service DODGE DURANGO 2004 2.G Workshop Manual

Brake System
Power Disc Brakes (Front)
Disc brakes do not require adjustment; however, several
hard stops during the break-in period are recommended
to seat the linings and wear off any foreign material.
Brake Master Cylinders
The fluid level in the master cylinders should be checked
whenever the vehicle is serviced, or immediately if the
brake system warning light is on. If necessary, add fluid
to bring level to the full mark on the side of the reservoir
of the brake master cylinder. Be sure to clean the top of
the master cylinder area before removing the cap. With
disc brakes, fluid level can be expected to fall as the brake
pads wear. Brake fluid level should be checked when
pads are replaced. If the brake fluid level is abnormally
low, check system for leaks.
Refer to Recommended Fluids, Lubricants and Genuine
Parts for correct fluid type.
MAINTAINING YOUR VEHICLE 313
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WARNING!
Use of brake fluid that may have a lower initial
boiling point, or is unidentified, as to specifications
may result in sudden brake failure during hard
prolonged braking. You could have an accident.
WARNING!
Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts and the
brake fluid catching on fire.
Use only brake fluid that has been in a tightly closed
container to avoid contamination from foreign matter or
moisture.
CAUTION!
Do not allow a petroleum-base fluid to contaminate
the brake fluid. Seal damage may result.
Brake Hoses
Inspection should be performed whenever the brake
system is serviced or at intervals specified. Inspect hy-
draulic brake hoses for surface cracking, scuffing or worn
spots. If there is any evidence of cracking, scuffing, or
worn spots, the hose should be replaced immediately!
Eventual deterioration of the hose can take place with
possible burst failure.
314 MAINTAINING YOUR VEHICLE

WARNING!
Worn brake hoses can burst and cause brake failure.
You could have an accident. If you see any sign of
cracking, scuffing, or worn spots, have the brake
hoses replaced immediately.
Automatic Transmission
Fluid Level Check ± 3.7L Engine
This fluid level should be checked when the engine is
fully warmed up and the fluid in the transmission is
heated to its normal operating temperature. Operation of
the transmission with an improper fluid level will greatly
reduce the life of the transmission and of the fluid. Check
the fluid whenever the vehicle is serviced for other
reasons.NOTE:Whenever the fluid level is checked, especially
on a vehicle used in severe service, the condition of the
fluid should be noted. If the fluid is dark and has a strong
odor, fluid should be changed.
A physical change in the fluid may be the result of
overheating, resulting in fluid degradation. This is pos-
sible in severe service or if the vehicle is equipped with a
non-factory installed air-conditioning unit.
To check the automatic transmission fluid level properly,
the following procedure must be used:
1. The vehicle must be on level ground.
2. The engine should be running at curb idle speed for a
minimum of 60 seconds.
3. Fully apply parking brake.
4. Place the gear selector briefly in each gear position
ending with the lever in N (Neutral).
MAINTAINING YOUR VEHICLE 315
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dipstick cap to spring back slightly from its fully seated
position, as long as its seal remains engaged in the
dipstick tube.
Automatic Transmission Fluid And Filter Change
To obtain best performance and long life for automatic
transmissions, the manufacturer recommends that they
be given regular maintenance service by an Authorized
Dodge Dealer or Service Center. It is important that the
transmission be adjusted periodically, the fluid main-
tained at the correct level, and that it be drained and
refilled as specified.
Follow the proper Maintenance Schedule for your type of
driving.
It is important that proper lubricant is used in the
transmission. Refer to Recommended Fluids, Lubricants
and Genuine Parts for correct fluid type. It is important
that the transmission fluid be maintained at the pre-
scribed level using the recommended fluid.
CAUTION!
Using a transmission fluid other than the manufac-
turers recommended fluid may cause deterioration
in transmission shift quality and/or torque converter
shudder. Using a transmission fluid other than the
manufacturers recommended fluid will result in
more frequent fluid and filter changes. Refer to
Recommended Fluids, Lubricants and Genuine Parts
for correct fluid type.
Special Additives
The manufacturer strongly recommends against the ad-
dition of any additives to the transmission. Exception to
this policy is the use of special dyes to aid in detecting
fluid leaks. The use of transmission sealers should be
avoided, since they may adversely affect seals.
318 MAINTAINING YOUR VEHICLE

