DODGE RAM 2500 DIESEL 2004 3.G Owners Manual

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.
Propeller Shaft Universal Joints
Cross Type (No fittings) ÐRelubrication of this type of
universal joint is not required. The seals should be
inspected for external leaks or damage. If external leaks
or damage is evident, the universal joint should be
replaced.
Rear Axle And 4x4 Front Driving Axle Fluid Level
For Model 9.25 Front Axles and 10.5º/11.5º Rear Axles
refer to Recommended Fluids, Lubricants and Genuine
Parts for the correct lubricant 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.When checking the fluid level, the vehicle should be in a
level position. The fluid level should be 1/4º   1/4º (6.4
mm   6.4 mm) below the fill hole on the 9.25º Front Axle.
The fluid level should be 3/4º   1/4º (19 mm   6.4 mm)
below the fill hole on all 10.5º and 1/4º   1/4º (6.4 mm
  6.4 mm) on 11.5º Rear Axles.
Drain And Refill
Vehicles operated in normal service do not have regularly
scheduled oil changes. If fluid has become contaminated
with water or subjected to severe service, follow the
recommended change intervals in Maintenance Schedule
ªBº in Section 8 of this manual.
Lubricant Selection
Refer to Recommended Fluids, Lubricants and Genuine
Parts for the correct lubricant 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
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encountered in some off-highway types of service, will
require draining and refilling the axle to avoid damage.
Limited-Slip Differentialsin vehicles equipped with
10.5º/11.5º AxlesDO NOT REQUIREany limited slip
oil additive (friction modifiers).
Transfer Case Ð If Equipped
Fluid Level Check
This fluid level can be checked by removing the filler
plug. The fluid level should be to the bottom edge of the
filler plug hole with the vehicle in a level position.
Lubricant Selection
Refer to Recommended Fluids, Lubricants and Genuine
Parts for the correct lubricant type.
Manual Transmission Ð If Equipped
Fluid Level Check
This fluid level can be checked by removing the filler
plug. If the level of the lubricant is more than 1/4º below
the bottom of the filler hole while the vehicle is on level
ground, enough lubricant should be added to bring the
level to the bottom of the filler hole.
Lubricant Selection for NV-4500 (5-Speed Manual
Transmission) Ð If Equipped
This transmission does not require periodic changing. If
it becomes necessary to add fluid or change the fluid, be
sure to use the same lubricant or equivalent. Refer to
Recommended Fluids, Lubricants and Genuine Parts for
the correct lubricant type.
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Lubricant Selection for NV-5600 (6-Speed Manual
Transmission) Ð If Equipped
This transmission does not require periodic changing. If
it becomes necessary to add fluid or change the fluid, be
sure to use the same lubricant or equivalent. Refer to
Recommended Fluids, Lubricants and Genuine Parts for
the correct lubricant type.
Automatic Transmission
Fluid Level Check
The fluid level should be checked when the engine is
fully warmed up and the fluid in the transmission is at
normal operating temperature. Operation of the trans-
mission 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.
Procedure For Checking Fluid Level
To properly check the automatic transmission fluid level,
the following procedure must be used:
1. The vehicle must be on level ground.
2. The engine should be running at curb idle speed for a
minimum of 60 seconds.
3. Fully apply parking brake.
4. Place the gear selector briefly in each gear position
ending with the lever in N (Neutral).
5. Remove the dipstick and determine if the fluid is hot
or warm. Hot fluid is approximately 180ÉF (82ÉC) which
is the normal operating temperature after the vehicle has
been driven at least 15 miles. The fluid can not be
comfortably held between the finger tips. Warm is when
fluid is between 85É - 125ÉF (29É - 52ÉC).
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6. Wipe the dipstick clean and reinsert until seated.
Remove dipstick and note reading.
a. If the fluid is hot, the reading should be in the
crosshatched area marked ªOKº.
b. If the fluid is warm, the reading should be between
the two holes. If the fluid level indicates low, add
sufficient fluid to bring to the proper level.
Fluid is added through the dipstick tube.
NOTE:To prevent dirt and water from entering the
transmission after checking or replenishing fluid, make
certain that the dipstick cap is properly seated.
Selection Of Lubricant
Refer to Recommended Fluids, Lubricants and Genuine
Parts for the correct lubricant type. It is important that the
transmission fluid be maintained at the prescribed level
using the recommended 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
Recommended Fluids, Lubricants and Genuine Parts
for correct fluid type.
Automatic Transmission Fluid and Filter Change
To obtain best performance and long life for automatic
transmissions, the manufacturer recommends that they
be given regular maintenance service by an Authorized
Dodge Dealer or Service Center. It is important that the
transmission be adjusted periodically, the fluid main-
tained at the correct level, and that it be drained and
refilled as specified.
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It is important that proper lubricant is used in the
transmission. Refer to Recommended Fluids, Lubricants
and Genuine Parts for the correct lubricant type. A band
adjustment and filter change should be made at the time
of the oil change.
