brake RAM CHASSIS CAB 2011 Repair Manual

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 labeled on the origi-
nal factory installed hydraulic master cylinder
reservoir.
(Continued) WARNING! (Continued)• To avoid contamination from foreign matter or
moisture, use only new brake fluid or fluid that
has been in a tightly closed container. Keep the
master cylinder reservoir cap secured at all times.
Brake fluid in a open container absorbs moisture
from the air resulting in a lower boiling point.
This may cause it to boil unexpectedly during hard
or prolonged braking, resulting in sudden brake
failure. This could result in a accident.
• Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts, causing
the brake fluid to catch fire. Brake fluid can also
damage painted and vinyl surfaces, care should be
taken to avoid its contact with these surfaces.
(Continued)
7 MAINTAINING YOUR VEHICLE 399

WARNING! (Continued)• Do not allow petroleum based fluid to contami-
nate the brake fluid. Brake seal components could
be damaged, causing partial or complete brake
failure. This could result in an accident.
Rear Axle And 4x4 Front Driving Axle Fluid Level
For models with 9.25 in Front Axles and 11.5 in Rear
Axles, refer to “Fluids, Lubricants, and Genuine Parts” in
“Maintaining Your Vehicle” for further information. For
normal service, periodic fluid level checks are not re-
quired. When the vehicle is serviced for other reasons, the
exterior surfaces of the axle assembly should be inspected.
When checking the fluid level (4500/5500 only), the
vehicle should be in a level position. The fluid level
should be 1/4 in ± 1/4 in (6.4 mm ± 6.4 mm) below the
fill hole on the front axle. The fluid level should be level
with the bottom of the fill hole on the rear axle. Drain And Refill
On 4500/5500 vehicles, remove the lower bolt to drain
the axle fluid.
Refer to “Maintenance Schedule” for the proper mainte-
nance intervals. 1 — 4500/5500 Rear Axle Fluid Fill Plug
2 — 4500/5500 Rear Axle Fluid Drain Plug400 MAINTAINING YOUR VEHICLE

transmission with an improper fluid level will greatly
reduce the life of the transmission and of the fluid. Check
the fluid level whenever the vehicle is serviced.
Fluid Level Check – 545RFE
Check the fluid level while the transmission is at normal
operating temperature 82°C (180°F). This occurs after at
least 15 miles (25 km) of driving. At normal operating
temperature the fluid cannot be held comfortably be-
tween the fingertips.
To check the automatic transmission fluid level properly,
the following procedure must be used:
1. Operate the engine at idle speed and normal operating
temperature.
2. The vehicle must be on level ground.
3. Fully apply the parking brake and press the brake
pedal. 4. Place the shift lever momentarily into each gear posi-
tion ending with the lever in PARK.
5. Remove the dipstick, wipe it clean and reinsert it until
seated.
6. Remove the dipstick again and note the fluid level on
both sides. The fluid level should be between the “HOT”
(upper) reference holes on the dipstick at normal operat-
ing temperature. Verify that solid coating of oil is seen on
both sides of the dipstick. If the fluid is low, add as
required into the dipstick tube. Do not overfill. After
adding any quantity of oil through the oil fill tube, wait
a minimum of two minutes for the oil to fully drain into
the transmission before rechecking the fluid level.
NOTE: If it is necessary to check the transmission below
the operating temperature, the fluid level should be
between the two “COLD” (lower) holes on the dipstick
with the fluid at approximately 70°F (21°C) (room tem-
perature). If the fluid level is correctly established at
7 MAINTAINING YOUR VEHICLE 403

room temperature, it should be between the “HOT”
(upper) reference holes when the transmission reaches
180°F (82°C). Remember it is best to check the level at the
normal operating temperature.
CAUTION!Be aware that if the fluid temperature is below 50°F
(10°C) it may not register on the dipstick. Do not add
fluid until the temperature is elevated enough to
produce an accurate reading.
7. Check for leaks. Release parking brake.
To prevent dirt and water from entering the transmission
after checking or replenishing fluid, make certain that the
dipstick cap is properly reseated. It is normal for the
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
Refer to “Maintenance Schedule” for the proper mainte-
nance intervals.
NOTE: If the transmission is disassembled for any
reason, the fluid and filter(s) should be changed.
It is important that proper lubricant is used in the trans-
mission. Refer to “Fluids, Lubricants, and Genuine Parts”
in “Maintaining Your Vehicle” for further information.
Special Additives
Automatic Transmission Fluid (ATF) is an engineered
product and its performance may be impaired by supple-
mental additives. Therefore, do not add any fluid addi-
tives to the transmission. The only exception to this
policy is the use of special dyes to aid in detecting fluid
leaks. In addition, avoid using transmission sealers as
they may adversely affect seals.404 MAINTAINING YOUR VEHICLE

• If you carry special cargo such as chemicals, fertilizers,
de-icer salt, etc., be sure that such materials are well
packaged and sealed.
• If a lot of driving is done on gravel roads, consider
mud or stone shields behind each wheel.
• Use MOPAR  Touch Up Paint or equivalent on
scratches as soon as possible. Your authorized dealer
has touch up paint to match the color of your vehicle.
Wheel and Wheel Trim Care
All wheels and wheel trim, especially aluminum and
chrome-plated wheels should be cleaned regularly with a
mild soap and water to prevent corrosion. To remove
heavy soil and/or excessive brake dust, use MOPAR 
Wheel Cleaner or equivalent or select a nonabrasive,
non-acidic cleaner. Do not use scouring pads, steel wool,
a bristle brush, or metal polishes. Only MOPAR  or
equivalent is recommended. Do not use oven cleaner. Avoid automatic car washes that use acidic solutions or
harsh brushes that may damage the wheels’ protective
finish.
Stain Repel Fabric Cleaning Procedure –
If Equipped
Stain Repel seats may be cleaned in the following man-
ner:
• Remove as much of the stain as possible by blotting
with a clean, dry towel.
• Blot any remaining stain with a clean, damp towel.
• For tough stains, apply MOPAR  Total Clean or
equivalent, or a mild soap solution to a clean, damp
cloth and remove stain. Use a fresh, damp towel to
remove soap residue.
7 MAINTAINING YOUR VEHICLE 407

