Dodge 5500 Chassis Cab (2008 year). Instruction

NOTE:

Tighten the gas cap 1/4 turn until you hear one

click. This is an indication that the cap is properly
tightened.

If the gas cap is not tightened properly, the Malfunction
Indicator Light will come on, Be sure the gas cap is
tightened every time the vehicle is refueled.

WARNING!

A fire may result if gasoline is pumped into a
portable container that is inside of a vehicle. You
could be burned. Always place gas containers on the
ground while filling.

Loose Fuel Filler Cap Message
If the vehicles diagnostic system determines that the fuel
filler cap in loose, improperly installed, or damaged, a
GASCAP message will be displayed in the instrument
cluster. Tighten the gas cap until a “clicking” sound is
heard. This is an indication that the gas cap is properly
tightened. Press the odometer reset button to turn the
message off. If the problem persists, the message will
appear the next time the vehicle is started. This might
indicate a damaged cap. If the problem is detected twice
in a row, the system will turn on the Malfunction
Indicator Light (MIL). Resolving the problem will turn
the MIL light off.

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Adding Fuel (Diesel Engines)

CAUTION!

To avoid fuel spillage and overfilling, do not “top
off” the fuel tank after filling.

NOTE:

• When the fuel nozzle “clicks” or shuts off, the fuel

tank is full.

• Tighten the gas cap until you hear a “clicking” sound.

This is an indication that the gas cap is properly
tightened.

• Make sure that the gas cap is tightened each time the

vehicle is refueled.

WARNING!

A fire may result if fuel is pumped into a portable
container that is on a truck bed. You could be burned.
Always place fuel containers on the ground while
filling.

Fuel Filler Cap (Gas Cap)
If the gas cap is lost or damaged, be sure the replacement
cap is for use with this vehicle.

CAUTION!

Damage to the fuel system or emission control sys-
tem could result from using an improper fuel tank
filler tube cap (gas cap). A poorly fitting cap could let
impurities into the fuel system.

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WARNING!

• Never have any smoking materials lit in or near

the vehicle when the gas cap is removed or the
tank filled.

• Never add fuel to the vehicle when the engine is

running.

Avoid Using Contaminated Fuel
Fuel that is contaminated by water or dirt can cause
severe damage to the engine fuel system. Proper main-
tenance of the engine fuel filter and fuel tank is essential.
(See Section 7 for Maintenance Procedures).

NOTE:

Climatized Ultra Low Sulfur diesel fuel is a

blend of Number 2 Ultra Low Sulfur and Number 1 Ultra
Low Sulfur Diesel fuel which reduces the temperature at
which wax crystals form in the fuel.

Bulk Fuel Storage
If you store quantities of fuel, good maintenance of the
stored fuel is also essential. Fuel contaminated with
water will promote the growth of “microbes.” These
microbes form “slime” that will clog fuel filters and lines.
Drain condensation from the supply tank and change the
line filter on a regular basis.

NOTE:

When a diesel engine is allowed to run out of

fuel, air is pulled into the fuel system.

You may try priming as described below. However, if the
engine will not start, refer to the fuel priming procedure
in the Service Instruction or have the vehicle towed to an
authorized Dodge dealer.

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WARNING!

Do not open the high pressure fuel system with the
engine running. Engine operation causes high fuel
pressure. High pressure fuel spray can cause serious
injury or death.

Priming if the engine has run out of fuel

1. Add a substantial quantity of fuel to the tank 5 to 10
gallons (19 to 38L).

2. Crank the engine for 1 to 2 seconds. If the engine does
not start, then release the key or starter button back to the
RUN position (do not turn the key back to the OFF
position). The electric fuel transfer pump will continue to
run and purge air from the system for about 20 seconds.
After 20 seconds, attempt to start the engine again.

3. Start the engine using the Normal Starting Procedure.

4. Repeat the procedure if the engine does not start.

CAUTION!

Do not engage the starter motor for more than 15
seconds at a time. Allow two minutes between the
cranking intervals.

