transmission DODGE RAM 2500 DIESEL 2009 4.G Repair Manual

ONBOARD DIAGNOSTIC SYSTEM (OBD II)Your vehicle is equipped with a sophisticated onboard
diagnostic system called OBDII. This system monitors
the performance of the emissions, engine, and automatic
transmission control systems. When these systems are
operating properly, your vehicle will provide excellent
performance and fuel economy, as well as engine emis-
sions well within current government regulations.
If any of these systems require service, the OBD II system
will turn on the Malfunction Indicator Light (MIL). It will
also store diagnostic codes and other information to
assist your service technician in making repairs. Al-
though your vehicle will usually be drivable and not
need towing, see your authorized dealer for service as
soon as possible.
CAUTION!
•
Prolonged driving with the MIL on could cause
further damage to the emission control system. It
could also affect fuel economy and drivability. The
vehicle must be serviced before any emissions
tests can be performed.
•
If the MIL is flashing, severe catalytic converter
damage and power loss will soon occur. Immedi-
ate service is required.
Loose Fuel Filler Cap MessageIf the vehicle’s diagnostic system determines that the fuel
filler cap in loose, improperly installed, or damaged, a
GASCAP message will be displayed in the instrument
cluster. Tighten the gas cap until a “clicking” sound is
heard. This is an indication that the gas cap is properly
tightened. Press the odometer reset button to turn the
message off. If the problem persists, the message will
428 MAINTAINING YOUR VEHICLE

To minimize the possibility of catalyst damage:•
Do not shut off the engine or interrupt the ignition
when the transmission is in gear and the vehicle is in
motion.
•
Do not try to start the engine by pushing or towing the
vehicle.
•
Do not idle the engine with any spark plug wires
disconnected or removed, such as when diagnostic
testing, or for prolonged periods during very rough
idling or malfunctioning operating conditions.
Cooling System
WARNING!
You or others can be badly burned by hot engine
coolant (antifreeze) or steam from your radiator. If
you see or hear steam coming from under the hood,
do not open the hood until the radiator has had time
to cool. Never try to open a cooling system pressure
cap when the radiator is hot.Engine Coolant ChecksCheck the engine coolant (antifreeze) protection every
12 months (before the onset of freezing weather, where
applicable). If the engine coolant (antifreeze) is dirty or
rusty in appearance, the system should be drained,
flushed and refilled with fresh engine coolant (anti-
freeze). Check the front of the A/C condenser for any
MAINTAINING YOUR VEHICLE 441
7

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.
2500/3500 Model Axles DO NOT REQUIREany limited
slip oil additive (friction modifiers).Transfer Case
Drain And RefillRefer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.Lubricant SelectionRefer to “Fluids, Lubricants, and Genuine Parts” in this
section for the correct fluid type.
Fluid Level CheckThis 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.Automatic Transmission
Selection Of LubricantIt is important that the proper lubricant is used in the
transmission to assure optimum transmission perfor-
mance. Use only the manufacturer ’s recommended trans-
mission fluid. Refer to “Fluids, Lubricants, and Genuine
Parts” in this section for the correct fluid type. It is
important that the transmission fluid be maintained at
the prescribed level using the recommended fluid. No
chemical flushes should be used in any transmission;
only the approved lubricant may be used.
MAINTAINING YOUR VEHICLE 449
7

CAUTION!
Using a transmission fluid other than the manufac-
turer’s recommended fluid may cause deterioration
in transmission shift quality and/or torque converter
shudder. Using a transmission fluid other than the
manufacturer’s recommended fluid will result in
more frequent fluid and filter changes. Refer to
“Fluids, Lubricants, and Genuine Parts” in this sec-
tion for correct fluid type.Fluid Level CheckIf your vehicle is equipped with a dipstick, use the
following procedure. If your vehicle has a capped dip-
stick tube, it is sealed and should not be tampered with.
Your authorized dealer has the proper tools to ensure that
the fluid level is set properly. The fluid level should be
checked when the engine is fully warmed up and thefluid in the transmission is at normal operating tempera-
ture. Operation of the transmission 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.
Fluid Level Check – 545RFECheck the fluid level while the transmission is at normal
operating temperature 82°C (180°F). 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.
450 MAINTAINING YOUR VEHICLE

3. Fully apply the parking brake and press the brake
pedal.
4. Place the shift lever momentarily into each gear posi-
tion ending with the lever in 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 “HOT”
(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 minutes for the oil to fully drain into
the transmission before rechecking the fluid level.
NOTE: If it is necessary to check the transmission below
the operating temperature, the fluid level should be between the two “COLD” (lower) holes on the dipstick
with the fluid at approximately 70°F (21°C) (room tem-
perature). If the fluid level is correctly established at
room temperature, it should be between the “HOT”
(upper) reference holes when the transmission reaches
180°F (82°C). Remember it is best to check the level at the
normal operating temperature.
CAUTION!
Be aware that if the fluid temperature is below 50°F
(10°C) 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
MAINTAINING YOUR VEHICLE 451
7

