Dodge 5500 Chassis Cab (2008 year). Instruction

Engine Block Heater
The engine block heater warms engine coolant and
permits quicker starts in cold weather. Connect the heater
cord to a ground–fault interrupter protected 110–115 volt
AC electrical outlet with a grounded, three-wire exten-
sion cord.

The engine block heater cord is routed under the hood to
the right side and can be located just behind the grille
near the headlamp.

NOTE:

The engine block heater cord is a factory in-

stalled option. If your vehicle is not equipped, heater
cords are available from your authorized Mopar

t dealer.

The block heater must be plugged in at least one hour to
have an adequate warming effect on the coolant.

WARNING!

Remember to disconnect the cord before driving.
Damage to the 110–115 volt electrical cord could
cause electrocution.

NOTE:

The block heater will require 110 Volts AC and

6.5 Amps to activate the heater element.

Block Heater Usage

A. Temperatures below 0°F (-18°C)

• Block Heater Required for 15W-40
• Block Heater Recommended for 5W-40

B. Temperatures below - 20°F (-29°C)

• Block Heater Required for 5W-40

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Winter Front Usage
If a winter front or cold weather cover is to be used, a
percentage of the total grille opening area must be left
uncovered to provide sufficient air flow to the charge air
cooler and automatic transmission oil cooler. The per-
centage of opening must be increased with the increasing
ambient air temperature and/or engine load. If the
cooling fan can be heard cycling frequently, increase the
size of the opening in the winter front. A suitable cold
weather cover is available from your Mopar

t dealer.

Battery Blanket Usage
A battery loses 60% of its cranking power as the battery
temperature decreases to 0°F (-18°). For the same de-
crease in temperature, the engine requires twice as much
power to crank at the same RPM. The use of 120 VAC
powered battery blankets will greatly increase starting
capability at low temperatures. Suitable battery blankets
are available from your authorized Mopar

t dealer.

Arctic Operation
Where there are no provisions to keep the engine warm
when it is operating in ambient temperatures consistently
below (-10°F/-23°C), use 5W-40 synthetic engine oil and
fuel that meets the requirements in Section 7, “Mainte-
nance Procedures,” Engine Oil Selection.

Engine Warm-Up
Avoid full throttle operation when the engine is cold.
When starting a cold engine, bring the engine up to
operating speed slowly to allow the oil pressure to
stabilize as the engine warms up.

NOTE:

High-speed, no-load running of a cold engine

can result in excessive white smoke and poor engine
performance. No-load engine speeds should be kept
under 1,200 rpm during the warm-up period, especially
in cold ambient temperature conditions.

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265

If temperatures are below 32°F (0°C), operate the engine
at moderate speeds for 5 minutes before full loads are
applied.

Engine Idling — In Cold Weather

Avoid prolonged idling in ambient temperatures below
0°F. Long periods of idling may be harmful to your
engine because combustion chamber temperatures can
drop so low that the fuel may not burn completely.
Incomplete combustion allows carbon and varnish to
form on piston rings and injector nozzles. Also, the
unburned fuel can enter the crankcase, diluting the oil
and causing rapid wear to the engine. Excessive idle time
can also cause damage to the engine exhaust aftertreat-
ment system.

NOTE:

An optional driver-controlled high idle speed is

available on automatic transmission equipped vehicles

with speed control. This feature allows the driver to
select an elevated idle speed between 1100 and 1500
rpms. Your dealer can enable this feature.

NOTE:

• If ambient temperatures are low and the coolant

temperature is below 200°F (93°C), the engine idle
speed will slowly increase to 1000 RPM after 2 minutes
of idle, if the following conditions are met:

• foot is off brake pedal and throttle pedal
• automatic transmission is in Park (P)
• vehicle speed is zero
• Applying the throttle will cancel fast idle
• If the engine is equipped with an exhaust brake,

operating the exhaust brake at idle will greatly im-
prove warm up rate and will help keep the engine
close to operating temperature during extended idle.

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Stopping The Engine

Idle the engine a few minutes before routine shutdown.
After full load operation, idle the engine 3 to 5 minutes
before shutting it down. This idle period will allow the
lubricating oil and coolant to carry excess heat away from
the combustion chamber, bearings, internal components,
and turbocharger. This is especially important for turbo-
charged, charge air cooled engines.

