brake DODGE RAM 5500 CHASSIS CAB 2009 4.G Service Manual

3. Turn the ignition key to the ON position, but do not
start the engine.
4. Depress the brake pedal.
5. Shift transmission into NEUTRAL.
6. Using the point of a ballpoint pen or similar object,
depress the recessed transfer case NEUTRAL button for
four seconds.
7. After shift is completed and the NEUTRAL light
comes on, release the NEUTRAL button.
8. Start engine.
9. Shift transmission into REVERSE.
10. Release brake pedal for five seconds and ensure that
there is no vehicle movement.
11. Repeat steps 9 and 10 with the transmission in
DRIVE.12. Shut engine OFF and place ignition key in the
unlocked OFF position.
13. Shift transmission into PARK.
14. Apply parking brake.
15. Attach vehicle to tow vehicle with tow bar.
16. Release parking brake.
NOTE:
•Steps 1 through 5 are requirements that must be met
prior to depressing the NEUTRAL selection button,
and must continue to be met until the four seconds
elapses and the shift has been completed. If any of
these requirements (with the exception of 3 - Key ON)
are not met prior to depressing the NEUTRAL button
or are no longer met during the four second timer, then
the NEUTRAL indicator light will flash continuously
until all requirements are met or until the NEUTRAL
button is released.
308 STARTING AND OPERATING

•The ignition key must be ON for a shift to take place
and for the position indicator lights to be operable. If
the key in not ON, the shift will not take place and no
position indicator lights will be on or flashing.
•Flashing NEUTRAL position indicator light indicates
that shift requirements have not been met.
CAUTION!
Damage to the transmission may occur if the trans-
mission is shifted into PARK with the transfer case in
NEUTRAL and the engine running. With the transfer
case in NEUTRAL ensure, that the engine is OFF
prior to shifting the transmission into PARK.
Returning to Normal Operation — Electronic Shift
Transfer Case
Use the following procedure to prepare your vehicle for
normal usage:1. Bring vehicle to a complete stop.
2. Shut OFF the engine.
3. Turn the ignition key to the ON position, but do not
start the engine.
4. Depress the brake pedal.
5. Shift transmission into NEUTRAL.
6. Using the point of a ballpoint pen or similar object,
depress the recessed transfer case Neutral (N) button for
one second.
7. After the Neutral indicator light turns off, release the
Neutral (N) button.
8. After the Neutral (N) button has been released, the
transfer case will shift to the position identified by the
selector switch.
9. Shift transmission into PARK.
STARTING AND OPERATING 309
5

NOTE:
•The transfer case cannot be shifted into NEUTRAL
from the 4AUTO (if equipped) position.
•Steps 1 through 5 are requirements that must be met
prior to depressing the transfer case Neutral (N)
button, and must continue to be met until one second
elapses and the shift has been completed. If any of
these requirements (with the exception of step3-key
ON) are not met prior to depressing the Neutral (N)
button, or are no longer met during the one second
time, then all of the mode position indicator lights will
flash continuously until all requirements are met, or
until the Neutral (N) button is released.
•The ignition key must be ON for a transfer case shift to
take place and for the position indicator lights to be
operable. If the key is not ON, the shift will not take
place and no position indicator lights will be on or
flashing.
•Flashing Neutral position indicator light indicates that
shift requirements have not been met.
WARNING!
You or others could be injured if you leave the
vehicle unattended with the transfer case in the
NEUTRAL position without first fully engaging the
parking brake. The transfer case NEUTRAL position
disengages both the front and rear driveshafts from
the powertrain and will allow the vehicle to move
despite the transmission position. The parking brake
should always be applied when the driver is not in
the vehicle.
310 STARTING AND OPERATING

WARNING!
After using the jack and tools, always reinstall them
in the original carrier and location. While driving
you may experience abrupt stopping, rapid accelera-
tion, or sharp turns. A loose jack, tools, bracket or
other objects in the vehicle may move around with
force, resulting in serious injury.
4500/5500 Models
These vehicles do not come equipped with a jack.
NOTE:Jacking and tire changing on 4500/5500 models
should be performed by an authorized dealer, or knowl-
edgeable service personnel with the appropriate heavy
duty equipment, like a tire service company.
Preparations For Jacking
1. Park the vehicle on a firm level surface. Avoid ice or
slippery areas.
WARNING!
Do not attempt to change a tire on the side of the
vehicle close to moving traffic. Pull far enough off
the road to avoid the danger of being hit when
operating the jack or changing the wheel.
2. Set the parking brake.
3. Place the shift lever into PARK (automatic transmis-
sion) or REVERSE (manual transmission). On 4-Wheel
drive vehicles, shift the transfer case to the “4L” position.
4. Turn OFF the ignition.
5. Turn on the Hazard Warning flasher.
316 WHAT TO DO IN EMERGENCIES

