clutch DODGE POWER WAGON 2005 2.G User Guide

performance and reduce the potential for transmission
overheating or failure due to excessive shifting. When
operating in“TOW/HAUL”mode, 5th gear (if
equipped) is disabled and 2-3 and 3-4 shift patterns are
modified. Shifts into Overdrive (4th gear) are allowed
during steady cruise (for improved fuel economy) and
automatic closed-throttle downshifts to 3rd gear (for
improved braking) will occur during steady braking.
The“TOW/HAUL”light will illuminate in the instru-
ment cluster to indicate when the switch has been
activated. Pressing the switch a second time restores
normal operation. If the“TOW/HAUL”mode is desired,
the button must be pressed each time the engine is
started.
Torque Converter Clutch
A feature, designed to improve fuel economy, has been
included in the automatic transmission on your vehicle.A clutch within the torque converter engages automati-
cally at calibrated speeds. This may result in a slightly
different feeling or response during normal operation in
high gear. When the vehicle speed drops or during
acceleration when the transmission downshifts to second
gear, the clutch automatically disengages.
NOTE:The torque converter clutch will not engage
until the transmission fluid and engine coolant are warm
[usually after 1-3 miles (1.6 - 4.8 km) of driving]. Because
the engine speed is higher when the torque converter
clutch is not engaged, it may seem as if the transmission
is not shifting into Overdrive when cold. This is normal.
Pressing the“TOW/HAUL”button, when the transmis-
sion is sufficiently warm, will demonstrate that the
transmission is able to shift into and out of overdrive.
NOTE:If the vehicle has not been driven in several
days, the first few seconds of operation after shifting the
transmission into gear may seem sluggish. This is due to
274 STARTING AND OPERATING

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 of shifting from Park into
any other gear position.
Manual Transmission—6-Speed
NOTE:The parking brake should be engaged before
leaving the vehicle, especially on an incline.
This model is equipped with a clutch interlocking igni-
tion system. The clutch pedal must be fully depressed to
start the vehicle.
Fully depress the clutch pedal before shifting gears. As
you release the clutch pedal, lightly depress the accelera-
tor pedal. When launching a stationary vehicle, keep the
engine speed low until the clutch is fully engaged.G 56 Shift Pattern
–If Equipped
For improved clutch life, all six forward gears should be
used. For steady highway driving with light acceleration,
6th gear is recommended. When shifting from 4th to 5th
gear, apply side effort away and forward without push-
ing hard enough to engage Reverse gear. Shifting from
5th to 6th requires the same side effort or the lever will
return to center resulting in a shift into 4th gear and
damage the transmission, clutch, or engine.
STARTING AND OPERATING 275
5

You should use low gear when starting from a standing
position if under a heavy load.
To shift into Reverse, come to a complete stop. Depress
the clutch and pause briefly to allow the gear train to
stop. Move the shift lever from the Neutral position
straight across and up into Reverse.
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.
Recommended Shift Speeds
To use your manual transmission for fuel economy it
should be upshifted as listed below. Shift at the vehicle
speeds listed for acceleration. Earlier upshifts during
cruise conditions (relatively steady speeds) will result in
increased fuel economy, and may be used as indicated.
MANUAL TRANSMISSION
Recommended Shift Speeds
1-2 2-3 3-4 4-5 5-6
mph 15 25 40 50 60
(km/h) (24) (40) (65) (80) (97)
Higher upshift speeds may be used to obtain a desired
acceleration rate.
Downshifting
Moving from a high gear down to a lower gear is
recommended to preserve brakes when driving down
steep hills. In addition, downshifting at the right time
provides better acceleration when you desire to resume
speed. To avoid overspeeding the engine and clutch,
downshift progressively and do not skip gears. For
acceleration at speeds less than 15 mph (25 km/h), 2nd
gear is recommended.
276 STARTING AND OPERATING

