brake fluid Ram 5500 Chassis Cab 2012 Diesel Supplement

NOTE:The voltmeter may show a gauge fluctuation at
various engine temperatures. This cycling operation is
caused by the post-heat cycle of the intake manifold
heater system. The number of cycles and the length of the
cycling operation is controlled by the engine control
module. Post-heat operation can run for several minutes,
and then the electrical system and voltmeter needle will
stabilize.
18. Cargo Light The cargo light will illuminate when the cargo
light is activated by pressing the cargo light
button on the headlight switch.
19. Brake Warning Light This light monitors various brake functions,
including brake fluid level and parking brake
application. If the brake light turns on, it may indicate that the parking brake is applied, that the brake
fluid level is low, or that there is a problem with the
Anti-Lock Brake System reservoir.
If the light remains on when the parking brake has been
disengaged, and the fluid level is at the full mark on the
master cylinder reservoir, it indicates a possible brake
hydraulic system malfunction or that a problem with the
Brake Booster has been detected by the Anti-Lock Brake
System (ABS). In this case, the light will remain on until
the condition has been corrected. If the problem is related
to the brake booster, the ABS pump will run when
applying the brake and a brake pedal pulsation may be
felt during each stop.
The dual brake system provides a reserve braking capac-
ity in the event of a failure to a portion of the hydraulic
system. A leak in either half of the dual brake system is
3
UNDERSTANDING YOUR INSTRUMENT PANEL 19

indicated by the “Brake Warning Light,” which will turn
on when the brake fluid level in the master cylinder has
dropped below a specified level.
The light will remain on until the cause is corrected.
NOTE:The light may flash momentarily during sharp
cornering maneuvers, which change fluid level condi-
tions. The vehicle should have service performed, and
the brake fluid level checked.
If brake failure is indicated, immediate repair is neces-
sary.
WARNING!
Driving a vehicle with the “Brake Warning Light” on
is dangerous. Part of the brake system may have
failed. It will take longer to stop the vehicle. You
could have an accident. Have the vehicle checked
immediately. Vehicles equipped with the ABS, are also equipped with
Electronic Brake Force Distribution (EBD). In the event of
an EBD failure, the “Brake Warning Light” will turn on
along with the “ABS Warning Light.” Immediate repair
to the ABS system is required.
Operation of the “Brake Warning Light” can be checked
by turning the ignition switch from the OFF position to
the ON position. The light should illuminate for approxi-
mately two seconds. The light should then turn off unless
the parking brake is applied or a brake fault is detected.
If the light does not illuminate, have the light inspected
by an authorized dealer.
The light also will turn on when the parking brake is
applied with the ignition switch in the ON position.
NOTE:
This light shows only that the parking brake is
applied. It does not show the degree of brake application.
20 UNDERSTANDING YOUR INSTRUMENT PANEL

•When a diesel engine is allowed to run out of fuel or
the fuel gels at low temperatures, air is pulled into the
fuel system. If your engine has run out of fuel, refer to
“Maintenance Procedures/Priming If The Engine Has
Run Out Of Fuel” in “Maintaining Your Vehicle” for
further information.
Starting Fluids
WARNING!
Starting fluids or flammable liquids are never to be
used in the Cumminsdiesel engine (see Warning
label). Never pour diesel fuel, flammable liquid,
starting fluids (ether) into the air cleaner canister, air
intake piping, or turbocharger inlet in an attempt to
start the vehicle. This could result in a flash fire and
explosion causing serious personal injury and engine
damage. The engine is equipped with an automatic electric air
preheating system. If the instructions in this manual are
followed, the engine should start in all conditions.
WARNING!
•Do not leave children or animals inside parked
vehicles in hot weather. Interior heat build up may
cause serious injury or death.
•Leaving children in a vehicle unattended is dan-
gerous for a number of reasons. A child or others
could be seriously or fatally injured. Children
should be warned not to touch the parking brake,
brake pedal or the shift lever. Do not leave the key
in the ignition. A child could operate power win-
dows, other controls, or move the vehicle.
40 STARTING AND OPERATING

NOTE:
•The torque converter clutch will not engage, and the
transmission will not shift to sixth gear, until the
transmission fluid and engine coolant are warm [usu-
ally after 1 to 3 miles (1.6 to 4.8 km) of driving].
Because sixth gear is disabled, and engine speed is
higher when the torque converter clutch is not en-
gaged, it may seem as if the transmission is not
shifting properly when cold. This is normal. Using the
Electronic Range Select (ERS) feature, when the trans-
mission is sufficiently warm, will demonstrate that the
transmission is able to shift into and out of Overdrive.
•If the vehicle has not been driven for several days, the
first few seconds of operation after shifting the trans-
mission 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 after starting the engine.
Six-Speed Automatic Transmission – If Equipped
(Chassis Cab Only)
The shift lever position display (located in the instrument
panel cluster) indicates the transmission gear range. The
shift lever is mounted on the right side of the steering
column. You must press the brake pedal to move the shift
lever out of the PARK position (refer to “Brake/
Transmission Shift Interlock System” in this section). To
drive, move the shift lever from PARK or NEUTRAL to
the DRIVE position. Pull the shift lever toward you when
shifting into REVERSE or PARK, or when shifting out of
PARK.
The electronically-controlled transmission provides a
precise shift schedule. The transmission electronics are
self-calibrating; therefore, the first few shifts on a new
vehicle may be somewhat abrupt. This is a normal
condition, and precision shifts will develop within a few
hundred miles (kilometers).
64 STARTING AND OPERATING

