maintenance DODGE RAM 2500 DIESEL 2004 3.G User Guide

Avoid Using Contaminated Fuel
Fuel that is contaminated by water or dirt can cause
severe damage to the engine fuel system which is not
covered by the warranty. Proper maintenance of the
engine fuel filter and fuel tank is essential. (See Section 7
for Maintenance Procedures).
NOTE:Climatized diesel fuel is a blend of Number 2
and Number 1 Diesel fuel which reduces the temperature
at which wax crystals form in the fuel.
Bulk Fuel Storage
If you store quantities of fuel, good maintenance of the
stored fuel is also essential. Fuel contaminated with
water will promote the growth of ªmicrobes.º These
microbes form ªslimeº that will clog fuel filters and lines.
Drain condensation from the supply tank and change the
line filter on a regular basis.
Fuel Specifications
The Cummins Turbocharged, Charge Air Cooled, Diesel
engine has been developed to take advantage of the high
energy content and generally lower cost No. 2 diesel fuel
or No. 2 climatized diesel fuels. Experience has shown
that it also operates on No. 1 diesel fuels or other fuels
within the specifications in the following chart.
NOTE:As sufficient testing has not been completed,
organically blended diesel fuels (e.g. biodiesel, ethanol,
and methanol blends) are not recommended or approved
for use with your Cummins Diesel equipped Dodge Ram
Truck.
NOTE:In addition, commercially available fuel addi-
tives are not necessary for the proper operation of your
Cummins Diesel equipped Dodge Ram Truck.
NOTE:No. 1 diesel fuel should only be used where
extended arctic conditions (-10ÉF or 23ÉC) exist.
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CAUTION!
²During the first 500 miles (805 km) your new
vehicle is driven, do not tow a trailer. Doing so
may damage your vehicle.
²When first towing a trailer, limit your speed to 50
mph (80 km/h) during the first 500 miles (805 km)
of towing.
Perform the maintenance listed in the ªMaintenance
Schedulesº section of this manual (Section 8). When
towing a trailer, never exceed the Gross Axle Weight
Rating (GAWR), or Gross Combined Vehicle Weight
(GCVW).
CAUTION!
When hauling cargo or towing a trailer, do not
overload your vehicle or trailer. Overloading can
cause a loss of control, poor performance or damage
to brakes, axle, engine, transmission, steering, sus-
pension, body structure or tires.
Consider the following items when computing the
weight on the rear axle:
²the tongue weight of the trailer
²the weight of any other type of cargo or equipment put
in or on your vehicle
²the weight of passenger's and driver
NOTE:Remember that everything put into or on the
trailer adds to the load on your vehicle. Also, additional
factory-installed options, or dealer-installed options,
STARTING AND OPERATING 273
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²Highway DrivingÐreduce your speed.
²Air ConditioningÐturn it off temporarily.
²Hilly TerrainÐTurn overdrive off.
See Cooling System Operating information in the Service
and Maintenance section of this manual for more infor-
mation.
Automatic Transmission Oil Temperature Warning
Light
All vehicles with heavy duty transmission oil cooling are
equipped with a transmission sump oil temperature
sensor and warning light. If elevated transmission tem-
peratures are encountered, the engine controller will
select the most desirable gear until the transmission
temperatures are reduced. If transmission oil tempera-
tures continue to rise, a warning light located in theinstrument cluster will illuminate. If this should occur,
stop the vehicle, shift to Neutral, and run the engine at
idle or faster until the light goes off.
Towing With An Automatic Transmission
Vehicles equipped with an automatic transmission may
shift into and out of Overdrive, or a lower gear, when
driving in hilly areas, when heavily loaded, or when
towing into heavy winds.
When this condition occurs, press the ªTOW/HAULº
button or shift into a lower gear to prevent excessive
transmission wear and/or overheating, and to provide
better engine braking.
NOTE:Do not exceed the following RPM while manu-
ally downshifting:
²5.9L Diesel Engines 3200 RPM.
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NOTE:During snowplow usage on vehicles equipped
with an overhead console module, the outside tempera-
ture display will show higher temperatures than the
outside ambient temperature. The higher displayed tem-
perature is due to blocked or reduced airflow to the
underhood ambient temperature sensor by the snow-
plow. This is common and outside temperature display
operation will return to normal when the snowplow is
removed.
General Maintenance
Snowplows should be maintained in accordance with the
plow manufacturer's instructions.
Keep all snowplow electrical connections and battery
terminals clean and free of corrosion.
When plowing snow, to avoid transmission and driv-
etrain damage, the following precautions should be ob-
served.
²Operate with transfer case in 4L when plowing small
or congested areas where speeds are not likely to
exceed 15 mph (24 km/h). At higher speeds operate in
4H.
²Vehicles with 48RE transmissions should use 4L range
when plowing deep or heavy snow for extended
periods of time to avoid transmission overheating.
²Do not shift the transmission unless the engine has
returned to idle and wheels have stopped. Make a
practice of stepping on the brake pedal before shifting
the transmission.
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MAINTAINING YOUR VEHICLE
CONTENTS
mEngine Compartment....................320
N5.9L/5.9L HO Cummins Turbo Diesel.......320
mOnboard Diagnostic System (OBD II).........321
mReplacement Parts......................322
mDealer Service.........................322
mService Information.....................322
mMaintenance Procedures..................325
NEngine Oil..........................325
NDrive Belt...........................331NEngine Air Cleaner Filter................331
NDraining Fuel/Water Separator Filter.......334
NMaintenance Free Batteries...............336
NAir Conditioner Maintenance.............338
NPower Steering Ð Fluid Check............339
NFront Suspension Ball Joints..............340
NSteering Linkage Ð Inspection............340
NFront Axle Universal Drive Joints And Pivot
Bearings............................340
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NBody Lubrication.....................340
NWindshield Wiper Blades................341
NWindshield Washers...................341
NExhaust System......................342
NCooling System.......................343
NFan ...............................347
NCharge Air Cooler (Inter-Cooler)..........347
NHoses And Vacuum/Vapor Harnesses.......348
NBrake System........................348
NClutch Linkage.......................350
NClutch Hydraulic System................351
NPropeller Shaft Universal Joints...........351NRear Axle And 4X4 Front Driving Axle Fluid
Level..............................351
NTransfer Case Ð If Equipped.............352
NManual Transmission Ð If Equipped.......352
NAutomatic Transmission................353
NFront Wheel Bearings..................355
NSelection Of Lubricating Grease...........356
NNoise Control System Required
Maintenance & Warranty................357
NAppearance Care And Protection From
Corrosion...........................362
mFuse And Relay Center...................366
mVehicle Storage........................366
318 MAINTAINING YOUR VEHICLE