NOTE:

The engine may run rough until the air is forced

from all the fuel lines.

VEHICLE LOADING

Certification Label

As required by National Highway Traffic Safety Admin-
istration Regulations, your vehicle has a certification
label affixed to the driver’s side door or pillar.

This label contains the month and year of manufacture,
Gross Vehicle Weight Rating (GVWR), Gross Axle Weight

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347

Rating (GAWR) front and rear, and Vehicle Identification
Number (VIN). A Month-Day-Hour (MDH) number is
included on this label and indicates the Month, Day and
Hour of manufacture. The bar code that appears on the
bottom of the label is your Vehicle Identification Number
(VIN).

Gross Vehicle Weight Rating (GVWR)
The GVWR is the total permissible weight of your vehicle
including driver, passengers, vehicle, options and cargo.
The label also specifies maximum capacities of front and
rear axle systems (GAWR). Total load must be limited so
GVWR and front and rear GAWR are not exceeded.

Payload
The payload of a vehicle is defined as the allowable load
weight a truck can carry, including the weight of the
driver, all passengers, options and cargo.

Gross Axle Weight Rating (GAWR)
The GAWR is the maximum permissible load on the front
and rear axles. The load must be distributed in the cargo
area so that the GAWR of each axle is not exceeded.

Each axle GAWR is determined by the components in the
system with the lowest load carrying capacity (axle,
springs, tires or wheels). Heavier axles or suspension
components sometimes specified by purchasers for in-
creased durability does not necessarily increase the vehi-
cle’s GVWR.

Tire Size
The tire size on the Label represents the actual tire size on
your vehicle. Replacement tires must be equal to the load
capacity of this tire size.

Rim Size
This is the rim size that is appropriate for the tire size
listed.

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Inflation Pressure
This is the cold tire inflation pressure for your vehicle for
all loading conditions up to full GAWR.

Curb Weight
The curb weight of a vehicle is defined as the total weight
of the vehicle with all fluids, including vehicle fuel, at full
capacity conditions, and with no occupants or cargo
loaded into the vehicle. The front and rear curb weight
values are determined by weighing your vehicle on a
commercial scale before any occupants or cargo are
added.

Loading
The actual total weight and the weight of the front and
rear of your vehicle at the ground can best be determined
by weighing it when it is loaded and ready for operation.

The entire vehicle should first be weighed on a commer-
cial scale to insure that the GVWR has not been exceeded.
The weight on the front and rear of the vehicle should
then be determined separately to be sure that the load is
properly distributed over front and rear axle. Weighing
the vehicle may show that the GAWR of either the front
or rear axles has been exceeded but the total load is
within the specified GVWR. If so, weight must be shifted
from front to rear or rear to front as appropriate until the
specified weight limitations are met. Store the heavier
items down low and be sure that the weight is distributed
equally. Stow all loose items securely before driving.

Improper weight distributions can have an adverse effect
on the way your vehicle steers and handles and the way
the brakes operate.

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CAUTION!

Do not load your vehicle any heavier than the GVWR
or the maximum front and rear GAWR. If you do,
parts on your vehicle can break, or it can change the
way your vehicle handles. This could cause you to
lose control. Also overloading can shorten the life of
your vehicle.

An EXAMPLE of a loaded vehicle is shown in the
following chart. Note that neither GVWR nor GAWR
capabilities are exceeded. Overloading can cause poten-
tial safety hazards and shorten service life.

NOTE:

The weights shown in this chart are not

necessarily the weights for your vehicle. Also, the
amount of load added to both the front and rear axles

can be computed after the vehicle has been weighed
both in its

(curb weight( condition, and in its (loaded

and ready for operation

( condition.

Gross Vehicle Weight Rating (GVWR) 6500 LBS.

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TRAILER TOWING

In this section you will find safety tips and information
on limits to the type of towing you can reasonably do
with your vehicle. Before towing a trailer carefully re-
view this information to tow your load as efficiently and
safely as possible.

To maintain warranty coverage, follow the requirements
and recommendations in this instruction concerning ve-
hicles used for trailer towing.