vehicle in motion, the transfer case will engage / disen-
gage faster if you momentarily release the accelerator
pedal after completing the shift. Apply a constant force
when shifting the transfer case lever.
2H or 4H⇔4L
With the vehicle rolling at 2 to 3 mph (3 to 5 km/h), shift
an automatic transmission to N (Neutral) or depress the
clutch on a manual transmission. While the vehicle is
coasting at 2 to 3 mph (3 to 5 km/h), shift the transfer
case lever firmly to the desired position. Do not pause in
transfer case N (Neutral).
NOTE:Pausing in transfer case N (Neutral) in vehicles
equipped with an automatic transmission may require
shutting the engine OFF to avoid gear clash while
completing the shift. If difficulty occurs, shift automatic
transmission to N (Neutral), hold foot on brake, and turn
engine OFF. Make shift to the desired mode.NOTE:Shifting into or out of 4L is possible with the
vehicle completely stopped, however difficulty may oc-
cur due to the mating clutch teeth not being properly
aligned. Several attempts may be required for clutch
teeth alignment and shift completion to occur. The pre-
ferred method is with the vehicle rolling 2 to 3 mph (3 to
5 km/h). Avoid attempting to engage or disengage 4L
with the vehicle moving faster than 2 to 3 mph (3 to 5
km/h).
NOTE:Do not attempt to shift to or from 4L while the
transmission is in gear or clutch is engaged.
Transfer Case Reminder Light
The four-wheel-drive operating light (4WD), located in
the instrument cluster, is used to alert the driver that the
front axle is fully engaged and all four wheels are
driving.
280 STARTING AND OPERATING

RECREATIONAL TOWING—4–WHEEL DRIVE
VEHICLES (BEHIND MOTORHOME, ETC.)
CAUTION!
Internal damage to the transfer case will occur if a
front or rear wheel lift is used when recreational
towing.
NOTE:The transfer case must be shifted into Neutral
(N) for recreational towing. Automatic transmissions
must be placed in P (Park) position for recreational
towing. Manual transmissions must be left in gear (not in
neutral) for recreational towing. Refer below for the
proper transfer case Neutral shifting procedure for your
vehicle.
Recreational Towing Procedure—Manual Shift
Transfer Case—If Equipped
Use the following procedure to prepare your vehicle for
recreational towing:
CAUTION!
It is necessary to follow these steps to be certain that
the transfer case is fully in N (NEUTRAL) before
recreational towing to prevent damage to internal
parts.
1. Bring the vehicle to a complete stop.
2. Shut OFF the engine.
3. Depress the brake pedal.
4. Shift automatic transmission to N (NEUTRAL), or
depress the clutch on manual transmissions.
STARTING AND OPERATING 329
5

4. Shift automatic transmission to N (NEUTRAL), or
depress the clutch on manual transmissions.
5. Shift transfer case lever to desired position.
6. Shift automatic transmission into P (Park).
WARNING!
You or others could be injured if you leave the
vehicle unattended with the transfer case in the N
(NEUTRAL) position without first fully engaging
the parking brake. The transfer case N (NEUTRAL)
position disengages both the front and rear drive-
shafts from the powertrain and will allow the ve-
hicle to move regardless of the transmission posi-
tion. The parking brake should always be applied
when the driver is not in the vehicle.
CAUTION!
•Do not use a bumper mounted clamp-on tow bar
on your vehicle. The bumper face bar will be
damaged.
•Do not disconnect the rear driveshaft because
fluid will leak from the transfer case and damage
the internal parts.
TRACTION
When driving on wet or slushy roads, it is possible for a
wedge of water to build up between the tire and road
surface. This is known as hydroplaning and may cause
partial or complete loss of vehicle control and stopping
ability. To reduce this possibility, the following precau-
tions should be observed:
1. Slow down during rainstorms or when roads are
slushy.
STARTING AND OPERATING 331
5

