Dodge 5500 Chassis Cab (2008 year). Instruction

2. Connect one end of the other jumper cable to negative
(-) post of booster battery. Connect the other end of the
jumper cable to a good ground on the engine block of the
vehicle with the discharged battery. Make sure a good
connection is made, free of dirt and grease.

WARNING!

• Do not connect the cable to the negative post of the

discharge battery. The resulting electrical spark
could cause the battery to explode.

• During cold weather when temperatures are be-

low freezing point, electrolyte in a discharged
battery may freeze. Do not attempt jump starting
because the battery could rupture or explode. The
battery temperature must be brought up above
freezing point before attempting jump start.

3. Take care that the clamps from one cable do not
inadvertently touch clamps from the other cable. Do not
lean over the battery when making connection. The
negative connection must provide good electrical con-
ductivity and current carrying capacity.

4. After the engine is started or if the engine fails to start,
cables must be disconnected in the following order:

a. Disconnect the negative cable at the engine ground.

b. Disconnect the negative cable at the negative post
on booster battery.

c. Disconnect the cable from the positive post of both
batteries.

392

WHAT TO DO IN EMERGENCIES

WARNING!

Any procedure other than above could result in:

1. Personal injury caused by electrolyte squirting out
the battery vent;

2. Personal injury or property damage due to battery
explosion;

3. Damage to charging system of booster vehicle or
of immobilized vehicle.

With Portable Starting Unit

There are many types of these units available. Follow the
manufacturer’s instructions for necessary precautions
and operation.

CAUTION!

It is very important that the starting unit operating
voltage does not exceed 12 Volts D.C. or damage to
battery, starter motor, alternator, or electrical system
may occur.

FREEING A STUCK VEHICLE

If vehicle becomes stuck in snow, sand, or mud, it can
often be moved by a rocking motion. Move the gear
selector rhythmically between DRIVE and REVERSE
(automatic transmissions) and between 1st and RE-
VERSE (instruction transmissions), while applying slight
pressure to the accelerator.

WHAT TO DO IN EMERGENCIES

393

In general, the least amount of accelerator pedal pressure
to maintain the rocking motion without spinning the
wheels or racing the engine is most effective. Racing the
engine or spinning the wheels, due to the frustration of
not freeing the vehicle, may lead to transmission over-
heating and failure. Allow the engine to idle with the
transmission selector in NEUTRAL for at least one
minute after every five rocking-motion cycles. This will
minimize overheating and reduce the risk of transmis-
sion failure during prolonged efforts to free a stuck
vehicle.

EMERGENCY TOW HOOKS — IF EQUIPPED

Your vehicle may be equipped with emergency tow
hooks.

NOTE:

For off-road recovery, it is recommended to use

both of the front tow hooks to minimize the risk of
damage to the vehicle.

WARNING!

Chains are not recommended for freeing a stuck
vehicle. Chains may break, causing serious injury or
death.

394

WHAT TO DO IN EMERGENCIES

WARNING!

Stand clear of vehicles when pulling with tow hooks.
Tow straps and chains may break, causing serious
injury.

CAUTION!

Tow hooks are for emergency use only, to rescue a
vehicle stranded off road. Do not use tow hooks for
tow truck hookup or highway towing. You could
damage your vehicle.

TOWING A DISABLED VEHICLE

Proper towing or lifting equipment is required to prevent
damage to your vehicle. Use only tow bars and other
equipment designed for the purpose, following equip-
ment manufacturer’s instructions. Use of safety chains is
mandatory. Attach a tow bar or other towing device to
the main structural members of the vehicle—not to
bumpers or associated brackets. State and local laws
applying to vehicles under tow must be observed.

WHAT TO DO IN EMERGENCIES

395

4-Wheel- Drive Vehicles

CAUTION!

To avoid damage to the transfer case while towing,
always use one of the following methods.

NOTE:

The Transfer Case must be in the neutral posi-

tion, and the transmission must be in Park (Automatic
Transmission), or in gear (Instruction Transmission) to tow a
4WD vehicle with one end of the vehicle raised.

The manufacturer recommends towing with all wheels
OFF

the ground. Acceptable methods are to tow vehicle

on a flatbed or with one end of vehicle raised and the
opposite end on a towing dolly.

2–Wheel- Drive Vehicles

Provided that transmission is operable, tow on a flatbed
or with the front wheels raised and the rear wheels on a
dolly.

