brake Ram 5500 Chassis Cab 2011 Workshop Manual

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.
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.
360 WHAT TO DO IN EMERGENCIES

Jacking Instructions
Instructions
WARNING!
Carefully follow these tire changing warnings to
help prevent personal injury or damage to your
vehicle:
•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.(Continued)
WARNING! (Continued)
•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.
•If working on or near a roadway, be extremely
careful of motor traffic.(Continued)
6
WHAT TO DO IN EMERGENCIES 361

Preparations for Jump-Start
The battery in your vehicle is located in the front of the
engine compartment, behind the left headlight assembly.
NOTE:The positive battery post is covered with a
protective cap. Lift up on the cap to gain access to the
positive battery post.WARNING!
•Take care to avoid the radiator cooling fan when-
ever the hood is raised. It can start anytime the
ignition switch is on. You can be injured by
moving fan blades.
•Remove any metal jewelry such as watch bands or
bracelets that might make an inadvertent electrical
contact. You could be seriously injured.
•Batteries contain sulfuric acid that can burn your
skin or eyes and generate hydrogen gas which is
flammable and explosive. Keep open flames or
sparks away from the battery.
1. Set the parking brake, shift the automatic transmission
into PARK and turn the ignition to LOCK.
2. Turn off the heater, radio, and all unnecessary electri-
cal accessories.
Positive Battery Post
6
WHAT TO DO IN EMERGENCIES 371

3. If using a another vehicle to jump-start the battery,
park the vehicle within the jumper cables reach, set the
parking brake and make sure the ignition is OFF.
WARNING!
Do not allow vehicles to touch each other as this
could establish a ground connection and personal
injury could result.
Jump-Starting Procedure
WARNING!
Failure to follow this procedure could result in per-
sonal injury or property damage due to battery ex-
plosion.
CAUTION!
Failure to follow these procedures could result in
damage to the charging system of the booster vehicle
or the discharged vehicle.
1. Connect the positive (+)end of the jumper cable to the
positive (+)post of the discharged vehicle.
2. Connect the opposite end of the positive (+)jumper
cable to the positive (+)post of the booster battery.
3. Connect the negative end (-)of the jumper cable to the
negative (-)post of the booster battery.
4. Connect the opposite end of the negative (-)jumper
cable to a good engine ground (exposed metal part of the
discharged vehicle’s engine) away from the battery and
the fuel injection system.
372 WHAT TO DO IN EMERGENCIES

▫Exhaust System ..................... 394
▫ Cooling System ..................... 396
▫ Brake System ....................... 401
▫ Rear Axle And 4X4 Front Driving Axle Fluid
Level ............................. 404
▫ Transfer Case ....................... 405
▫ Automatic Transmission ............... 405
▫ Appearance Care And Protection From
Corrosion .......................... 409
 Fuses .............................. 414
▫ Totally Integrated Power Module ......... 414
 Vehicle Storage ....................... 419 
Replacement Bulbs .................... 420
 Bulb Replacement ..................... 420
▫ Dual Or Quad Headlamp/Front Park And
Turn Signal – If Equipped .............. 420
▫ Fog Lamps – If Equipped .............. 422
▫ Center High-Mounted Stoplamp (CHMSL)
With Cargo Lamp .................... 423
▫ Cab Top Clearance Lamps – If Equipped .... 424
 Fluid Capacities ...................... 426
 Fluids, Lubricants And Genuine Parts ....... 427
▫ Engine ............................ 427
▫ Chassis ........................... 428
380 MAINTAINING YOUR VEHICLE

ENGINE COMPARTMENT — 5.7L
1 — Air Cleaner Filter7 — Washer Fluid Reservoir
2 — Automatic Transmission Dipstick 8 — Integrated Power Module
3 — Engine Oil Fill 9 — Power Steering Fluid Reservoir
4 — Engine Oil Dipstick 10 — Coolant Pressure Cap
5 — Brake Fluid Reservoir 11 — Engine Coolant Reservoir
6 — Battery
7
MAINTAINING YOUR VEHICLE 381

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, also.
•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 engine coolant (antifreeze)
performance, poor gas mileage, and increased
emissions.
Brake System
In order to assure brake system performance, all brake
system components should be inspected periodically.
Refer to “Maintenance Schedule” for the proper mainte-
nance intervals.7
MAINTAINING YOUR VEHICLE 401

WARNING!
Riding the brakes can lead to brake failure and
possibly an accident. Driving with your foot resting
or riding on the brake pedal can result in abnormally
high brake temperatures, excessive lining wear, and
possible brake damage. You would not have your full
braking capacity in an emergency.
Brake Fluid Level Check
The fluid level of the master cylinder should be checked
when performing under the hood service or immediately
if the brake system warning lamp indicates system
failure.
The brake master cylinder has a translucent plastic
reservoir. On the outboard side of the reservoir, there is a
“MAX” dot and an “MIN” dot. The fluid level must be
kept within these two dots. Do not add fluid above the
MAX 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.
Use only the manufacturer’s recommended brake fluid.
Refer to “Fluids, Lubricants, and Genuine Parts” in
“Maintaining Your Vehicle” for further information.
402 MAINTAINING YOUR VEHICLE

WARNING!
•Use only manufacturer’s recommended brake
fluid. Refer to “Fluids, Lubricants, and Genuine
Parts” in “Maintaining Your Vehicle” for further
information. Using the wrong type of brake fluid
can severely damage your brake system and/or
impair its performance. The proper type of brake
fluid for your vehicle is also labeled on the origi-
nal factory installed hydraulic master cylinder
reservoir.(Continued)
WARNING! (Continued)
•To avoid contamination from foreign matter or
moisture, use only new brake fluid or fluid that
has been in a tightly closed container. Keep the
master cylinder reservoir cap secured at all times.
Brake fluid in a open container absorbs moisture
from the air resulting in a lower boiling point.
This may cause it to boil unexpectedly during hard
or prolonged braking, resulting in sudden brake
failure. This could result in a accident.
•Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts, causing
the brake fluid to catch fire. Brake fluid can also
damage painted and vinyl surfaces, care should be
taken to avoid its contact with these surfaces.(Continued)
7
MAINTAINING YOUR VEHICLE 403

WARNING! (Continued)
•Do not allow petroleum based fluid to contami-
nate the brake fluid. Brake seal components could
be damaged, causing partial or complete brake
failure. This could result in an accident.
Rear Axle And 4x4 Front Driving Axle Fluid Level
For models with 9.25 in Front Axles and 11.5 in Rear
Axles, refer to “Fluids, Lubricants, and Genuine Parts” in
“Maintaining Your Vehicle” for further information. For
normal service, periodic fluid level checks are not re-
quired. When the vehicle is serviced for other reasons,
the exterior surfaces of the axle assembly should be
inspected.
When checking the fluid level (4500/5500 only), the
vehicle should be in a level position. The fluid level
should be 1/4 in ± 1/4 in (6.4 mm ± 6.4 mm) below thefill hole on the front axle. The fluid level should be level
with the bottom of the fill hole on the rear axle.
Drain And Refill
On 4500/5500 vehicles, remove the lower bolt to drain
the axle fluid.
1 — 4500/5500 Rear Axle Fluid Fill Plug
2 — 4500/5500 Rear Axle Fluid Drain Plug
404 MAINTAINING YOUR VEHICLE