F49 –10 Amp RedInstrument Panel Cluster / HVAC (DS 1500 Only)
Instrument Cluster / MOD CSG (HD Only)
F50 –20 Amp Yellow Air Suspension Control Module – If Equipped
F51 –10 Amp RedIgnition Node Module / Keyless Ignition Node Module,
Radio Frequency Hub Module / Electric Steering Column
Lock - If Equipped
F52 –5 Amp Tan Battery Sensor
F53 –20 Amp Yellow Trailer Tow – Left Turn/Stop Lights - If Equipped
F54 –20 Amp Yellow Non Memory Adjustable Pedals - If Equipped
CavityCartridge Fuse Micro Fuse Description
6
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316IN CASE OF EMERGENCY
Jack Warning Label
1. If equipped, remove the spare wheel, jack,
and tools from storage.
2. Using the lug wrench, loosen, but do not remove, the lug nuts by turning them coun -
terclockwise one turn while the wheel is still
on the ground.
3. When changing the front wheel, assemble the jack driver to the jack and connect the
jack driver to the extension tube. Place the
jack under the axle as close to the tire as
possible with the jack driver extending to
the front. Connect the extension tubes and
lug wrench.
Front Jacking Locations
When changing a rear wheel, assemble the
jack driver to the jack and connect the jack
driver to the extension tubes. Securely
place the jack under the sway bar bracket (unless both tires are flat on one side, then
place jack under shock bracket) facing for
-
ward in vehicle. Connect the extension
tubes and lug wrench.
Rear Jacking Location
Before raising the wheel off the ground,
make sure that the jack will not damage
surrounding truck parts and adjust the jack
position as required.
NOTE:
If the jack will not lower by turning the dial
(thumbwheel) by hand, it may be necessary to
use the jack driver in order to lower the jack.
4. By rotating the lug wrench clockwise, raise the vehicle until the wheel just clears the
surface.
Only use the jack in the positions indicated
and for lifting this vehicle during a tire
change.
If working on or near a roadway, be
extremely careful of motor traffic.
To assure that spare tires, flat or inflated,
are securely stowed, spares must be
stowed with the valve stem facing the
ground.
CAUTION!
Do not attempt to raise the vehicle by jacking
on locations other than those indicated in the
Jacking Instructions for this vehicle.
WARNING! (Continued)
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IN CASE OF EMERGENCY317
5. Remove the lug nuts and pull the wheel off.
Install the spare wheel and lug nuts with the
cone shaped end of the nuts toward the
wheel on Single Rear-Wheel (SRW) models.
On Dual Rear-Wheel models (DRW) the lug
nuts are a two-piece assembly with a flat
face. Lightly tighten the nuts. To avoid risk
of forcing the vehicle off the jack, do not
fully tighten the nuts until the vehicle has
been lowered.
6. Using the lug wrench, finish tightening the nuts using a crisscross pattern. For the
proper lug nut torque specifications refer to
“Wheel And Tire Torque Specifications” in
“Technical Specifications.” If in doubt about
the correct tightness, have them checked
with a torque wrench by an authorized
dealer or at a service station. 7. Install wheel center cap (if equipped) and
remove wheel blocks. Do not install chrome
or aluminum wheel center caps on the
spare wheel. This may result in cap damage.
8. Lower the jack to its fully closed position. If the jack will not lower by turning the dial
(thumbwheel) by hand, it may be necessary
to use the jack driver in order to lower the
jack. Stow the replaced tire, jack, and tools
as previously described.
9. Adjust the tire pressure when possible.
10. After 25 miles (40 km), check the lug nut torque with a torque wrench to ensure that
all lug nuts are properly seated against the
wheel.
Dual Rear Wheels
Slots in the wheels will assist in properly
orienting the inner and outer wheels. Align
these slots when assembling the wheels for
best access to the tire valve on the inner wheel.
The tires of both dual wheels must be
completely off the ground when tightening to
insure wheel centering and maximum wheel
clamping.
Dual wheel models require a special heavy-duty
lug nut tightening adapter (included with the
vehicle) to correctly tighten the lug nuts. Also,
when it is necessary to remove and install dual
rear wheels, use a proper vehicle lifting device.
NOTE:
When installing a spare tire (if equipped) as part
of a dual rear wheel end combination, the tire
diameter of the two individual tires must be
compared. If there is a significant difference,
the larger tire should be installed in a front loca-
tion. The correct direction of rotation for dual
tire installations must also be observed.WARNING!
Raising the vehicle higher than necessary can
make the vehicle less stable. It could slip off
the jack and hurt someone near it. Raise the
vehicle only enough to remove the tire.
WARNING!
A loose tire or jack thrown forward in a
collision or hard stop, could endanger the
occupants of the vehicle. Always stow the jack
parts and the spare tire in the places
provided.
6
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