396

WHAT TO DO IN EMERGENCIES

MAINTAINING YOUR VEHICLE

CONTENTS

m Engine Compartment — 6.7L Diesel Engine . . . . 400
m Engine Compartment— 5.7L Gas Engine . . . . . . 401
m Onboard Diagnostic System (OBD II) . . . . . . . . . 402

▫ Loose Fuel Filler Cap Message . . . . . . . . . . . . 402

m Replacement Parts . . . . . . . . . . . . . . . . . . . . . . 403
m Engine Data Plate . . . . . . . . . . . . . . . . . . . . . . 403
m Dealer Service . . . . . . . . . . . . . . . . . . . . . . . . . 403
m Service Information . . . . . . . . . . . . . . . . . . . . . 404
m Maintenance Procedures . . . . . . . . . . . . . . . . . . 406

▫ Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 406
▫ Drive Belts (Gas Engines) . . . . . . . . . . . . . . . 413
▫ Drive Belt (Diesel Engines) . . . . . . . . . . . . . . 413
▫ Engine Air Cleaner Filter (Gas Engines) . . . . . 413
▫ Engine Air Cleaner Filter (Diesel Engines) . . . . 414
▫ Draining Fuel/Water Separator Filter (Diesel

Engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417

▫ Engine Fuel Filter (Gas Engines) . . . . . . . . . . . 420
▫ Spark Plugs (Gas Engines) . . . . . . . . . . . . . . . 420

▫ Catalytic Converter (Gas Engines) . . . . . . . . . 420
▫ Intervention Regeneration Strategy – EVIC

Message Process Flow (Catalyst Full Message)
(Diesel Engines Only) . . . . . . . . . . . . . . . . . . 422

▫ Emission-Related Components (Gas Engines) . . 425
▫ Maintenance Free Battery (Gas Engines) . . . . . 425
▫ Maintenance Free Batteries (Diesel Engines) . . . 426
▫ Air Conditioner Maintenance . . . . . . . . . . . . . 427
▫ Power Steering — Fluid Check . . . . . . . . . . . . 428
▫ Front Suspension Ball Joints . . . . . . . . . . . . . . 429
▫ Steering Linkage — Inspection . . . . . . . . . . . . 429
▫ Front Prop Shaft Lubrication . . . . . . . . . . . . . 430
▫ Front Axle Universal Drive Joints And

Ball Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

▫ Body Lubrication . . . . . . . . . . . . . . . . . . . . . 430
▫ Windshield Wiper Blades . . . . . . . . . . . . . . . . 431
▫ Windshield Washers . . . . . . . . . . . . . . . . . . . 431
▫ Exhaust System . . . . . . . . . . . . . . . . . . . . . . 432
▫ Cooling System . . . . . . . . . . . . . . . . . . . . . . . 433
▫ Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
▫ Charge Air Cooler — Inter-Cooler

(Diesel Engines) . . . . . . . . . . . . . . . . . . . . . . 439

▫ Hoses And Vacuum/Vapor Harnesses . . . . . . . 440
▫ Fuel System Connections . . . . . . . . . . . . . . . . 440
▫ Brake System . . . . . . . . . . . . . . . . . . . . . . . . 440
▫ Clutch Hydraulic System . . . . . . . . . . . . . . . . 443
▫ Clutch Linkage . . . . . . . . . . . . . . . . . . . . . . . 443

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MAINTAINING YOUR VEHICLE

▫ Rear Axle And 4X4 Front Driving Axle

Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . 443

▫ Transfer Case — If Equipped . . . . . . . . . . . . . 445
▫ Instruction Transmission — If Equipped . . . . . . . 445
▫ Automatic Transmission (Gas Engine Only) . . . 446
▫ Automatic Transmission (Diesel Engine

Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448

▫ Front And Rear Wheel Bearings . . . . . . . . . . . 451
▫ Noise Control System Required Maintenance

& Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 451

▫ Appearance Care And Protection From

Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 457

m Fuses (Integrated Power Module) . . . . . . . . . . . 462

m Vehicle Storage . . . . . . . . . . . . . . . . . . . . . . . . 467
m Replacement Light Bulbs . . . . . . . . . . . . . . . . . 468
m Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . 468

▫ Headlight (Halogen)/Front Park And Turn

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468

▫ Fog Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 472
▫ Cab Top Clearance Lights — If Equipped . . . . 473

m Fluid And Capacities . . . . . . . . . . . . . . . . . . . . 474
m Fluids, Lubricants And Genuine Parts . . . . . . . . 476

▫ Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
▫ Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478

MAINTAINING YOUR VEHICLE

399

ONBOARD DIAGNOSTIC SYSTEM (OBD II)

Vehicles equipped with California emissions controls
have a sophisticated onboard diagnostic system called
OBDII. This system monitors the performance of the
emissions, engine, and automatic transmission control
systems. When these systems are operating properly,
your vehicle will provide excellent performance and fuel
economy, as well as engine emissions well within current
government regulations.

If any of these systems require service, the OBD II system
will turn on the “Malfunction Indicator Light.” It will
also store diagnostic codes and other information to
assist your service technician in making repairs. Al-
though your vehicle will usually be driveable and not
need towing, see your dealer for service as soon as
possible.

CAUTION!

Prolonged driving with the “Malfunction Indicator
Light” on could cause further damage to the emission
control system. It could also affect fuel economy and
driveability. The vehicle must be serviced before any
emissions tests can be performed.

If the “Malfunction Indicator Light” is flashing,
severe catalytic converter damage and power loss
will soon occur. Immediate service is required.

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

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MAINTAINING YOUR VEHICLE

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.