REPLACEMENT PARTS
Use of genuine Mopartparts for normal/scheduled
maintenance and repairs is highly recommended to in-
sure the designed performance. Damage or failures
caused by the use of non-Mopar parts for maintenance
and repairs will not be covered by the manufacturer's
warranty.
DEALER SERVICE
Your dealer has the qualified service personnel, special
tools and equipment to perform all service operations in
an expert manner. Service manuals are available which
include detailed service information for your vehicle.
Refer to these manuals before attempting any procedure
yourself.
NOTE:Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
WARNING!
You can be badly injured working on or around a
motor vehicle. Do only that service work for which
you have the knowledge and the proper equipment.
If you have any doubt about your ability to perform
a service job, take your vehicle to a competent
mechanic.
SERVICE INFORMATION
Mopar Fluids, Lubricants and Parts are available from
your dealer and will help you keep your vehicle operat-
ing at its best. Your dealer also has the qualified service
personnel, special tools and equipment to perform all
service operations in an expert manner. Service manuals
are available which include detailed service information
for your vehicle. Refer to these manuals before attempt-
ing any procedure yourself. See Service Publications
information at the back of this manual.
322 MAINTAINING YOUR VEHICLE

NOTE:Failure to perform maintenance service at the
specified intervals as outlined in theMaintenance
Schedulesmay void provisions of your Vehicle Warranty.
CAUTION!
To maintain your vehicle safely follow these guide-
lines:
²Watch your vehicle's mileage and check yourMainte-
nance Schedulesregularly for required servicing. Ex-
cessive wear or damage to certain vehicle components
can result if required services are not performed.
²If you have your vehicle undercoated, inspect for
undercoating material on the propeller shafts. Such
material could cause the shafts to become unbalanced
and result in drivetrain vibrations. Remove any under-
coating with solvent.
²If you have your vehicle undercoated, make sure no
undercoating material is sprayed on the exhaust sys-
tem or components of the seat belt system.
NOTE:It is not possible for the manufacturer and
Cummins, Inc. to anticipate every possible circumstance
that can involve a potential hazard.
WARNING!
To maintain your vehicle safely and avoid personal
injury, follow these guidelines:
²Never spray or pour diesel fuel, flammable liquid or
starting fluids (ether) into the air cleaner canister, air
intake piping or turbocharger inlet in an attempt to
start the vehicle.
MAINTAINING YOUR VEHICLE 323
7

²Do not use alcohol or gasoline as a fuel blending agent.
They can be unstable under certain conditions and be
hazardous or explosive when mixed with diesel fuel.
²If an engine has been operating and the coolant is hot,
allow the engine to cool before you slowly loosen the
filler cap and relieve the pressure from the cooling
system.
²To avoid burns, remember that the engine components
will stay hot after the engine is shut off.
²Do not use gasoline or other flammable materials to
clean parts. Always use approved cleaning solvents.
²Relieve all pressure in the fuel, oil and cooling systems
before any lines, fittings or related items are removed
or disconnected. Be alert for possible pressure when
disconnecting any device from a system that utilizespressure. Do not check for pressure leaks with your
hand. High pressure oil or fuel can cause personal
injury.
WARNING!
Do not open the high pressure fuel system with the
engine running. Engine operation causes high fuel
pressure. High pressure fuel spray can cause serious
injury or death.
²Important:All maintenance other than that listed in
this manual, as well as some procedures listed here,
MUSTbe performed by your local Dodge Truck
Dealer. Your authorized Dodge Dealer has been
trained and has the necessary parts to maintain your
engine.
324 MAINTAINING YOUR VEHICLE

MAINTENANCE PROCEDURES
The pages that follow contain therequiredmaintenance
services determined by the engineers who designed your
vehicle.
Besides the maintenance items for which there are fixed
maintenance intervals, there are other items that should
operate satisfactorily without periodic maintenance.
However, if a malfunction of these items does occur, it
could adversely affect the engine or vehicle performance.
These items should be inspected if a malfunction is
observed or suspected.
Engine Oil
Checking Oil Level
To assure proper lubrication of your vehicle's engine, the
engine oil must be maintained at the correct level. Check
the oil level at regular intervals. The best time to check
the oil level is before starting the engine after it has been
parked overnight. When checking oil after operating the
engine, first ensure the engine is at full operating tem-
perature, then wait at least 15 minutes after engine
shutdown to check the oil.
MAINTAINING YOUR VEHICLE 325
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