NOTE:

During engine shut down on vehicles equipped

with instruction transmissions, it is normal for the diesel
engine to resonate heavily for a moment during engine
shut off. When the engine is connected to a instruction
transmission, this resonance causes load gear rattle from
the transmission. This is commonly referred to as “shut
down rattle”. The manufacturer recommends performing
engine shut down with the clutch pedal pushed to the
floor (clutch disengaged). When engine shut down is
performed in this manner the rattle is reduced (not
eliminated).

Driving

Condition

Load

Turbo-

charger

Temperature

Idle Time

(min.) Be-

fore Engine

Shutdown

Stop and

Empty

Cool

Less than

One

Stop and

Medium

One

Highway

Speeds

Medium

Warm

Two

City Traffic

Maximum

GCWR

Three

Highway

Speeds

Maximum

GCWR

Four

Uphill

Grade

Maximum

GCWR

Hot

Five

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267

Engine Speed Control

CAUTION!

Prevent overspeeding the engine going down hill.
When descending steep grades, use a combination of
gears and service brakes to control vehicle/engine
speed. Overspeed can cause severe engine damage.

Operating Precautions

Avoid Overheating The Engine
The temperature of the coolant (a mixture of 50%
ethylene-glycol and 50% water) must not exceed the
normal range of the temperature gauge (240°F/116°C)
with a 16 psi (110 kPa) radiator cap.

Usually the coolant temperature indicated during opera-
tion will be to the left of center in the normal range of the
gauge.

Avoid Low Coolant Temperature Operation
Continual operation at low coolant temperature below
the normal range on the gauge (140°F/60°C) can be
harmful to the engine. Low coolant temperature can
cause incomplete combustion which allows carbon and
varnish to form on piston rings and injector nozzles.
Also, the unburned fuel can enter the crankcase, diluting
the lubricating oil and causing rapid wear to the engine.

Cooling System Tips — Automatic Transmission

To reduce potential for engine and transmission over-
heating in high ambient temperature conditions, take the
following actions:

• City Driving —
when stopped, put transmission in neutral and increase
engine idle speed.

• Highway Driving —
reduce your speed.

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• Up Steep Hills —
select a lower transmission gear, but try and keep the
torque converter clutch engaged.

• Air Conditioning —
turn it off temporarily.

Do Not Operate The Engine With Low Oil
Pressure
When the engine is at normal operating temperature, the
minimum oil pressures required are:

Idle 700 to 800 RPM . . . . . . . . . . . . . . . 10 psi (69 kPa)
Full speed and load . . . . . . . . . . . . . . 30 psi (207 kPa)

CAUTION!

If oil pressure falls to less than normal readings, shut
the engine off immediately. Failure to do so could
result in immediate and severe engine damage.

Do Not Operate The Engine With Failed Parts
Practically all failures give some warning before the parts
fail. Be on the alert for changes in performance, sounds,
and visual evidence that the engine requires service.
Some important clues are:

• engine misfiring or vibrating severely
• sudden loss of power
• unusual engine noises
• fuel, oil or coolant leaks
• sudden change, outside the normal operating range, in

the engine operating temperature

• excessive smoke
• oil pressure drop

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269

ENGINE BLOCK HEATER (GAS ENGINES)— IF
EQUIPPED

The engine block heater warms engine coolant and
permits quicker starts in cold weather. Connect the cord
to a standard 110-115 volt AC electrical outlet with a
grounded, three-wire extension cord.

The engine block heater cord, on gas engines, is routed
under the hood on the driver side of the vehicle. It has a
removable cap that is located on the driver side of the
Integrated Power Module.

WARNING!

Remember to disconnect the cord before driving.
Damage to the 110-115 volt electrical cord could cause
electrocution.

DIESEL EXHAUST BRAKE (ENGINE BRAKING) –
IF EQUIPPED

The exhaust brake feature will only function when the
driver turns the exhaust brake switch to the on position.
Once the switch is in the on position and the vehicle is
moving faster than 5 MPH; the exhaust brake will
automatically operate when the driver removes pressure
from the accelerator pedal. Exhaust braking is most
effective when the engine RPM is higher. The automatic
transmission has been programmed to downshift more
aggressively when the exhaust brake is enabled to in-
crease brake performance.