6. Block both the front and rear of the
wheel diagonally opposite the jacking
position. For example, if the right front
wheel is being changed, block the left
rear wheel.
NOTE: Passengers should not remain in the vehicle
when the vehicle is being jacked.
Jacking Instructions
Instructions
WARNING!
Carefully follow these tire changing warnings to
help prevent personal injury or damage to your
vehicle:
(Continued)
WARNING! (Continued)
•Always park on a firm, level surface as far from
the edge of the roadway as possible before raising
the vehicle.
•Block the wheel diagonally opposite the wheel to
be raised.
•Set the parking brake firmly and set an automatic
transmission in PARK; a manual transmission in
REVERSE.
•Never start or run the engine with the vehicle on a
jack.
•Do not let anyone sit in the vehicle when it is on a
jack.
•Do not get under the vehicle when it is on a jack.
•Only use the jack in the positions indicated and
for lifting this vehicle during a tire change.(Continued)
WHAT TO DO IN EMERGENCIES 317
6

Your vehicle is equipped with two 12-Volt batteries. If it
becomes necessary to use a booster battery with jumper
cables to start a vehicle’s engine because its batteries are
discharged, the following procedure should be used:
Set the parking brake and place the transmission in
PARK. Turn off lights, heater and other electrical loads.
Observe charge indicator (if equipped) in both batteries.
If the indicator (if equipped) is light or yellow on either
battery, replace that battery.CAUTION!
Use the Jump-Start Procedure only when the charge
indicator (if equipped) in both batteries is dark in the
center. Do not attempt jump-starting when either
battery charge indicator (if equipped) is bright or
yellow. If the charge indicator (if equipped) has a
green dot in the center, failure to start is not due to a
discharged battery and cranking system should be
checked.
1. Attach one jumper cable to the positive terminal of
booster battery and the other end of the same cable to the
positive terminal of the discharged battery.
WHAT TO DO IN EMERGENCIES 327
6

MAINTAINING YOUR VEHICLE
CONTENTS
Engine Compartment— 5.7L .............. 335
 Onboard Diagnostic System (OBD II) ....... 336
▫ Loose Fuel Filler Cap Message ........... 336
 Replacement Parts ..................... 337
 Dealer Service ........................ 337
 Maintenance Procedures ................. 338
▫ Engine Oil ......................... 338
▫ Engine Air Cleaner Filter ............... 340
▫ Maintenance Free Battery .............. 341 ▫
Air Conditioner Maintenance ............ 342
▫ Body Lubrication .................... 343
▫ Windshield Wiper Blades ............... 344
▫ Adding Washer Fluid ................. 344
▫ Exhaust System ..................... 345
▫ Cooling System ..................... 348
▫ Brake System ....................... 353
▫ Rear Axle And 4X4 Front Driving Axle Fluid
Level ............................. 355
7

ENGINE COMPARTMENT— 5.7L
1 — Air Cleaner Filter7 — Engine Oil Dipstick
2 — Automatic Transmission Dipstick 8 — Power Steering Fluid Reservoir
3 — Engine Oil Fill 9 — Washer Fluid Reservoir
4 — Brake Fluid Reservoir 10 — Engine Coolant Reservoir
5 — Battery 11 — Coolant Pressure Cap
6 — Integrated Power Module MAINTAINING YOUR VEHICLE 3357

If an examination of your engine compartment shows no
evidence of radiator or hose leaks, the vehicle may be
safely driven. The vapor will soon dissipate.
•Do not overfill the coolant recovery bottle.
•Check engine coolant (antifreeze) freeze point in the
radiator and in the coolant recovery bottle. If engine
coolant (antifreeze) needs to be added, contents of
coolant recovery bottle must also be protected against
freezing.
•If frequent engine coolant (antifreeze) additions are
required, or if the level in the coolant recovery bottle
does not drop when the engine cools, the cooling
system should be pressure tested for leaks.
•Maintain engine coolant (antifreeze) concentration at
50% HOAT engine coolant (antifreeze) (minimum)
and distilled water for proper corrosion protection of
your engine, which contains aluminum components.
•Make sure that the radiator and coolant recovery
bottle overflow hoses are not kinked or obstructed.
•Keep the front of the radiator clean. If your vehicle is
equipped with air conditioning, keep the front of the
condenser clean.
•Do not change the thermostat for Summer or Winter
operation. If replacement is ever necessary, install
ONLY the correct type thermostat. Other designs may
result in unsatisfactory cooling performance, poor gas
mileage, and increased emissions.
Brake System
Brake Master Cylinder – Brake Fluid Level Check
The fluid level of the master cylinder should be checked
when performing under the hood service, or immedi-
ately if the brake system warning lamp indicates system
failure.
MAINTAINING YOUR VEHICLE 353
7

The brake master cylinder has a translucent plastic
reservoir. On the outboard side of the reservoir, there is a
“MAX” mark and an “MIN” mark (4500/5500 vehicles
only). The fluid level must be kept within these two
marks. Do not add fluid above the full mark because
leakage may occur at the cap.
With disc brakes, the fluid level can be expected to fall as
the brake linings wear. However, an unexpected drop in
fluid level may be caused by a leak and a system check
should be conducted.
Refer to “Fluids, Lubricants, and Genuine Parts” in this
section for the correct fluid type.WARNING!
•Use of a brake fluid that may have a lower initial
boiling point, or unidentified as to specification,
may result in sudden brake failure during hard
prolonged braking. You could have an accident.
•Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts and the
brake fluid catching fire.
Use only brake fluid that has been in a tightly closed or
sealed container to avoid contamination from foreign
matter or moisture.
CAUTION!
Do not allow a petroleum-based fluid to contaminate
the brake fluid. Seal damage and loss of brake
performance may result.
354 MAINTAINING YOUR VEHICLE