▫Power Steering—Fluid Check............367
▫Front Suspension Ball Joints..............367
▫Steering Linkage—Inspection............368
▫Front Prop Shaft Lubrication.............368
▫Body Lubrication.....................369
▫Windshield Wiper Blades................369
▫Windshield Washers...................369
▫Exhaust System......................370
▫Cooling System.......................371
▫Hoses And Vacuum/Vapor Harnesses.......375
▫Brake System........................376
▫Clutch Hydraulic System................377
▫Clutch Linkage.......................378▫Rear Axle And 4X4 Front Driving Axle Fluid
Level..............................378
▫Transfer Case........................379
▫Front Drive Shaft.....................379
▫Manual Transmission..................379
▫Automatic Transmission................380
▫Front Wheel Bearings..................383
▫Selection Of Lubricating Grease...........383
▫Noise Control System Required Maintenance
& Warranty.........................384
▫Appearance Care And Protection From
Corrosion...........................388

Fuse And Relay Center...................393

Vehicle Storage........................393
350 MAINTAINING YOUR VEHICLE

WARNING!
Use of a brake fluid that may have a lower initial
boiling point, or is unidentified as to specification,
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 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.
Clutch Hydraulic System
The clutch hydraulic system is a sealed maintenance-free
system. In the event of leakage or other malfunction, the
system must be replaced.
MAINTAINING YOUR VEHICLE 377
7

Clutch Linkage
If the clutch pedal linkage begins to squeak or grunt, the
clutch pedal pivot bushings should be lubricated. Refer
to Recommended Fluids, Lubricants and Genuine Parts
for the correct lubricant type.
Rear Axle And 4x4 Front Driving Axle Fluid Level
Refer to Recommended Fluids, Lubricants and Genuine
Parts for the correct Fluid type. For normal service,
periodic fluid level checks are not required. When the
vehicle is serviced for other reasons the exterior surfaces
of the axle assembly should be inspected. If gear oil
leakage is suspected inspect the fluid level.
This inspection should be made with the vehicle in a level
position. The fluid level should be even with the bottom
of the fill hole for the Manufacturer’s C205F HD Front
Axles. The fluid level should be 5/8”(16 mm) below on
9 1/4”Manufacturer’s Rear Axles.For all 2500 Model axles, the fluid level should be 1/4”±
1/4”(6.4 mm ± 6.4 mm) below the fill hole on the 9.25”
Front and 3/4”± 1/4”(19 mm ± 6.4 mm) on 10.5”Rear
axles. The 11.5”Rear Axle level should be 1/4”± 1/4”
(6.4 mm ± 6.4 mm) below the fill hole.
Drain and Refill
Vehicles operated in normal service do not have regularly
scheduled oil changes. If fluid has become contaminated
with water or to provide the correct viscosity grade, drain
and refill.
Lubricant Selection
Refer to Recommended Fluids, Lubricants and Genuine
Parts for correct fluid type.
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.
378 MAINTAINING YOUR VEHICLE

AIR CLEANER
•Removal of the air cleaner.
•Inverting the air cleaner lid.
•Removal of the air ducting.
EXHAUST SYSTEM
•Removal or rendering inoperative exhaust system
components including the muffler or tailpipe.
ENGINE COOLING SYSTEM
•Removal or rendering inoperative the fan clutch.
•Removal of the fan shroud.
Noise Emission Warranty
The manufacturer warrants that this vehicle as manufac-
tured by the manufacturer, was designed, built and
equipped to conform at the time it left the manufacturers
control with all applicable U.S. EPA Noise Control Regu-
lations.
This warranty covers this vehicle as designed, built and
equipped by the manufacturer, and is not limited to any
particular part, component or system of the vehicle
manufactured by the manufacturer. Defects in design,
assembly or in any part, component or system of the
vehicle as manufactured by the manufacturer, which, at
the time it left the manufacturers control, caused noise
emissions to exceed Federal standards, are covered by
this warranty for the life of the vehicle.
386 MAINTAINING YOUR VEHICLE