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STARTING AND OPERATING

NOTE:

For optimum braking power it is recommended

to use the Exhaust Brake while in Tow/Haul Mode.

The purpose of the exhaust brake (engine braking) fea-
ture is to supply negative (braking) torque to the engine.
Typically, the engine braking is used for, but not limited
to, vehicle towing applications where vehicle braking can
be achieved by the internal engine power, thereby spar-
ing the mechanical brakes of the vehicle.

Benefits of the exhaust brake are:

• vehicle driving control
• reduced brake fade
• longer brake life
• faster cab warm-up.

The exhaust brake feature can also be used to reduce the
engine warm up time. To use the exhaust brake as a
warm-up device, the vehicle must be moving less than 5
MPH, the exhaust brake switch must be in the on
position, and the coolant temperature must below 180 F
and ambient temperature below 60 F.

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STARTING AND OPERATING

AUTOMATIC TRANSMISSION

CAUTION!

Damage to the transmission may occur if the follow-
ing precautions are not observed:
• Shift into PARK only after the vehicle has come to

a complete stop.

• Shift into or out of REVERSE only after the

vehicle has come to a complete stop and the engine
is at idle speed.

• Do not shift from REVERSE, PARK, or NEUTRAL

into any forward gear when the engine is above
idle speed.

• Before shifting into any gear, make sure your foot

is firmly on the brake pedal.

WARNING!

It is dangerous to shift the selector lever out of “P” or
“N” if the engine speed is higher than idle speed. If
your foot is not firmly on the brake pedal, the vehicle
could accelerate quickly forward or in reverse. You
could lose control of the vehicle and hit someone or
something. Only shift into gear when the engine is
idling normally and when your right foot is firmly on
the brake pedal.

Automatic Transmission with Overdrive (5 Speed
545RFE) — If Equipped

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273

lever out of park (P) position (Brake Interlock System). To
drive, move the selector lever from Park or Neutral to the
desired drive position. Pull the selector lever toward you
when shifting into Reverse, Second, First or Park, or
when shifting out of Park.

Gear Ranges
DO NOT race the engine when shifting from Park or
Neutral position into another gear range.

“P” Park
This gear position supplements the parking brake by
locking the transmission. The engine can be started in
this range. Never use Park while the vehicle is in motion.
Apply the parking brake when leaving the vehicle in this
range. Always apply parking brake first, then place the
selector in Park position. On 4-wheel drive vehicles be
sure that the transfer case is in a drive position!

WARNING!

Never use Park position on an automatic transmis-
sion as a substitute for the parking brake. Always
apply parking brake fully when parked to guard
against vehicle movement and possible injury or
damage.

WARNING!

Your vehicle could move and injure you and others if
it is not completely in P (Park). Check by trying to
move the gearshift lever back and forth without first
pulling it toward you after you have set it in P. Make
sure it is in Park before leaving the vehicle.

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STARTING AND OPERATING

WARNING!

“R” Reverse
Use this range only after the vehicle has come to a
complete stop.

“N” Neutral
Shift to Neutral when the vehicle is standing for pro-
longed periods with the engine running. The engine may
be started in this range. Set the parking brake if you must
leave the vehicle.

“D” Drive
This position provides all forward gears, including 3rd
gear direct and 4th or 5th gear overdrive (see Overdrive
Operation). Use this range for most city and highway
driving.

“2” Second
Use this position for driving slowly in heavy city traffic
or on mountain roads where more precise speed control
is desirable. Use it also when climbing long grades, and
for engine braking when descending moderately steep
grades. To prevent excessive engine speed do not exceed
45 mph (72 km/h) in this range.

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275

“1” First
Use this position for driving up very steep hills and for
engine braking at low speeds 20 mph (32 km/h) or less
when going downhill. To prevent excessive engine speed,
do not exceed 25 mph (40 km/h) in this range.

NOTE:

Use caution when operating a heavily loaded

vehicle in “2” Second or “1” First gear selections in high
ambients as torque converter slip can impose significant
additional heat load on the cooling system.

Overdrive Operation
The overdrive automatic transmission contains an elec-
tronically controlled fourth and fifth speed (Overdrive).
The transmission will automatically shift from Drive to
Overdrive if the following conditions are present:

• the transmission selector is in Drive;
• the engine coolant has reached normal operating tem-

perature;

• vehicle speed is above approximately 30 mph (48

km/h);

• the “TOW HAUL O/D OFF” switch has not been

activated;

• transmission has reached normal operating tempera-

ture.

