brake DODGE POWER WAGON 2007 2.G Workshop Manual

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.
Clutch Linkage
If the clutch pedal linkage begins to squeak or grunt, the
clutch pedal pivot bushings should be lubricated. Refer
to Fluids, Lubricants and Genuine Parts for the correct
lubricant type.
410 MAINTAINING YOUR VEHICLE

Fluid Level Check ± 545RFE
Check the fluid level while the transmission is at normal
operating temperature 82ÉC (180ÉF). 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 gear selector momentarily in each gear
position ending with the lever in P (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 ªHOTº
(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 (2) minutes for the oil to fully drain
into the transmission before rechecking the fluid level.
NOTE:If it is necessary to check the transmissionbelow
the operating temperature, the fluid level should be
between the two ªCOLDº (lower) holes on the dipstick
with the fluid at approximately 70ÉF (21ÉC) (room tem-
perature). If the fluid level is correctly established at
room temperature, it should be between the ªHOTº
MAINTAINING YOUR VEHICLE 413
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(upper) reference holes when the transmission reaches
180ÉF (82ÉC). Remember it is best to check the level at the
normal operating temperature.
CAUTION!
Be aware that if the fluid temperature is below 50ÉF
(10ÉC) 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.
Selection Of Lubricant
Refer to Fluids, Lubricants and Genuine Parts for correct
fluid type. It is important that the transmission fluid be
maintained at the prescribed level using the recom-
mended 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
Fluids, Lubricants and Genuine Parts for correct
fluid type.
414 MAINTAINING YOUR VEHICLE

Cavity Cartridge
FuseMini
FuseDescription
1 20 Amp
YellowPower Outlet Console
2 20 Amp
YellowCabin Compartment
Node (CCN) Door
Locks/Brake Trans-
mission Shift Inter-
lock (BTSI)
3 20 Amp
YellowSpare
4 15 Amp
BlueSpare
5 20 Amp
YellowPower Sunroof
6 10 Amp
RedVIST Fan/WastegateCavity Cartridge
FuseMini
FuseDescription
7 15 Amp
BlueReverse Lockout Sole-
noid Battery (SRT-10
Only)
8 10 Amp
RedHeated Mirrors
9 30 Amp
PinkOff Road Module
Power
10 5 Amp
OrangeTrx-Off Rd Pkg Sen
(Gas Engine Only)
426 MAINTAINING YOUR VEHICLE

Cavity Cartridge
FuseMini
FuseDescription
11 20 Amp
YellowIgnition Off Draw
(IOD)-Cabin Com-
partment Node
(CCN)/Radio/Under
Hood Lamp/Wireless
Control Module
(WCM)/Satellite Digi-
tal Audio Receiver
(SDARS)/Hands Free
Module (HFM)
12 30 Amp
PinkElectric Brake
13 25 Amp
NaturalPower-Battery
RWAL/ABS Module
Feed
14 15 Amp
BluePark Lamps LeftCavity Cartridge
FuseMini
FuseDescription
15 20 Amp
YellowTrailer Park Lamps
16 15 Amp
BluePark Lamps Right
17 15 Amp
BlueSpare
18 40 Amp
GreenABS Pump
19 30 Amp
PinkTrailer Tow
20 10 Amp
RedOccupant Restraints
Controller (ORC) 2
21 10 Amp
RedOccupant Restraints
Controller (ORC) Pre-
set Carrier
22 2 Amp
GrayIGN Switch Feed
MAINTAINING YOUR VEHICLE 427
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Cavity Cartridge
FuseMini
FuseDescription
23 10 Amp
RedEngine Control Mod-
ule (ECM)/Wireless
Control Module
(WCM)/HVC
24 20 Amp
BlueSubwoofer Amplifier
(SRT-10 Only)
25 10 Amp
RedPower Mirror
26 20 Amp
YellowBrake Switch/Center
High Mount Stop
Lamp (CHMSL)
27 40 Amp
GreenPower Seats
28 10 Amp
RedPower Run/Start-
NCC/Wireless Con-
trol Module (WCM)/
ABS/RWALCavity Cartridge
FuseMini
FuseDescription
29 10 Amp
RedSwitches/EC Mirror/
Smart Bar
30 15 Amp
BlueSpare
31 10 Amp
RedPCM/Transfer Case
Brake
32 10 Amp
RedHVAC/Ajustable
Pedals/Heated Seats
Switch LED/Exhaust
Brake
33 10 Amp
RedPower-IGN Run Misc
34 10 Amp
RedSpare
35 15 Amp
BlueCabin Compartment
Node (CCN) Illumi-
nation
428 MAINTAINING YOUR VEHICLE