Transfer Case
Inspect the transfer case for fluid leaks. If a fluid leak is
evident the transfer case fluid level may be low. Have the
transfer case serviced immediately.
CAUTION!
Damage may result from operation of the vehicle
with low transfer case fluid.
The transfer case fluid should be drained and refilled at
the intervals specified.
Lubricant Selection
Refer to Recommended Fluids, Lubricants and Genuine
Parts for correct fluid type.
Axles
Refer to Recommended Fluids, Lubricants and Genuine
Parts for correct fluid type.
The manufacturer does not recommend regularly sched-
uled oil changes for axles in vehicles whose operation is
classified as normal truck service.
NOTE:The presence of water in the gear lubricant will
result in corrosion and possible failure of differential
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.
Rear Axle
Rear Axle fluid levels should be 7/89(22 mm) below the
fill plug hole for 8 1/49axles, and 1 5/89(41 mm) below
the fill plug hole for 9 1/49axles.
MAINTAINING YOUR VEHICLE 319
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REPLACEMENT LIGHT BULBS
Dome Light........................WL212±2
Liftgate Lamp........................... 567
Overhead Console Lights............. PLW214±2A
Reading Light.......................WL212±2
Visor Vanity Lights............... NotServiceable
LIGHT BULBS Ð Outside Bulb No.
Headlight............................. H13
Front Park and Turn Sidemarker...........3457AK
Front Auxilliary Park...................... 194
Back-Up..............................3057
Center High Mounted Stoplight.............. 921
Fog Lamp...........................9006LL
Rear Sidemarker......................... 168
License Plate Light....................... 168
Rear Tail, Stop, Turn Signal.................3057
BULB REPLACEMENT
Headlights/Parking/Turn Signal
1. Remove the two bolts attaching the headlight to the
inner fender panel.
MAINTAINING YOUR VEHICLE 327
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EMISSION CONTROL SYSTEM MAINTENANCE
The ªScheduledº maintenance services, listed inbold
typeon the following pages must be done at the times or
mileages specified to assure the continued proper func-
tioning of the emission control system. These, and all
other maintenance services included in this manual,
should be done to provide best vehicle performance and
reliability. More frequent maintenance may be needed for
vehicles in severe operating conditions such as dusty
areas and very short trip driving.
Inspection and service also should be done any time a
malfunction is suspected.
NOTE:Maintenance, replacement, or repair of the emis-
sion control devices and systems on your vehicle may be
performed by any automotive repair establishment or
individual using any automotive part which has been
certified pursuant to U.S. EPA or, in the State of Califor-
nia, California Air Resources Board regulations.
EMISSIONS TESTING
In some localities, it may be or will become a legal
requirement to ensure that all emissions components and
systems are functioning properly as a part of the test
procedure. The test center accomplishes this by checking
the On Board Diagnostic System (OBD) system with an
electronic scan tool. If your vehicle has recently been
serviced, the OBD system may have been reset to a9not
ready9condition because the OBD system has not had
sufficient time since the servicing to reconfirm that
emissions components are operating properly. In most
cases, a reasonable mix and amount of normal city and
highway driving and at least one overnight-off period
will be required to prepare your vehicle for this check;
however your dealer has the equipment and procedures
required to make certain that the OBD system of your
vehicle is ready for the required testing.
340 MAINTENANCE SCHEDULES
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MAINTENANCE SCHEDULES
There are two maintenance schedules that show the
requiredservice for your vehicle.
First is ScheduleªBº. It is for vehicles that are operated
under the conditions that are listed below and at the
beginning of the schedule.
²Day or night temperatures are below 32É F (0É C).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 10 miles (16 km).
²More than 50% of your driving is at sustained high
speeds during hot weather, above 90É F (32É C).
²Trailer towing.
²Taxi, police, or delivery service (commercial service).
²Off-road or desert operation.
²If equipped for and operating with E-85 (ethanol)
fuel.
NOTE:IfANYof these apply to you then change your
engine oil every 3,000 miles (5 000 km) or 3 months,
whichever comes first and follow schedule ªBº of the
9Maintenance Schedules9section of this manual.
NOTE:Most vehicles are operated under the conditions
listed for Schedule9B9.
Second is ScheduleªAº. It is for vehicles that are not
operated under any of the conditions listed under Sched-
ule9B9.
Use the schedule that best describes your driving condi-
tions. Where time and mileage are listed, follow the
interval that occurs first.
NOTE:Under no circumstances should oil change in-
tervals exceed 6000 miles (10 000 km) or 6 months
whichever comes first.
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Schedule ªBº
Follow schedule ªBº if you usually operate your vehicle
under one or more of the following conditions.
²Day or night temperatures are below 32É F (0É C).
²Stop and go driving.
²Extensive engine idling.
²Driving in dusty conditions.
²Short trips of less than 10 miles (16 km).
²More than 50% of your driving is at sustained high
speeds during hot weather, above 90É F (32É C).
²Trailer towing.
²Taxi, police, or delivery service (commercial service).
²Off-road or desert operation.
²If equipped for and operating with E-85 (ethanol)
fuel.
NOTE:IfANYof these apply to you then change your
engine oil every 3,000 miles (5 000 km) or 3 months,
whichever comes first and follow schedule ªBº of the
9Maintenance Schedules9section of this manual.
SCHEDULE ªBº 343
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Miles 105,000 108,000 111,000 114,000 117,000 120,000
(Kilometers) (168 000) (173 000) (178 000) (182 000) (187 000) (192 000)
Drain and refill automatic transmission fluid,
change filter (3.7L). This applies only if your
vehicle is used for police, taxi, fleet, or trailer
towing.X
Drain and refill automatic transmission fluid
and change main sump filter (4.7L/5.7L only).X
* This maintenance is recommended by the manufacture
to the owner but is not required to maintain the emis-
sions warranty.
³ This maintenance is not required if previously replaced.Inspection and service should also be performed anytime
a malfunction is observed or suspected. Retain all re-
ceipts.
352 SCHEDULE ªBº
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