transmission Ram 5500 Chassis Cab 2012 Repair Manual

▫Exhaust System..................... 419
▫Cooling System..................... 421
▫Brake System....................... 427
▫Rear Axle And 4X4 Front Driving Axle Fluid
Level............................. 430
▫Transfer Case....................... 431
▫Automatic Transmission............... 432
▫Appearance Care And Protection From
Corrosion.......................... 435
Fuses.............................. 440
▫Totally Integrated Power Module......... 440
Vehicle Storage....................... 445Replacement Bulbs.................... 446
Bulb Replacement..................... 447
▫Dual Or Quad Headlamp/Front Park And
Turn Signal – If Equipped.............. 447
▫Fog Lamps – If Equipped.............. 449
▫Center High-Mounted Stoplamp (CHMSL)
With Cargo Lamp.................... 449
▫Cab Top Clearance Lamps – If Equipped.... 451
Fluid Capacities...................... 453
Fluids, Lubricants And Genuine Parts....... 454
▫Engine............................ 454
▫Chassis........................... 455
404 MAINTAINING YOUR VEHICLE

ENGINE COMPARTMENT — 5.7L
1 — Air Cleaner Filter 7 — Washer Fluid Reservoir
2 — Automatic Transmission Dipstick 8 — Integrated Power Module (Fuses)
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 405

ONBOARD DIAGNOSTIC SYSTEM (OBD II)
Your vehicle is equipped with a sophisticated onboard
diagnostic system called OBD II. 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, while the engine is running,
severe catalytic converter damage and power loss
will soon occur. Immediate service is required.
Loose Fuel Filler Cap Message
If the vehicle diagnostic system determines
that the fuel filler cap is loose, improperly
installed, or damaged, a loose gascap indicator
will display in the EVIC telltale display area.
Refer to “Electronic Vehicle Information Center (EVIC) in
“Understanding Your Instrument Panel” for further in-
formation. Tighten the fuel filler cap properly and press
406 MAINTAINING YOUR VEHICLE

CAUTION! (Continued)
•Your vehicle has been built with improved fluids
that protect the performance and durability of
your vehicle and also allow extended maintenance
intervals. Do not use chemical flushes in these
components as the chemicals can damage your
engine, transmission, power steering or air condi-
tioning. Such damage is not covered by the New
Vehicle Limited Warranty. If a flush is needed
because of component malfunction, use only the
specified fluid for the flushing procedure.
Engine Oil
Checking Oil Level
To assure proper lubrication of your vehicle’s engine, the
engine oil must be maintained at the correct level. Check
the oil level at regular intervals, such as every fuel stop.The best time to check the engine oil level is about five
minutes after a fully warmed up engine is shut off.
Checking the oil while the vehicle is on level ground will
improve the accuracy of the oil level readings. Always
maintain the oil level within the SAFE zone on the
dipstick. Adding one quart of oil when the reading is at
the bottom of the SAFE zone will result in a reading at the
top of the safe zone on these engines.
CAUTION!
Overfilling or underfilling the crankcase will cause
oil aeration or loss of oil pressure. This could damage
your engine.
410 MAINTAINING YOUR VEHICLE

To minimize the possibility of catalytic converter dam-
age:
•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
idle or malfunctioning operating conditions.
Cooling System
WARNING!
You or others can be badly burned by hot coolant 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 Checks
Check 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 coolant. Check the front of
the A/C condenser for any accumulation of bugs, leaves,
etc. If dirty, clean by gently spraying water from a garden
hose vertically down the face of the condenser.
7
MAINTAINING YOUR VEHICLE 421

Automatic Transmission
Selection Of Lubricant
It 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 “Maintaining Your Vehicle” for further informa-
tion. It is important that the transmission fluid be main-
tained at the prescribed level using the recommended
fluid.
CAUTION!
•Do not use chemical flushes in your transmission
as the chemicals can damage your transmission
components. Such damage is not covered by the
New Vehicle Limited Warranty.
(Continued)
CAUTION! (Continued)
•Using a transmission fluid other than the manu-
facturer’s recommended fluid may cause deterio-
ration in transmission shift quality and/or torque
converter shudder. Using a transmission fluid
other than the manufacturer’s recommended fluid
will require more frequent fluid and filter
changes. Refer to “Fluids, Lubricants, and Genu-
ine Parts” in “Maintaining Your Vehicle” for fur-
ther information.
Special Additives
Automatic 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.
432 MAINTAINING YOUR VEHICLE

Fluid Level Check
The fluid level should be checked when the engine is
fully warmed up and the fluid in the transmission is at
normal operating temperature. Operation of the trans-
mission 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 – 5.7L Engine
Check 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.
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.
7
MAINTAINING YOUR VEHICLE 433

NOTE:If it is necessary to check the transmissionbelow
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
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 Change
Refer to the “Maintenance Schedule” 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 proper lubricant is used in the
transmission. Refer to “Fluids, Lubricants, and Genuine
Parts” in “Maintaining Your Vehicle” for further
information.
434 MAINTAINING YOUR VEHICLE

Cavity Cartridge
FuseMini
FuseDescription
J03 30 Amp
PinkDiesel Powertrain
Control Module – If
Equipped
J04 25 Amp
NaturalDriver Door Node
J05 25 Amp
NaturalPassenger Door Node
J06 40 Amp
GreenAntilock Brakes
Pump/Stability Con-
trol System
J07 30 Amp
PinkAntilock Brakes
Valve/Stability Con-
trol System
J08 40 Amp
GreenPower Seat
J10 30 Amp
PinkSway Bar Module – If
EquippedCavity Cartridge
FuseMini
FuseDescription
J11 30 Amp
PinkTransfer Case Module
J12 30 Amp
PinkRear Defroster
J13 60 Amp
YellowMain Ignition Off
Draw (IOD) Fuse
J14 20 Amp
BlueTrailer Tow Lamps/
Park Lamps
J15 40 Amp
GreenFront Blower
J17 40 Amp
GreenStarter Motor Sole-
noid
J18 20 Amp
BluePowertrain Control
Module Transmission
Range
J19 60 Amp
YellowRad Fan Motor HI/
Rad Fan Motor Low
7
MAINTAINING YOUR VEHICLE 441

Chassis
Component Fluid, Lubricant, or Genuine Part
Automatic Transmission (5.7L En-
gine Only)MOPARATF+4Automatic Transmission Fluid or equivalent licensed
ATF+4product.
Transfer Case MOPARATF+4Automatic Transmission Fluid or equivalent licensed
ATF+4product.
Front and Rear Axle Fluid (4500/
5500)GL-5 SAE 75W-90 Synthetic (MS-9763) or equivalent.
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 MOPARPower Steering Fluid +4, MOPARATF+4Automatic Trans-
mission Fluid or equivalent licensed ATF+4product.
7
MAINTAINING YOUR VEHICLE 455