Chassis
Component Fluids, Lubricants and Genuine Parts.
Automatic Transmission MopartATF+4, Automatic Transmission Fluid
Transfer Case MopartATF+4, Automatic Transmission Fluid
Manual Transmission Fluid (G-56) MopartATF+4, Automatic Transmission Fluid
Front Driveshaft Grease Fitting. Use Moparttype MS-6560 (lithium based grease), or equivalent.
Clutch Linkage Multipurpose Grease, NLGI Grade 2 E.P.
Front and Rear Axle Synthetic, GL-5 SAE, 75W-90. Limited-Slip 10.5 inch Rear AxleDOES NOT
REQUIREa limited slip additive.
Brake Master Cylinder MopartDOT 3 and SAE J1703 should be used. If DOT 3 brake fluid is not
available, then DOT 4 is acceptable. Use only recommended brake fluids.
Power Steering Reservoir MopartATF+4, Automatic Transmission Fluid
MAINTAINING YOUR VEHICLE 443
7

At Each Stop for Fuel
²Check the engine oil level about 5 minutes after a fully
warmed engine is shut off. Checking the oil level while
the vehicle is on level ground will improve the accu-
racy of the oil level reading. Add oil only when the
level is at or below the ADD or MIN mark.
²Check the windshield washer solvent and add if
required.
Once a Month
²Check tire pressure and look for unusual wear or
damage.
²Inspect the battery and clean and tighten the terminals
as required.
²Check the fluid levels of coolant bottle, brake master
cylinder, and transmission and add as needed.
²Check all lights and all other electrical items for correct
operation.
At Each Oil Change
²Change the engine oil filter.
²Lubricate the front driveshaft grease fitting and tie rod
end links.
²Inspect the exhaust system.
²Inspect the brake hoses.
²Inspect the UÐjoints and front suspension compo-
nents.
²Check the automatic transmission fluid level.
²Check the manual transmission fluid level.
²Check the coolant level, hoses, and clamps.
²Lubricate Front Drive Shaft Fitting.
448 MAINTENANCE SCHEDULES
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Miles 3,000 6,000 9,000 12,000 15,000
(Kilometers) (5 000) (10 000) (14 000) (19 000) (24 000)
Change engine oil and engine oil filter, or at 3
months, whichever comes first.X X XXX
Lubricate Front Drive Shaft Fitting. X X X X X
Rotate tires. X X
Check spare tire for proper pressure and correct
stowage.XX
Lubricate tie rod end links. X X X X X
Change rear axle fluid.X
Change front axle fluid.X
Inspect brake linings.X
Inspect engine air cleaner filter, replace if neces-
sary.X
450 SCHEDULE ªBº
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Miles 18,000 21,000 24,000 27,000 30,000
(Kilometers) (29 000) (34 000) (39 000) (43 000) (48 000)
Change engine oil and engine oil filter, or at 3
months, whichever comes first.X X XXX
Lubricate Front Drive Shaft Fitting. X X X X X
Rotate tires. X X X
Check spare tire for proper pressure and correct
stowage.XXX
Lubricate tie rod end links. X X X X X
Change rear axle fluid.X
Change front axle fluid.X
Check transfer case fluid level.X
Inspect brake linings. X
Inspect engine air cleaner filter, replace if neces-
sary.X
Replace spark plugs.X
Inspect PCV valve, replace as necessary.**X
SCHEDULE ªBº 451
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