Cavity Cartridge
Fuse Mini
Fuse Description
J03 25 Amp
Natural Bat – Passenger Door
Node
J04 40 Amp
Green Bat – ABS Pump
J05 30 Amp
Pink Bat – ABS Valve
J06 30 Amp
Pink Bat – H/Lamp Wash/
MTV/CM2200/Elec
Vac Pump
J07 25 Amp
Natural Bat – Driver Door
Node
J08 30 Amp
Pink Bat – DTCM/Axle
Locks
J09 30 Amp
Pink Bat – Plg/Electric
Brake
J10 40 Amp
Green Bat – L/Bar/Off-Road Cavity Cartridge
Fuse Mini
Fuse Description
J11 30 Amp
Pink Bat – Sway/
Thatchum/Rear
Doors
J12 40 Amp
Green Starter Solenoid
J13 60 Amp
Yellow Bat – Rad Fan #1/#2/
SSR
J14 40 Amp
Green Bat – Folding Seat/
PZEV
J15 60 Amp
Yellow Bat – IOD Main
J16 40 Amp
Green Frt HVAC Motor
M17 25 Amp
Natural Bat – Sunroof/
Skylight
M18 25 Amp
Natural TCM/Trans Range
7 MAINTAINING YOUR VEHICLE 411

Cavity Cartridge
Fuse Mini
Fuse Description
M19 5 Amp
Ta n Ign R/ACC –
Sunroof/Window Sw
Illum
M20 25 Amp
Natural Frt Wiper
M21 25 Amp
Natural Door Locks
M22 20 Amp
Yellow Fuel Pump
M23 20 Amp
Yellow Bat – Trlr Light/Pre-
Safe #2
M24 20 Amp
Yellow Bat – Trlr Tow BUX/
HGM
M25 10 Amp
Red Bat – J1962 Diag/
Mirrors
M26 10 Amp
Red Bat – Ign Sw, WIN,
PASS Cavity Cartridge
Fuse Mini
Fuse Description
M27 15 Amp
Blue Bat – CHMSL/Brake
Sw
M28 10 Amp
Red Bat – Corax TPM/
PEM/HVAC Htr
Pump
M29 15 Amp
Blue Bat – Folding Mirror
M30 25 Amp
Natural Bat – Inverter
M31 20 Amp
Yellow Bat – Pwr Out #1
M32 20 Amp
Yellow Fr/Rr Washer
M33 15 Amp
Blue Bat – NGC/EATX/
PCM
M34 15 Amp
Blue Bat – CCN/Interior
Light/SCM/Sw Bank412 MAINTAINING YOUR VEHICLE

Cavity Cartridge
Fuse Mini
Fuse Description
M51 20 Amp
Yellow ASD #3
M52 10 Amp
Red IGN R/S-SWAY/
TCASE/DTCM/
FAD/TRLR BRAKE
MOD.
M53 15 Amp
Blue IGN R/S-MFSW/
CNN/SCM/TPM/RR
View
M54 20 Amp
Yellow IOD – Spare CAUTION!• When installing the totally integrated power mod-
ule cover, it is important to ensure the cover is
properly positioned and fully latched. Failure to
do so may allow water to get into the totally
integrated power module and possibly result in a
electrical system failure.
• When replacing a blown fuse, it is important to
use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated
may result in a dangerous electrical system over-
load. If a properly rated fuse continues to blow, it
indicates a problem in the circuit that must be
corrected.414 MAINTAINING YOUR VEHICLE

Chassis
Component Fluid, Lubricant, or Genuine Part
Automatic Transmission
(Five-Speed 545RFE) MOPAR  ATF+4  Automatic Transmission Fluid or equivalent licensed
ATF+4  product.
Transfer Case MOPAR  ATF+4  Automatic Transmission Fluid or equivalent licensed
ATF+4  product.
Front and Rear Axle Fluid
(4500/5500) GL-5 SAE 75W-90 Synthetic (MS-9763) or equivalent.
Brake Master Cylinder MOPAR  DOT 3 and SAE J1703 should be used or equivalent. If DOT 3
brake fluid is not available, then DOT 4 is acceptable. Use only recom-
mended brake fluids.
Power Steering Reservoir MOPAR  Power Steering Fluid +4, MOPAR  ATF+4  Automatic Trans-
mission Fluid or equivalent licensed ATF+4  product.424 MAINTAINING YOUR VEHICLE

Once a Month
• Check tire pressure and look for unusual wear or
damage.
• Inspect the battery and clean and tighten the terminals
as required.
• Check the fluid levels of coolant reservoir, brake
master cylinder, power steering and transmission and
add as needed.
• Check all lights and other electrical items for correct
operation. At Each Oil Change
• Change the engine oil filter.
• Inspect the brake hoses and lines.
• Lubricate outer tie rod ends.
CAUTION!Failure to perform the required maintenance items
may result in damage to the vehicle.
Required Maintenance Intervals
Refer to the Maintenance Schedules on the following
pages for the required maintenance intervals.
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