Common Towing Definitions

The following trailer towing related definitions will assist
you in understanding the following information:

Gross Vehicle Weight Rating (GVWR)
The GVWR is the total allowable weight of your vehicle.
This includes driver, passengers, cargo and tongue
weight. The total load must be limited so that you do not
exceed the GVWR.

Gross Trailer Weight (GTW)
The gross trailer weight (GTW) is the weight of the trailer
plus the weight of all cargo, consumables and equipment
(permanent or temporary) loaded in or on the trailer in its

9loaded and ready for operation9 condition. The recom-
mended way to measure GTW is to put your fully loaded
trailer on a vehicle scale. The entire weight of the trailer
must be supported by the scale.

Gross Combination Weight Rating (GCWR)
The gross combination weight rating (GCWR) is the total
permissible weight of your vehicle and trailer when
weighed in combination. (Note that GCWR ratings in-
clude a 68 kg (150 lbs) allowance for the presence of a
driver).

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Gross Axle Weight Rating (GAWR)
The GAWR is the maximum capacity of the front and rear
axles. Distribute the load over the front and rear axles
evenly. Make sure that you do not exceed either front or
rear GAWR.

WARNING!

It is important that you do not exceed the maximum
front or rear GAWR. A dangerous driving condition
can result if either rating is exceeded. You could lose
control of the vehicle and have an accident.

Tongue Weight (TW)
The downward force exerted on the hitch ball by the
trailer. In most cases it should not be less than 10% or
more than 15% of the trailer load. You must consider this
as part of the load on your vehicle.

Frontal Area
The maximum height and maximum width of the front of
a trailer.

Trailer Sway Control
The trailer sway control is a telescoping link that can be
installed between the hitch receiver and the trailer tongue
that typically provides adjustable friction associated with
the telescoping motion to dampen any unwanted trailer
swaying motions while traveling.

Weight-Carrying Hitch
A weight-carrying hitch supports the trailer tongue
weight, just as if it were luggage located at a hitch ball or
some other connecting point of the truck. These kind of
hitches are the most popular on the market today and
they’re commonly used to tow small- and medium-sized
trailers.

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Weight-Distributing Hitch
A weight-distributing system works by applying lever-
age through spring (load) bars. They are typically used
for heavier loads, to distribute trailer tongue weight to
the tow vehicle’s front axle and the trailer axle(s). When
used in accordance with the manufacturers’ directions, it
provides for a more level ride, offering more consistent
steering and brake control thereby enhancing towing
safety. The addition of a friction / hydraulic sway control
also dampens sway caused by traffic and crosswinds and
contributes positively to tow vehicle and trailer stability.
Trailer sway control and a weight distributing (load
equalizing) hitch are recommended for heavier Tongue
Weights (TW) and may be required depending on Vehicle
and Trailer configuration / loading to comply with gross
axle weight rating (GAWR) requirements.

WARNING!

An improperly adjusted Weight Distributing Hitch
system may reduce handling, stability, braking per-
formance, and could result in an accident.

Weight Distributing Systems may not be compatible
with Surge Brake Couplers. Consult with your hitch
and trailer manufacturer or a reputable Recreational
Vehicle dealer for additional information.

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Fifth-Wheel Hitch
A special high platform with a coupling that mounts over
the rear axle of the tow vehicle in the truck bed. Connects
a vehicle and fifth-wheel trailer with a coupling king pin.

Gooseneck Hitch
The gooseneck hitch employs a pivoted coupling arm
which attaches to a ball mounted in the bed of a pickup
truck. The coupling arm connects to the hitch mounted
over the rear axle in the truck bed.

Trailer Hitch Classification

The rear bumper is intended to tow trailers up to 2,000
lbs (907 kg) without added equipment or alterations to
the standard equipment. Your vehicle may be factory
equipped for safe towing of trailers weighing over 2,000
lbs (907 kg) with the optional Trailer Tow Prep Package.
See your dealer for package content.