MANUAL TRANSMISSION — IF EQUIPPED
WARNING!
You or others could be injured if you leave the
vehicle unattended without having the parking
brake fully applied. The parking brake should al-
ways be applied when the driver is not in the vehicle,
especially on an incline.
CAUTION!
Never drive with your foot resting on the clutch
pedal, or attempt to hold the vehicle on a hill with the
clutch pedal partially engaged, as this will cause
abnormal wear on the clutch.
NOTE: During cold weather, you may experience in-
creased effort in shifting until the transmission fluid
warms up. This is normal.
Shifting
Truck models with manual transmission are equipped
with a clutch interlocking ignition system. The clutch
pedal must be fully pressed to start the vehicle.
Shift Pattern
4
STARTING AND OPERATING 75

JUMP STARTING
WARNING!
•To prevent personal injury or damage to clothing,
do not allow battery fluid to contact eyes, skin or
fabrics. Do not lean over a battery when connect-
ing jumper cables or allow cable clamps to touch
each other. Keep open flames or sparks away from
battery vent holes. Always wear eye protection
when working with batteries.
•Do not use a booster battery or any other booster
source that has a greater than 12 Volt system, i.e.,
do not use a 24 Volt power source.
NOTE: Replacement batteries should both be of equal
size to prevent damage to the vehicle’s charging system.
Your vehicle is equipped with two 12 Volt batteries. If it
becomes necessary to use a booster battery with jumper cables to start a vehicle’s engine because its batteries are
discharged, the following procedure should be used:
Set the parking brake and place an automatic transmis-
sion in PARK (or NEUTRAL for a manual transmission).
Turn off lights, heater and other electrical loads. Observe
charge indicator (if equipped) in both batteries. If the
indicator (if equipped) is light or yellow on either battery,
replace that battery.
CAUTION!
Use the jump start procedure only when the charge
indicator (if equipped) in both batteries is dark in the
center. Do not attempt jump starting when either
battery charge indicator (if equipped) is bright or
yellow. If the charge indicator (if equipped) has a
green dot in the center, failure to start is not due to a
discharged battery and cranking system should be
checked.
92 WHAT TO DO IN EMERGENCIES

MAINTAINING YOUR VEHICLE
CONTENTS
Engine Compartment — 6.7L Diesel ......... 99
 Maintenance Procedures ................. 100
▫ Engine Oil ......................... 100
▫ Engine Air Cleaner Filter ............... 104
▫ Draining Fuel/Water Separator Filter ...... 106
▫ Fuel Filter Replacement ................ 108
▫ Priming If The Engine Has Run Out Of
Fuel .............................. 110
▫ Intervention Regeneration Strategy – EVIC
Message Process Flow ..................111 ▫
Diesel Exhaust Fluid – Chassis Cab Only . . . 114
▫ Maintenance-Free Batteries ............. 114
▫ Cooling System ..................... 115
▫ Charge Air Cooler – Inter-Cooler ......... 121
▫ Brake System ....................... 121
▫ Clutch Hydraulic System ............... 123
▫ Transfer Case – If Equipped ............. 123
▫ Manual Transmission – If Equipped ....... 124
▫ Automatic Transmission – If Equipped ..... 124
6

ENGINE COMPARTMENT — 6.7L DIESEL
1 — Battery6 — Washer Fluid Reservoir
2 — Engine Coolant Reservoir 7 — Integrated Power Module
3 — Automatic Transmission Dipstick (If Equipped) 8 — Engine Oil Fill
4 — Engine Oil Dipstick 9 — Coolant Pressure Cap
5 — Brake Fluid Reservoir 10 — Air Cleaner Filter
6
MAINTAINING YOUR VEHICLE 99

•Keep the front of the radiator clean. If your vehicle is
equipped with air conditioning, keep the front of the
condenser clean.
•Do not change the thermostat for Summer or Winter
operation. If replacement is ever necessary, install
ONLY the correct type thermostat. Other designs may
result in unsatisfactory cooling performance, poor gas
mileage, and increased emissions.
Charge Air Cooler – Inter-Cooler
The charge air cooler is positioned between the radiator
and the air conditioner condenser. Air enters the engine
through the air cleaner and passes through the turbo-
charger, where it is pressurized. This pressurized air
rapidly reaches high temperature. The air is then directed
through a hose to the charge air cooler and through
another hose to the intake manifold of the engine. The air
entering the engine has been cooled by about 50° to 100°F(10° to 38°C). This cooling process enables more efficient
burning of fuel resulting in fewer emissions.
To guarantee optimum performance of the system, keep
the surfaces of the charge air cooler, condenser and
radiator clean and free of debris. Periodically check the
hoses leading to and from the charge air cooler for cracks
or loose clamps resulting in loss of pressure and reduced
engine performance.
Brake System
Brake Master Cylinder – Brake Fluid Level Check
The fluid level of the master cylinder should be checked
when performing under the hood service, or immedi-
ately if the “Brake System Warning Light” indicates
system failure.6
MAINTAINING YOUR VEHICLE 121

The brake master cylinder has a translucent plastic
reservoir. On the outboard side of the reservoir, there is a
“MAX” mark and an “MIN” mark. The fluid level must
be kept within these two marks. Do not add fluid above
the full mark because leakage may occur at the 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.
Refer to “Fluids, Lubricants, and Genuine Parts” in
“Maintaining Your Vehicle” for further information.WARNING!
•Use only manufacturer’s recommended brake
fluid. Refer to “Fluids, Lubricants, and Genuine
Parts” in “Maintaining Your Vehicle” for further
information. 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 cylin-
der reservoir.(Continued)
122 MAINTAINING YOUR VEHICLE