dipstick cap to spring back slightly from its fully seated
position, as long as its seal remains engaged in the
dipstick tube.Automatic Transmission Fluid and Filter ChangeRefer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.
NOTE:If the transmission is disassembled for any
reason, the fluid and filter(s) should be changed.
It is important that the proper lubricant is used in the
transmission. Refer to “Fluids, Lubricants, and Genuine
Parts” in this section for the correct fluid type.Special AdditivesAutomatic Transmission Fluid (ATF) is an engineered
product and its performance may be impaired by supple-
mental additives. Therefore, do not add any fluid addi-
tives to the transmission. The only exception to this policy is the use of special dyes to aid in detecting fluid
leaks. In addition, avoid using transmission sealers as
they may adversely affect seals.
Appearance Care and Protection from Corrosion
Protection of Body and Paint from CorrosionVehicle body care requirements vary according to geo-
graphic locations and usage. Chemicals that make roads
passable in snow and ice, and those that are sprayed on
trees and road surfaces during other seasons, are highly
corrosive to the metal in your vehicle. Outside parking,
which exposes your vehicle to airborne contaminants,
road surfaces on which the vehicle is operated, extreme
hot or cold weather and other extreme conditions will
have an adverse affect on paint, metal trim, and under-
body protection.
The following maintenance recommendations will enable
you to obtain maximum benefit from the corrosion
resistance built into your vehicle.
452 MAINTAINING YOUR VEHICLE

Cavity CartridgeFuseMini
Fuse Description
1 20 Amp
YellowPower Outlet Console
2 20 Amp
YellowCabin Compartment
Node (CCN) Door
Locks
3——
4 15 Amp
BlueAisin Transmission
Controls (Diesel Only)
5 20 Amp
YellowPower Sunroof
6 10 Amp
RedVistronic Fan/
Wastegate Solenoid
7——
8 10 Amp
RedHeated Mirrors
Cavity Cartridge
FuseMini
Fuse Description
9 30 Amp Pink Off Road Module
Power
10 5 Amp
OrangeTrx-Off Rd Pkg Sen
(Gas Engine Only)
NOTE: Insert 5 amp
fuse in this cavity to
enable the TRX capa-
bility (If Equipped).
11 20 Amp
Yellow Ignition 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)/EOM
MAINTAINING YOUR VEHICLE 459
7

ChassisComponentFluid, Lubricant, or Genuine Part
Automatic Transmission MOPARATF+4 Automatic Transmission Fluid
Transfer Case MOPARATF+4 Automatic Transmission Fluid
NVG 246 Automatic Transfer Case
Only MOPAR
PN 05179014AA, NVG 246 Automatic Transmission Fluid or
equivalent
2500/3500 Model Front and Rear
Axle Synthetic, GL-5 SAE, 75W-90 or equivalent. Limited-Slip 10.5/11.5 inch
Rear Axles
Limited slip additive is not required.
Brake Master Cylinder MOPARDOT 3 and SAE J1703 should be used or equivalent. If DOT 3
brake fluid is not available, then DOT 4 is acceptable. Use only recom-
mended brake fluids.
Power Steering Reservoir MOPARATF+4 Automatic Transmission Fluid480 MAINTAINING YOUR VEHICLE

At Each Stop for Fuel•
Check 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.
•
Check the windshield washer solvent and add if
required.
Once a Month
•
Check tire pressure and look for unusual wear or
damage.
•
Inspect the battery, clean and tighten the terminals as
required.
•
Check the fluid levels of the coolant reservoir, brake
master cylinder, power steering and transmission and
add as needed.
•
Check all lights and other electrical items for correct
operation.
At Each Oil Change
•
Change the engine oil filter.
•
Inspect the brake hoses and lines.
CAUTION!
Failure to perform the required maintenance items
may result in damage to the vehicle.Required Maintenance IntervalsRefer to the Maintenance Schedules on the following
pages for the required maintenance intervals.
484 MAINTENANCE SCHEDULES
8M A I
N T
E
N A
N CE
S
C
H E
D
U L
E
S

54,000 Miles (90,000 km) or
54 Months Maintenance
Service Schedule❏Change the engine oil and engine oil
filter.
❏ Rotate tires.
❏ Lube front drive shaft fitting (2500/3500
(4x4) models only).
❏ Inspect the front & rear axle fluid.
Change if using your vehicle for police,
taxi, fleet, off-road or frequent trailer
towing.Odometer Reading DateRepair Order #Dealer CodeSignature Authorized Chrysler Dealer
60,000 Miles (100,000 km) or 60 Months Maintenance Service
Schedule❏Change the engine oil and engine oil filter.
❏ Rotate tires.
❏ Replace the engine air cleaner filter.
❏ Replace the spark plugs (5.7L engine).
❏ Inspect the brake linings, replace if necessary.
❏ Lube front drive shaft fitting (2500/3500 (4x4) models only).
❏ Change the automatic transmission fluid & filter(s) if using your vehicle for any of the
following: police, taxi, fleet or frequent trailer towing.
❏ Inspect the transfer case fluid.
❏ Flush and replace the engine coolant at 60 months if not done at 102,000 miles
(170 000 km).
Odometer Reading DateRepair Order #Dealer CodeSignature Authorized Chrysler Dealer
MAINTENANCE SCHEDULES 489
8M
A I
N T
E
N A
N CE
S
C
H E
D
U L
E
S