DODGE RAM 5500 CHASSIS CAB 2008 3.G Owners Manual

CAUTION!
Damage to the catalytic converter can result if your
vehicle is not kept in proper operating condition. In
the event of engine malfunction, particularly involv-
ing engine misfire or other apparent loss of perfor-
mance, have your vehicle serviced promptly. Contin-
ued operation of your vehicle with a severe
malfunction could cause the converter to overheat,
resulting in possible damage to the converter and the
vehicle.
NOTE:Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
WARNING!
A hot exhaust system can start a fire if you park over
materials that can burn. Such materials might be
grass or leaves coming into contact with your exhaust
system. Do not park or operate your vehicle in areas
where your exhaust system can contact anything that
can burn.
In unusual situations involving grossly malfunctioning
engine operation, a scorching odor may indicate severe
and abnormal catalyst overheating. If this occurs, the
vehicle should be stopped, the engine shut off and the
vehicle allowed to cool. Thereafter, service, including a
tune-up to manufacturer's specifications, should be ob-
tained immediately.
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To minimize the possibility of catalyst damage:
²Do not shut off the engine or interrupt the ignition
when the transmission is in gear and the vehicle is in
motion.
²Do not try to start engine by pushing or towing the
vehicle.
²Do 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.
Intervention Regeneration Strategy ± EVIC
Message Process Flow (Catalyst Full Message)
(Diesel Engines Only)
Your new Cummins 6.7L diesel meets all EPA Heavy
Duty Diesel Engine Emissions Standards, resulting in the
lowest emitting diesel engine ever produced.To achieve these emission standards your vehicle is
equipped with state of the art engine and exhaust system.
The engine and exhaust aftertreatment system work
together to achieve the EPA Heavy Duty Diesel Engine
Emissions Standards. These systems are seamlessly inte-
grated into your vehicle and managed by the Cummins
6.7L engine Powertrain Control Module (PCM). The PCM
manages engine combustion to allow the exhaust sys-
tem's catalyst to trap and burn Particulate Matter (PM)
pollutants, with no input or interaction on your part.
Additionally, the overhead console in your vehicle has
the ability to alert you to additional maintenance re-
quired on your truck or engine. Refer to the following
messages that may be displayed on your Electronic
Vehicle Information Center (EVIC):
422 MAINTAINING YOUR VEHICLE

WARNING!
A hot exhaust system can start a fire if you park over
materials that can burn. Such materials might be
grass or leaves coming into contact with your exhaust
system. Do not park or operate your vehicle in areas
where your exhaust system can contact anything that
can burn.
Service CCV Filter
The 6.7L Cummins engine utilizes a Closed Crankcase
Ventilation (CCV) system. This system filters and recycles
gasses produced in the crankcase during the normal
combustion process. Service CCV Filter will be displayed
on the overhead console of your Dodge truck if the CCV
filter is due for required maintenance. This filter is
located on the top of the engine valve cover. For addi-
tional information, see your Dodge truck dealer.
Catalyst Full See Owner Manual
Catalyst Full See Owner Manual will be displayed on the
overhead console of your vehicle if the exhaust particu-
late filter reaches 80% of its maximum storage capacity.
Under conditions of exclusive short duration and low
speed driving cycles, your Cummins engine and exhaust
aftertreatment system may never reach the conditions
required to remove the trapped PM, if this occurs Cata-
lyst Full See Owner Manual will be displayed on the
overhead console in your vehicle. If this message is
displayed you will hear one chime to assist in alerting
you of this condition.
Catalyst Stat::::::::::80%
Catalyst Stat::::::::::80% will replace the message Catalyst
Full See Owner Manual after it is displayed for one
minute. The engine Powertrain Control Module (PCM)
will continue to monitor the amount of particulate matter
MAINTAINING YOUR VEHICLE 423
7

trapped in the particulate filter. This message indicates
the percentage of the particulate filter capacity that has
been used.
By simply driving your vehicle at highway speeds for as
little as 45 minutes you can remedy the condition in the
particulate filter system and allow your Cummins engine
and exhaust Aftertreatment system to remove the
trapped PM and restore the system to normal operating
condition.
Catalyst Stat:::::::::::80%, 90%, 99%
Catalyst Stat:::::::::::80%, 90%, 99% If you are unable to
drive your vehicle under these conditions for an ex-
tended period of time after the initial warning notifica-
tion, the Engine PCM will continue to monitor the
particulate filter and will display the progression of
particulate filter usage (80, 90, 99%) on the EVIC message
center.
CATALYST FULL SERVICE REQD
If the particulate filter reaches 99% of it's capacity the
overhead console in your vehicle will chime twice and
display the message CATALYST FULL SERVICE REQD.
At this point the engine PCM will register a fault code,
the instrument panel will display a MIL light and the
engine PCM will derate the truck reducing its horse-
power and torque output.
The PCM derates the engine in order to limit the likeli-
hood of permanent damage to the aftertreatment system.
If this condition is not corrected and a dealer service is
not performed, extensive exhaust aftertreatment damage
can occur. In order to correct this condition it will be
necessary to have the truck serviced by your local
authorized dealer.
424 MAINTAINING YOUR VEHICLE

