SERVICING AND MAINTENANCE351
the EPA Heavy Duty Diesel Engine Emissions
Standards. These systems are seamlessly
integrated into your vehicle and managed by the
Cummins® Powertrain Control Module (PCM). The
PCM manages engine combustion to allow the
exhaust system’s catalyst to trap and burn
Particulate Matter (PM) pollutants, with no input or
interaction on your part.
If the engine is allowed to idle or the truck is driven
on low engine speed drive cycles for more than two
hours, the system will automatically enter an
emissions operating mode that will increase the
engine idle speed to 1,050 RPM. While in this
mode, which is designed to help maintain the
Diesel Particulate Filter, the engine idle speed will
return to normal when the brake pedal is applied.
A small change in engine tone or a slight change in
engine performance while accelerating may also
be noticeable at speeds below 20 mph (32 km/h).
This operating mode may last for up to an hour of
idle time, or around 20 minutes of driving time.
Additionally, your vehicle has the ability to alert you
to additional maintenance required on your truck
or engine Ú page 81.
DIESEL EXHAUST FLUID (DEF)
DEF sometimes known simply by the name of its
active component, UREA—is a key component of
Selective Catalytic Reduction (SCR) systems, which
help diesel vehicles meet stringent emission
regulations. DEF is a liquid reducing agent that
reacts with engine exhaust in the presence of a
catalyst to convert smog-forming nitrogen oxides
(NOx) into harmless nitrogen and water vapor
Úpage 404.
You can receive assistance in locating DEF by
contacting an authorized dealer.
BODY LUBRICATION
Locks and all body pivot points, including such
items as seat tracks, door hinge pivot points and
rollers, liftgate, tailgate, decklid, sliding doors and
hood hinges, should be lubricated periodically with
a lithium-based grease, such as Mopar® Spray
White Lube to ensure quiet, easy operation and to protect against rust and wear. Prior to the
application of any lubricant, the parts concerned
should be wiped clean to remove dust and grit;
after lubricating excess, oil and grease should be
removed. Particular attention should also be given
to hood latching components to ensure proper
function. When performing other underhood
services, the hood latch, release mechanism and
safety catch should be cleaned and lubricated.
The external lock cylinders should be lubricated
twice a year, preferably in the Autumn and Spring.
Apply a small amount of a high quality lubricant,
such as Mopar® Lock Cylinder Lubricant directly
into the lock cylinder.
WINDSHIELD WIPER BLADES
Clean the rubber edges of the wiper blades and the
windshield periodically with a sponge or soft cloth
and a mild nonabrasive cleaner. This will remove
accumulations of salt or road film.
Operation of the wipers on dry glass for long
periods may cause deterioration of the wiper
blades. Always use washer fluid when using the
wipers to remove salt or dirt from a dry windshield.
Avoid using the wiper blades to remove frost or ice
from the windshield. Keep the blade rubber out of
contact with petroleum products such as engine
oil, gasoline, etc.
WARNING!
A hot exhaust system can start a fire if you park
over materials that can burn. Such materials
might be grass or leaves coming into contact
with your exhaust system. Do not park or oper
-
ate your vehicle in areas where your exhaust sys -
tem can contact anything that can burn.
8
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SERVICING AND MAINTENANCE353
3. Tilt the lower end of the wiper blade away from the arm and with one finger, push the release
tab toward the wiper arm.
Wiper Disengaging
4. Slide the wiper blade down towards the base of the wiper arm.
5. With the wiper blade disengaged, remove the wiper blade from the wiper arm by holding the
wiper arm with one hand and separating the
wiper blade from the wiper arm with the other
hand (move the wiper blade down toward the
base of the wiper arm and away from the J
hook in the end of the wiper arm).
Removing Wiper From Wiper Arm
6. Gently lower the wiper arm onto the glass.
Installing The Front Wipers
1. Lift the wiper arm off of the glass, until the wiper arm is in the full up position.
2. Position the wiper blade under the hook on the tip of the wiper arm with the wiper locking tab
open.
3. Insert the receiver bracket on the wiper assembly into the hook on the tip of the arm
through the opening in the wiper blade under
the locking tab. 4. Slide the wiper blade up into the hook on the
wiper arm until it is latched (engagement will
be accompanied by an audible click). Fold
down the latch release tab and snap it into its
locked position.