The following chart provides the industry standard for
the maximum trailer weight a given trailer hitch class can

tow and should be used to assist you in selecting the
correct trailer hitch for your intended towing condition.
Refer to “Trailer Towing Weights (Maximum Trailer
Weight Ratings)” for the website address that contains
the necessary information for your specific drivetrain.

Trailer Hitch Classification

Class

Max. GTW

(Gross Trailer Wt.)

Class I - Light Duty

2,000 lbs (907 kg)

Class II - Medium
Duty

3,500 lbs (1587 kg)

Class III - Heavy Duty

5,000 lbs (2268 kg)

Class IV - Extra
Heavy Duty

10,000 lbs (4540 kg)

Fifth Wheel/
Gooseneck

Greater than 10,000 lbs

(4540 kg)

All trailer hitches should be professionally installed on
your vehicle.

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Trailer Towing Weights (Maximum Trailer Weight
Ratings)

NOTE:

For additional trailer towing information (maxi-

mum trailer weight ratings) refer to the following website
addresses:

• http:// www.dodge.com/towing.
• http:// www.dodge.ca (Canada).

Trailer and Tongue Weight

Always load a trailer with 60% to 65% of the weight in
the front of the trailer. This places 10% to 15% of the
Gross Trailer Weight (GTW) on the tow hitch of your
vehicle. Loads balanced over the wheels or heavier in the
rear can cause the trailer to sway severely side to side
which will cause loss of control of vehicle and trailer.
Failure to load trailers heavier in front is the cause of
many trailer accidents.

Never exceed the maximum tongue weight stamped on
your bumper or trailer hitch.

Consider the following items when computing the
weight on the rear axle of the vehicle:

• The tongue weight of the trailer.

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• The weight of any other type of cargo or equipment

put in or on your vehicle.

• The weight of the driver and all passengers.

NOTE:

Remember that everything put into or on the

trailer adds to the load on your vehicle. Also, additional
factory-installed options, or dealer-installed options,
must be considered as part of the total load on your
vehicle. Refer to the Tire and Loading Information plac-
ard in the Tire Safety Information Section of this instruction.

Towing Requirements

To promote proper break-in of your new vehicle driv-
etrain components the following guidelines are recom-
mended:

CAUTION!

• Avoid towing a trailer for the first 500 miles (805

km) of vehicle operation. Doing so may damage
your vehicle.

• During the first 500 miles (805 km) of trailer

towing, limit your speed to 50 mph (80 km/h).

Perform the maintenance listed in Section 8 of this
instruction. When towing a trailer, never exceed the GAWR,
or GCWR, ratings.

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WARNING!

Improper towing can lead to an injury accident.
Follow these guidelines to make your trailer towing
as safe as possible:

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 an accident.

• When hauling cargo or towing a trailer, do not over-

load your vehicle or trailer. Overloading can cause a
loss of control, poor performance or damage to brakes,
axle, engine, transmission, steering, suspension, chas-
sis structure or tires.

• Safety chains must always be used between your

vehicle and trailer. Always connect the chains to the
frame or 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 automatic transmission in
P for Park. With a instruction transmission, shift the
transmission into reverse. And with four-wheel-drive
vehicles, make sure the transfer case is not in neutral.
Always, block or

9chock9 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:

1. GVWR

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2. GTW

3. GAWR

4. Tongue weight rating for the trailer hitch utilized
(This requirement may limit the ability to always
achieve the 10% to 15% range of tongue weight as a
percentage of total trailer weight).

Towing Requirements — Tires

− Do not attempt to tow a trailer while using a compact

spare tire.

− Proper tire inflation pressures are essential to the safe

and satisfactory operation of your vehicle. Refer to the
Tires–General Information section of this instruction on
Tire Pressures for proper tire inflation procedures.

− Also, 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 the Tires–General
Information section of this instruction on Tread Wear
Indicators for the proper inspection procedure.

− When replacing tires refer to the Tires–General Infor-

mation section of this instruction on Replacement Tires for
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 inadequate braking and possible
personal injury.

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Dodge 5500 Chassis Cab (2008 year). Instruction - part 22