REPLACEMENT PARTS

Use of genuine Mopar

t parts for normal/scheduled

maintenance and repairs is highly recommended to in-
sure the designed performance. Damage or failures
caused by the use of non-Mopar parts for maintenance
and repairs will not be covered by the manufacturer’s
warranty.

ENGINE DATA PLATE

Use the information from the engine data plate when
discussing service or sourcing parts for your engine. The
engine data plate is located on the intake side of the
breather cover.

DEALER SERVICE

Your dealer has the qualified service personnel, special
tools and equipment to perform all service operations in
an expert manner. Service instructions are available which
include detailed service information for your vehicle.
Refer to these instructions before attempting any procedure
yourself.

NOTE:

Intentional tampering with emissions control

systems can result in civil penalties being assessed
against you.

MAINTAINING YOUR VEHICLE

403

WARNING!

You can be badly injured working on or around a
motor vehicle. Do only that service work for which
you have the knowledge and the proper equipment.
If you have any doubt about your ability to perform
a service job, take your vehicle to a competent
mechanic.

SERVICE INFORMATION

Mopar Fluids, Lubricants and Parts are available from
your dealer and will help you keep your vehicle operat-
ing at its best. Your dealer also has the qualified service
personnel, special tools and equipment to perform all
service operations in an expert manner. Service instructions
are available which include detailed service information

for your vehicle. Refer to these instructions before attempt-
ing any procedure yourself. See Service Publications
information at the back of this instruction.

CAUTION!

To maintain your vehicle safely follow these
guidelines:

• Watch your vehicle’s mileage and check your Mainte-

nance Schedules

regularly for required servicing. Ex-

cessive wear or damage to certain vehicle components
can result if required services are not performed.

• If you have your vehicle undercoated, inspect for

undercoating material on the propeller shafts. Such
material could cause the shafts to become unbalanced
and result in drivetrain vibrations. Remove any under-
coating with solvent.

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MAINTAINING YOUR VEHICLE

• If you have your vehicle undercoated, make sure no

undercoating material is sprayed on the exhaust sys-
tem or components of the seat belt system.

NOTE:

It is not possible for the manufacturer and

Cummins, Inc. to anticipate every possible circumstance
that can involve a potential hazard.

WARNING!

To maintain your vehicle safely and avoid personal
injury, follow these guidelines:

• Never spray or pour diesel fuel, flammable liquid or

starting fluids (ether) into the air cleaner assembly, air
intake piping or turbocharger inlet in an attempt to
start the vehicle, unintended engine acceleration may
occur.

• Do not use alcohol or gasoline as a fuel blending agent.

They can be unstable under certain conditions and be
hazardous or explosive when mixed with diesel fuel.

• If an engine has been operating and the coolant is hot,

allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling
system.

• To avoid burns, remember that the engine components

will stay hot after the engine is shut off.

• Do not use gasoline or other flammable materials to

clean parts. Always use approved cleaning solvents.

• Relieve all pressure in the fuel, oil and cooling systems

before any lines, fittings or related items are removed
or disconnected. Be alert for possible pressure when
disconnecting any device from a system that utilizes

MAINTAINING YOUR VEHICLE

405

pressure. Do not check for pressure leaks with your
hand. High pressure oil or fuel can cause personal
injury.

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.

• Important: All maintenance other than that listed in

this instruction, as well as some procedures listed here,
MUST

be performed by your local Dodge Truck

Dealer. Your authorized Dodge Dealer has been
trained and has the necessary parts to maintain your
engine.

MAINTENANCE PROCEDURES

The pages that follow contain the required maintenance
services determined by the engineers who designed your
vehicle.

Besides the maintenance items for which there are fixed
maintenance intervals, there are other items that should
operate satisfactorily without periodic maintenance.
However, if a malfunction of these items does occur, it
could adversely affect the engine or vehicle performance.
These items should be inspected if a malfunction is
observed or suspected.

Engine Oil

Checking Oil Level
To assure proper lubrication of your vehicle’s engine, the
engine oil must be maintained at the correct level. Check
the oil level at regular intervals. The best time to check
the oil level is before starting the engine after it has been
parked overnight. When checking oil after operating the

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MAINTAINING YOUR VEHICLE

engine, first ensure the engine is at full operating tem-
perature, then wait for 30 minutes (6.7L Diesel Engine),
and 15 minutes (5.7L Gas Engine) after engine shutdown
to check the oil.

Checking the oil while the vehicle is on level ground will
improve the accuracy of the oil level readings. Always
maintain the oil level within the SAFE zone on the
dipstick. Adding one quart of oil when the reading is at
the bottom of the SAFE zone will result in a reading at the
top of the safe zone on these engines.

CAUTION!

Overfilling or underfilling the crankcase will cause
oil aeration or loss of oil pressure. This could damage
your engine.

Never operate the engine with oil level below the “ADD”
mark or above the upper “SAFE” mark.

Change Engine Oil (Gas Engines)
Follow the Gas Engine Maintenance Schedule for recom-
mended engine oil change intervals.

MAINTAINING YOUR VEHICLE

407

Dodge 5500 Chassis Cab (2008 year). Instruction - part 25