5. Gently lower the wiper blade onto the glass.
EXHAUST SYSTEM
The best protection against carbon monoxide entry
into the vehicle body is a properly maintained
engine exhaust system.
If you notice a change in the sound of the exhaust
system; or if the exhaust fumes can be detected
inside the vehicle; or when the underside or rear of
the vehicle is damaged; have an authorized
technician inspect the complete exhaust system
and adjacent body areas for broken, damaged,
deteriorated, or mispositioned parts. Open seams
or loose connections could permit exhaust fumes
to seep into the passenger compartment. In
addition, have the exhaust system inspected each
time the vehicle is raised for lubrication or oil
change. Replace as required.
1 — Locking Tab
2 — Wiper
3 — Release Tab
1 — Wiper
2 — Locking Tab
3 — Wiper Arm J Hook
8
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358SERVICING AND MAINTENANCE
(Continued)
BRAKE SYSTEM
In order to ensure brake system performance, all
brake system components should be inspected
periodically Úpage 329.
Fluid Level Check — Brake Master Cylinder
The fluid level of the master cylinder should be
checked when performing under the hood service
or immediately if the Brake System Warning Light
indicates system failure.
If necessary, add fluid to bring level within the
designated marks on the side of the reservoir of
the brake master cylinder. Be sure to clean the top
of the master cylinder area before removing 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.
For further information Ú page 407.
AUTOMATIC TRANSMISSION
Special Additives
The manufacturer strongly recommends against
using any special additives in the transmission.
Automatic Transmission Fluid (ATF) is an
engineered product and its performance may be
impaired by supplemental additives. Therefore, do
not add any fluid additives to the transmission. The
only exception to this policy is the use of special
dyes for diagnosing fluid leaks in 6-speed
transmissions. Avoid using transmission sealers as
they may adversely affect seals.
WARNING!
Riding the brakes can lead to brake failure and
possibly 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.
WARNING!
Use only manufacturer's recommended brake
fluid Úpage 407. Using the wrong type of
brake fluid can severely damage your brake
system and/or impair its performance. The
proper type of brake fluid for your vehicle is
also identified on the original factory installed
hydraulic master cylinder reservoir.
To avoid contamination from foreign matter or
moisture, use only new brake fluid or fluid that
has been in a tightly closed container. Keep
the master cylinder reservoir cap secured at
all times. Brake fluid in an open container
absorbs moisture from the air resulting in a
lower boiling point. This may cause it to boil
unexpectedly during hard or prolonged
braking, 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 contam -
inate the brake fluid. Brake seal components
could be damaged, causing partial or
complete brake failure. This could result in a
collision.
CAUTION!
Do not use chemical flushes in your
transmission as the chemicals can damage your
transmission components. Such damage is not
covered by the New Vehicle Limited Warranty.
WARNING!
22_DPF_OM_EN_USC_t.book Page 358
SERVICING AND MAINTENANCE359
Fluid Level Check — 8-Speed Transmission
The fluid level is preset at the factory and does not
require adjustment under normal operating
conditions. Routine fluid level checks are not
required, therefore the transmission has no
dipstick. An authorized dealer can check your
transmission fluid level using special service tools.
If you notice fluid leakage or transmission
malfunction, visit an authorized dealer
immediately to have the transmission fluid level
checked. Operating the vehicle with an improper
fluid level can cause severe transmission damage.
Fluid Level Check — 6-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 Ú page 81.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 Ú page 407. 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 trans -
mission service or fluid change. Re-check the fluid
level, and adjust as required, once the trans -
mission reaches normal operating temperature.
8. Reinsert the dipstick. Check for leaks. Release the parking brake.
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.
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
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360SERVICING AND MAINTENANCE
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 trans -
mission service or fluid change. Re-check the fluid
level, and adjust as required, once the trans -
mission reaches normal operating temperature.
Fluid And Filter Changes — 8-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 — 6-Speed
Transmission
For the proper maintenance intervals Úpage 329.
In addition, change the fluid and filters if the fluid
becomes contaminated (with water, etc.), or if the
transmission is disassembled for any reason.
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 Ú page 407. It is important to
maintain the transmission fluid at the correct level
using the recommended fluid. No chemical flushes
should be used in any transmission; only the
approved lubricant should be used.
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. This inspection
should be made with the vehicle in a level position.
