service DODGE RAM 2500 DIESEL 2005 3.G Workshop Manual

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.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(s) should be changed and the bands
adjusted (if equipped) ) as specified in the Maintenance
Schedule (Section 8). Vehicles having severe usage should
follow Maintenance Schedule “B” of the Maintenance
Schedule (Section 8).
Severe usage consists of:•Off-the-highway operation;
•Trailer towing;
•Snow plow operation;
•Prolonged operation with heavy loading, especially in
hot weather.
372 MAINTAINING YOUR VEHICLE

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 observedor 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.
MAINTAINING YOUR VEHICLE 375
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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 noiseemissions to exceed Federal standards, are covered by
this warranty for the life of the vehicle.
Maintenance Log and Service Chart — 24 Valve Cummins Turbo Diesel
Noise Systems Maintenance Chart and Service Log — 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
MAINTAINING YOUR VEHICLE 377
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Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest to
the mileage at which service was performed.
MILES 67,500 75,000 82,500 90,000 97,500 84,000 105,00 112,500
KILOMETERS 108 000 120 000 132 000 144 000 126 000 156 000 168 000 181 000
Exhaust system-inspect
Air cleaner assembly-inspect
ODOMETER READING
PERFORMED BY
PERFORMED AT
378 MAINTAINING YOUR VEHICLE

EMISSION CONTROL SYSTEM MAINTENANCE
The “Scheduled” maintenance services, listed inbold
typein this section (Section 8) must be done at the times
or mileages specified to assure the continued proper
functioning of the emission control system. These, and all
other maintenance services included in this manual,
should be done to provide best vehicle performance and
reliability. More frequent maintenance may be needed for
vehicles in severe operating conditions such as dusty
areas and very short trip driving.
Inspection and service also should be done any time a
malfunction is suspected.
NOTE:Maintenance, replacement, or repair of the emis-
sion control devices and systems on your vehicle may be
performed by any automotive repair establishment or
individual using any automotive part which has been
certified pursuant to U.S. EPA or, in the State of Califor-
nia, California Air Resources Board regulations.
MAINTENANCE SCHEDULES — 24–VALVE
CUMMINS TURBO DIESEL
There are two maintenance schedules that show the
requiredservice for your vehicle.
First is Schedule“B”. It is for vehicles that are operated
under the conditions that are listed below and at the
beginning of the schedule.
•Frequent short trips where the engine does not achieve
full operating temperature (operating temperature de-
fined as 190° F (66° C) coolant temperature).
•Extensive engine idling (over 10 minutes per hour of
operation) at ambient temperatures less than 32° F (0°
C).
•Driving in dusty conditions.
•Frequent trailer towing.
•Taxi, police, or delivery service (commercial service).
402 MAINTENANCE SCHEDULES
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Schedule “B”
Follow schedule “B” if you usually operate your vehicle
under one or more of the following conditions.
•Frequent short trips where the engine does not achieve
full operating temperature (operating temperature de-
fined as 190° F (66° C) coolant temperature).
•Extensive engine idling (over 10 minutes per hour of
operation) at ambient temperatures less than 32° F (0°
C).
•Driving in dusty conditions.
•Frequent trailer towing.
•Taxi, police, or delivery service (commercial service).
•Off-road or desert operation.
•Extensive operation at high engine speeds (greater
than 2900 rpm) and loads (greater than 70% throttle).
NOTE:IfANYof these apply to you then change your
coolant every 102,000 miles (163 000 km) or 60 months,
whichever comes first and follow schedule “B” of the
Maintenance Schedulessection of this manual.
SCHEDULE “B” 405
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Miles 116,250 120,000 123,750 127,500 131,250 135,000
(Kilometers) (186 000) (192 000) (198 000) (204 000) (210 000) (216 000)
Replace fuel filter element. Clean the water in
fuel sensor.XX
Inspect front wheel bearings. X
Change rear axle fluid. X X
Change front axle fluid (4X4). X X
Change 6-spd manual transmission (G-56)
fluid 2500/3500 models only.X
Inspect brake linings. X X
Inspect and adjust parking brake if necessary. X X
Drain and refill automatic transmission fluid
and change main sump and spin-on cooler
return filter (if equipped) (545 RFE only).X
Drain and refill automatic transmission fluid.
Replace filter and adjust bands (48RE only).X
Inspection and service should also be performed anytime a
malfunction is observed or suspected. Retain all receipts.
SCHEDULE “B” 415
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Miles 112,500 120,000 127,500 135,000 142,500 150,000
(Kilometers) (181 000) (193 000) (205 000) (217 000) (229 000) (241 000)
[Months] [90] [96] [102] [108] [114] [120]
Replace fuel filter element. Clean the water in
fuel sensor.XXX
Inspect front wheel bearings. X X
Inspect brake linings. X X
Inspect and adjust parking brake if necessary. X X
Adjust valve lash clearance.X
Inspection and service should also be performed anytime
a malfunction is observed or suspected. Retain all re-
ceipts.
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 right equipment. If
you have any doubt about your ability to perform a
service job, take your vehicle to a competent me-
chanic.
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IF YOU NEED CONSUMER ASSISTANCE
CONTENTS

Suggestions For Obtaining Service For Your
Vehicle..............................424
▫Prepare For The Appointment............424
▫Prepare A List........................424
▫Be Reasonable With Requests.............424

If You Need Assistance...................424
Warranty Information....................426

MoparParts.........................428

Reporting Safety Defects..................428
▫In Canada..........................428

Publication Order Forms..................429
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SUGGESTIONS FOR OBTAINING SERVICE FOR
YOUR VEHICLE
Prepare For The Appointment
If you’re having warranty work done, be sure to have the
right papers with you. Take your warranty folder. All
work to be performed may not be covered by the
warranty, discuss additional charges with the service
manager. Keep a maintenance log of your vehicle’s
service history. This can often provide a clue to the
current problem.
Prepare A List
Make a written list of your vehicle’s problems or the
specific work you want done. If you’ve had an accident,
or work done that is not on your maintenance log, let the
service advisor know.
Be Reasonable With Requests
If you list a number of items, and you must have your
vehicle by the end of the day, discuss the situation with the
service advisor and list the items in order of priority. At
many dealers you may obtain a rental vehicle at a minimal
daily charge. If you need a rental, it is advisable to make
these arrangements when you call for an appointment.
IF YOU NEED ASSISTANCE
The manufacturer and its dealers are vitally interested in
your satisfaction. We want you to be happy with our
products and services.
Warranty service must be done by an authorized Chrysler,
Dodge, or Jeep dealer. We strongly recommend that you
take your vehicle to you selling dealer. They know you
and your vehicle best, and are most concerned that you
get prompt and high quality service. The manufacturer’s
dealers have the facilities, factory-trained technicians,
special tools, and the latest information to assure your
vehicle is fixed correctly and in a timely manner.
424 IF YOU NEED CONSUMER ASSISTANCE