Emission-Related Components (Gas Engines)
Positive Crankcase (PCV) Valve
Proper operation of the crankcase ventilation system
requires that the PCV valve be free of sticking or plug-
ging from deposits. Deposits can accumulate in the PCV
valve and passages with increasing mileage. Have the
PCV valve, hoses, and passages checked for proper
operation at the intervals specified. If the valve is
plugged or sticking, replace with a new valveÐdo not
attempt to clean the old PCV valve!Check the ventila-
tion hoses for indications of damage, weepage or plug-
ging with deposits. Replace if necessary.
Maintenance Free Battery (Gas Engines)
The top of the maintenance free battery is permanently
sealed. You will never have to add water, nor is periodic
maintenance required.
WARNING!
²Battery fluid is a corrosive acid solution and can
burn or even blind you. Don't allow battery fluid
to contact your eyes, skin or clothing. Don't lean
over a battery when attaching clamps. If acid
splashes in eyes or on skin, flush the area imme-
diately with large amounts of water.
²Battery gas is flammable and explosive. Keep
flame or sparks away from the battery. Don't use a
booster battery or any other booster source with an
output greater than 12 volts. Don't allow cable
clamps to touch each other.
²Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
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7

CAUTION!
²It is essential when replacing the cables on the
battery that the positive cable is attached to the
positive post and the negative cable is attached to
the negative post. Battery posts are marked (+)
positive and negative (-) and identified on the
battery case.
²If a ªfast chargerº is used while battery is in
vehicle, disconnect both vehicle battery cables
before connecting the charger to battery. Do not
use a ªfast chargerº to provide starting voltage.
Maintenance Free Batteries (Diesel Engines)
The top of the maintenance free batteries are perma-
nently sealed. You will never have to add water, nor is
periodic maintenance required.
NOTE:Replacement batteries should both be of equal
capacity to prevent damage to the vehicle's charging
system.
426 MAINTAINING YOUR VEHICLE

CAUTION!
It is essential when replacing the cables on the
battery that the positive cable is attached to the
positive post and the negative cable is attached to the
negative post. Battery posts are marked (+) positive
and negative (-) and identified on the battery case.
Also, if a ªfast chargerº is used while battery is in
vehicle, disconnect both vehicle battery cables before
connecting the charger to battery. Do not use a ªfast
chargerº to provide starting voltage.
WARNING!
Battery posts, terminals, and related accessories con-
tain lead and lead compounds. Always wash hands
after handling the battery.
Battery Blanket Usage
A battery loses 60% of its cranking power as the battery
temperature decreases to 0ÉF (-18É). For the same de-
crease in temperature, the engine requires twice as much
power to crank at the same RPM. The use of 120 VAC
powered battery blankets will greatly increase starting
capability at low temperatures. Suitable battery blankets
are available from your authorized Mopartdealer.
Air Conditioner Maintenance
For best possible performance, your air conditioner
should be checked and serviced by an Authorized Dealer
at the start of each warm season. This service should
include cleaning of the condenser fins and a performance
test. Drive belt tension should also be checked at this
time.
NOTE:Refer to Section 3 of the Warranty Information
book for further warranty information.
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WARNING!
²Use only refrigerants and compressor lubricants
approved by the manufacturer for your air condi-
tioning system. Some unapproved refrigerants are
flammable and can explode, injuring you. Other
unapproved refrigerants or lubricants can cause
the system to fail, requiring costly repairs. Refer to
Section 3 of the Warranty Information book for
further warranty information.
²The air conditioning system contains refrigerant
under high pressure. To avoid risk of personal
injury or damage to the system, adding refrigerant
or any repair requiring lines to be disconnected
should be done by an experienced repairman.
Refrigerant Recovery and Recycling
R-134a Air Conditioning Refrigerant is a hydrofluorocar-
bon (HFC) that is endorsed by the Environmental Pro-
tection Agency and is an ozone-saving product. How-
ever, the manufacturer recommends that air conditioning
service be performed by dealers or other service facilities
using recovery and recycling equipment.
Power Steering Ð Fluid Check
Checking the power steering fluid level at a defined
service interval is not required. The fluid should only be
checked if a leak is suspected, abnormal noises are
apparent, and/or the system is not functioning as antici-
pated. Coordinate inspection efforts through a certified
DaimlerChrysler Dealership.9
428 MAINTAINING YOUR VEHICLE

WARNING!
Fluid level should be checked on a level surface and
with the engine off to prevent injury from moving
parts and to insure accurate fluid level reading. Do
not overfill. Use only manufacturers recommended
power steering fluid.
If necessary, add fluid to restore to the proper indicated
level. With a clean cloth, wipe any spilled fluid from all
surfaces. Refer to Fluids, Lubricants, and Genuine Parts
for correct fluid type.
Front Suspension Ball Joints
The ball joints originally supplied with the vehicle are
permanently lubricated at the factory and do not require
service. The ball joints and seals should be inspected
whenever the vehicle is serviced for other reasons.
Steering Linkage Ð Inspection
Whenever the vehicle is hoisted, all steering linkage
joints should be inspected for evidence of damage. If
seals are damaged, parts should be replaced to prevent
leakage or contamination of the grease.
MAINTAINING YOUR VEHICLE 429
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Front Prop Shaft Lubrication
Lubricate the front driveshaft grease fitting at each oil
change listed in the appropriate Maintenance Schedule
for your vehicle. Use Moparttype MS-6560 (lithium
based grease), or equivalent.
Front Axle Universal Drive Joints And Ball Joints
The front axle universal joint and ball joints are perma-
nently lubricated and do not require servicing.
Body Lubrication
Locks and all body pivot points, including such items as
seat tracks, doors, liftgate and hood hinges, should be
lubricated periodically to assure quiet, easy operation
and to protect against rust and wear. Prior to the appli-
cation of any lubricant, the parts concerned should be
wiped clean to remove dust and grit; after lubricating
excess oil and grease should be removed. Particular
attention should also be given to hood latching compo-
nents to insure proper function. When performing other
underhood services, the hood latch, release mechanism
and safety catch should be cleaned and lubricated.
The external lock cylinders should be lubricated twice a
year, preferably in the fall and spring. Apply a small
Front Driveshaft Grease Fitting
430 MAINTAINING YOUR VEHICLE