NOTE:

If the vehicle is started in extremely cold tem-

peratures, the transmission may not shift into Overdrive
and will automatically select the most desirable gear for
operation at this temperature. Normal operation will
resume when the transmission fluid temperature has
risen to a suitable level. Refer also to the Note under
torque converter clutch, later in this section.

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STARTING AND OPERATING

If the transmission temperature gets extremely hot, the
transmission will automatically select the most desirable
gear for operation at this temperature. If the transmission
temperature becomes hot enough the TRANS TEMP light
may illuminate and the transmission may downshift out
of Overdrive until the transmission cools down. After
cooldown, the transmission will resume normal opera-
tion.

The transmission will downshift from Overdrive to Drive
if the accelerator pedal is fully depressed at vehicle
speeds above approximately 35 mph (56 km/h).

When To Use “TOW HAUL” and “O/D OFF”
Modes

When driving in hilly areas, towing a trailer, carrying a
heavy load, etc., and frequent transmission shifting oc-
curs, press the “TOW HAUL O/D OFF” button once to
select TOW HAUL. This will improve performance and

Tow Haul O/D Off Switch

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277

reduce the potential for transmission overheating or
failure due to excessive shifting. When operating in
“TOW HAUL” mode, 5th gear is disabled and 2-3 and 3-4
shift patterns are modified. Shifts into Overdrive (4th
gear) are allowed during steady cruise (for improved fuel
economy) and automatic closed-throttle downshifts to
3rd gear (for improved braking) will occur during steady
braking. Pressing the “TOW HAUL O/D OFF” button a
second time to select O/D OFF will disable 4th and 5th
gear completely, which should eliminate any excessive
transmission shifting.

The “TOW HAUL” or “O/D OFF” light will illuminate in
the instrument cluster to indicate when the switch has
been activated. Pressing the switch a third time restores
normal operation. If the “TOW HAUL” or “O/D OFF”
modes are desired, the button must be pressed each time
the engine is started.

When To Lock Out Overdrive
When driving in hilly areas, towing a trailer, carrying a
heavy load, etc., and frequent 4–3–4 transmission shifting
occurs, press the “TOW/HAUL” button twice to disable
the overdrive. This will improve performance and reduce
the potential for transmission overheating or failure due
to excessive shifting.

Torque Converter Clutch
A feature, designed to improve fuel economy, has been
included in the automatic transmission on your vehicle.
A clutch within the torque converter engages automati-
cally at calibrated speeds. This may result in a slightly
different feeling or response during normal operation in
high gear. When the vehicle speed drops or during
acceleration when the transmission downshifts to second
gear, the clutch automatically disengages.

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STARTING AND OPERATING

NOTE:

The torque converter clutch will not engage

until the transmission fluid and engine coolant are warm
[usually after 1-3 miles (1.6 - 4.8 km) of driving]. Because
the engine speed is higher when the torque converter
clutch is not engaged, it may seem as if the transmission
is not shifting into Overdrive when cold. This is normal.
Pressing the “TOW/HAUL” button, when the transmis-
sion is sufficiently warm, will demonstrate that the
transmission is able to shift into and out of overdrive.

NOTE:

If the vehicle has not been driven in several

days, the first few seconds of operation after shifting the
transmission into gear may seem sluggish. This is due to
the fluid partially draining from the torque converter into
the transmission. This condition is normal and will not
cause damage to the transmission. The torque converter
will refill within five seconds of shifting from Park into
any other gear position.

Automatic Transmission (6 Speed AS68RC) — If
Equipped

The gear shift selector display, located in the instrument
panel cluster, indicates the transmission gear range (the
selector is illuminated for night driving). The selector
lever is mounted on the right side of the steering column.
You must depress the brake pedal, to pull the selector
lever out of park (P) position (Brake Interlock System). To
drive, move the selector lever from Park or Neutral to the
desired drive position. Pull the selector lever toward you
when shifting into Reverse, Second, First or Park, or
when shifting out of Park.

Gear Ranges
DO NOT race the engine when shifting from Park or
Neutral position into another gear range.

STARTING AND OPERATING

279

Dodge 5500 Chassis Cab (2008 year). Instruction - part 17