When checking the fluid level, the vehicle should
be in a level position. The fluid level at room
temperature should be as follows:
3500 Front Axle: ¼ inch ± ¼ inch (6.4 mm ±
6.4 mm) below the bottom of the fill hole.
3500 Rear Axle: ¼ inch ± ¼ inch (6.4 mm ±
6.4 mm) below the bottom of the fill hole.
4500/5500 Front Axle: ¼ inch +/- ¼ inch (6.4 mm
± 6.4 mm) below the bottom of the fill hole.
4500/5500 Rear Axle: 1/8 inch +/- 1/8 inch
(3.2 mm +/- 3.2 mm) below the bottom of the fill
hole.
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!
Using a transmission fluid other than the
manufacturer’s recommended fluid may cause
deterioration in transmission shift quality and/or
torque converter shudder, and (for 6-speed
transmissions) will require more frequent fluid
and filter changes Ú page 407.
22_DPF_OM_EN_USC_t.book Page 360
SERVICING AND MAINTENANCE361
Drain And Refill
On 4500/5500 vehicles, remove the lower bolt to
drain the axle fluid.
4500/5500 Rear Axle Plugs
For the proper maintenance intervals Úpage 329.
Lubricant Selection
For further information Ú page 407.
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).
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 operation of the
limited slip differential.
TRANSFER CASE
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
For the proper maintenance intervals Úpage 329.
Selection Of Lubricant
Use only the manufacturer's recommended fluid
Úpage 407.
NOISE CONTROL SYSTEM REQUIRED
M
AINTENANCE & WARRANTY
All vehicles built over 10,000 lb (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.
1 — 4500/5500 Rear Axle Fluid Fill Plug
2 — 4500/5500 Rear Axle Fluid Drain Plug
8
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368SERVICING AND MAINTENANCE
F43 –15 Amp Blue Heated Strng Wheel *
F44 –10 Amp Red Diagnostic Port
F45 ––Spare
F46 –10 Amp Red Upfitters Relay Coils *
F47 ––Spare
F48 ––Spare
F49 –10 Amp Red IP Cluster / CSG
F50 –20 Amp Yellow Air Suspension Mod *
F51 –10 Amp Red IGN Mod / KIN Mod/ RF Hub
F52 –5 Amp Tan Batt Snsr
F53 –20 Amp Yellow Trlr Tow – Lt Turn/Stop
F54 –20 Amp Yellow Non-Memory Adjustable Pedals *
F55 ––Spare
F56 –10 Amp Red Fuel Vapor Blocking Valve (VBV) *
F57 –20 Amp Yellow TCM / PCM / Trans PRSR SW
F58 –10 Amp Red Bed Lighting
F59 ––Spare
F60 ––Spare
F61 –10 Amp Red NH3 Sensor / PM Sensor *
F62 –10 Amp Red A/C Clutch
CavityCartridge Fuse Micro Fuse Description
* If Equipped
22_DPF_OM_EN_USC_t.book Page 368
SERVICING AND MAINTENANCE369
F63 –20 Amp Yellow Ignition Coils / CAPS
F64 –25 Amp Clear Fuel Injectors
F65 ––Spare
F66 –10 Amp RedSunroof / USB Rear * / Inside Rearview Mirror / Passenger
Window SW
F67 –10 Amp Red
UCI Port / USB Front / Trailer Gateway Module (360 Camera) /
Tachograph
F68 –10 Amp Red AEB RACAM HTR *
F69 –15 Amp Blue SCR Mod 12 Volt *
F70 –30 Amp Green Fuel Pump Mtr/ Fuel Htr RLY
F71 –25 Amp Clear Amp / Act Noise Cnsl
F72 ––Spare
F73 –20 Amp Yellow Fuel Transfer Pump *
F74 –10 Amp Red Backup Alarm
F75 –10 Amp Red SCR RLY / ATMM*
F76 –10 Amp Red Electronic Stability Control (ESC) *
F77 –10 Amp Red DTCM / TCM / FAD MOD / STOM
F78 –15 Amp Blue ECM / PCM / IRCM / AUX PDC Relay Coil Feed / HRLS
F79 –15 Amp Blue ID / Clearance Lt
F80 –10 Amp Red Ovrdh Con / Assist / 911
F81 –20 Amp Yellow Trlr tow Rt turn/Stop
Cavity Cartridge Fuse Micro Fuse Description
* If Equipped
8
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