The fluid and filter should be changed and the bands
adjusted as specified in the Maintenance Schedule (Sec-
tion 8). Vehicles having severe usage should follow
Maintenance Schedule ªBº of the Maintenance Schedule
(Section 8).
Severe usage consists of:
²Off-the-highway operation;
²Trailer towing;
²Snow plow operation;
²Prolonged operation with heavy loading, especially in
hot weather.NOTE:If the transmission is disassembled for any
reason, the fluid and filter should be changed, and the
bands adjusted.
Special Additives
The manufacturer recommends against the addition of
any additives to the transmission. Exception to this
policy is the use of special dyes to aid in detecting fluid
leaks. The use of transmission sealers should be avoided,
since they may adversely affect seals.
Front Wheel Bearings
Front wheel bearings for all Dodge Ram Trucks are
sealed-for-life. They do not require greasing or seal
replacement. In some instances, these bearings will
ªpurgeº excess grease and the bearing housing will look
slightly wet. This is normal.
²Periodic inspection for excess play is recommended.
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²If a bearing assembly is accidentally separated when
servicing the brake rotors, it should be replaced.
Rear Wheel Bearings
Clean and repack when brake linings are replaced or
rotors resurfaced.
Selection Of Lubricating Grease
The National Lubricating Grease Institute (NLGI) has
developed a symbol (Certification Mark) to aid the
vehicle owner in the proper selection of grease for the
lubrication of wheel bearings and chassis components.
This symbol (an example shown below) is located on the
grease container and identifies the application and qual-
ity of the grease.There are two groups
identified: those for wheel
bearings (Letter ªGº) and
those for chassis (Letter
ªLº) lubrication. Perfor-
mance categories within
these groups result in dual
letter designations for
each group. The letter des-
ignations shown in the ex-
ample are the highest
quality level available and when combined as shown can
be used for both wheel bearing and chassis lubrication.
Use only those greases that have the NLGI symbol on the
container along with the proper quality level for your
application.
356 MAINTAINING YOUR VEHICLE

Noise Control System Required Maintenance &
Warranty
For 3500 Two-Wheel Drive and Four-Wheel Drive mod-
els over 10,000 lbs. (4 535 kg) Gross Vehicle Weight
Rating.
All vehicles built over 10,000 lbs. (4 535 kg) Gross Vehicle
Weight Rating and manufactured for sale and use in the
United States are required to comply with the Federal
Government's Exterior Noise Regulations. These vehicles
can be identified by the Noise Emission Control Label
located in the operator's compartment.
Required Maintenance For Noise Control Systems
The following maintenance services must be performed
every 6 months or 6,000 miles (9 600 km), whichever
comes first, to assure proper operation of the noise
control systems. In addition, inspection and service
should be performed anytime a malfunction is observed
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or suspected. Proper maintenance of the entire vehicle
will help the effectiveness of the noise control systems.
Exhaust System
Inspect the entire exhaust system for leaks and damaged
parts. Devices such as hangers, clamps, and U-bolts
should be tight and in good condition. Damaged compo-
nents, burned or blown out mufflers, burned or rusted
out exhaust pipes should be replaced according to the
procedures and specifications outlined in the appropriate
service manual.
Air Cleaner Assembly
Inspect air cleaner housing for proper assembly and fit.
Make certain that the air cleaner is properly positioned
and that the cover is tight. Check all hoses leading to the
cleaner for tightness. The air filter element must also be
clean and serviced according to the instructions outlined
in the Maintenance Schedule Section of this manual.Tampering With Noise Control System Prohibited
Federal law prohibits the following acts or the causing
thereof: (1) the removal or rendering inoperative by any
person, other than for purposes of maintenance, repair, or
replacement, of any device or element of design incorpo-
rated into any new vehicle for the purpose of noise
control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or (2) the use of the vehicle
after such device or element of design has been removed
or rendered inoperative by any person.
Among those acts presumed to constitute tampering are
the acts listed below.
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²AIR CLEANER
þRemoval of the air cleaner.
þRemoval of the air cleaner filter element from the air
cleaner housing.
þRemoval of the air ducting.
²EXHAUST SYSTEM
þRemoval or rendering inoperative exhaust system
components including the muffler or tailpipe.
²ENGINE COOLING SYSTEM
þRemoval or rendering inoperative the fan clutch.
þRemoval 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 manufacturer's
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 manufacturer's control, caused noise
emissions to exceed Federal standards, are covered by
this warranty for the life of the vehicle.
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Maintenance Log and Service Chart Ð 24 Valve Cummins Turbo Diesel
Noise Systems Maintenance Chart and Service Log Ð Insert Month, Day, Year under column mileage closest to
the mileage at which service was performed.
MILES 7,500 15,000 22,500 30,000 37,500 45,000 52,500 60,000
KILOMETERS 12 000 24 000 36 000 48 000 60 000 72 000 84 000 96 000
Exhaust system-
inspect
Air cleaner
assembly-inspect
ODOMETER
READING
PERFORMED
BY
PERFORMED
AT
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