service Ram 5500 Chassis Cab 2014 Repair Manual

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 are identified on the
battery case. Cable clamps should be tight on the
terminal posts and free of corrosion.
• If a “fast charger” is used while the battery is in the
vehicle, disconnect both vehicle battery cables be-
fore connecting the charger to the battery. Do not
use a “fast charger” to provide starting voltage.
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.
WARNING!
•
Use 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
Warranty Information Book, located on the DVD,
for further warranty information.
• The 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 technician.
456 MAINTAINING YOUR VEHICLE

CAUTION!
Do not use chemical flushes in your air conditioning
system as the chemicals can damage your air condi-
tioning components. Such damage is not covered by
the New Vehicle Limited Warranty.
Front Prop Shaft Lubrication — Four-Wheel Drive
Models
Lubricate the front driveshaft grease fitting at each oil
change. Refer to the “Maintenance Schedule” for the
proper maintenance intervals. Use MOPAR® Type MS-
6560 (lithium-based grease), or equivalent.
Body Lubrication
Locks and all body pivot points, including such items as
seat tracks, door hinge pivot points and rollers, liftgate,
tailgate, decklid, sliding doors and hood hinges, should
be lubricated periodically with a lithium based grease,such as MOPAR® Spray White Lube to assure quiet, easy
operation and to protect against rust and wear. Prior to
the application 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
components to ensure proper function. When performing
other underhood services, the hood latch, release mecha-
nism 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
amount of a high quality lubricant, such as MOPAR®
Lock Cylinder Lubricant directly into the lock cylinder.
Windshield Wiper Blades
Clean the rubber edges of the wiper blades and the
windshield periodically with a sponge or soft cloth and a
mild nonabrasive cleaner. This will remove accumula-
tions of salt or road film.
7
MAINTAINING YOUR VEHICLE 457

CAUTION!
•The catalytic converter requires the use of un-
leaded fuel only. Leaded gasoline will destroy the
effectiveness of the catalyst as an emissions control
device and may seriously reduce engine perfor-
mance and cause serious damage to the engine.
• Damage to the catalytic converter can result if your
vehicle is not kept in proper operating condition.
In the event of engine malfunction, particularly
involving engine misfire or other apparent loss of
performance, have your vehicle serviced promptly.
Continued operation of your vehicle with a severe
malfunction could cause the converter to overheat,
resulting in possible damage to the converter and
vehicle. Under normal operating conditions, the catalytic con-
verter will not require maintenance. However, it is im-
portant to keep the engine properly tuned to assure
proper catalyst operation and prevent possible catalyst
damage.
NOTE:
Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
In unusual situations involving grossly malfunctioning
engine operation, a scorching odor may suggest severe
and abnormal catalyst overheating. If this occurs, stop
the vehicle, turn off the engine and allow it to cool.
Service, including a tune-up to manufacturer’s specifica-
tions, should be obtained immediately.
460 MAINTAINING YOUR VEHICLE

3. Check the coolant level on the dipstick.
The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking for
engine coolant (antifreeze) freeze point or replacing en-
gine coolant (antifreeze). Advise your service attendantof this. As long as the engine operating temperature is
satisfactory, the coolant bottle need only be checked once
a month.
When additional engine coolant (antifreeze) is needed to
maintain the proper level, it should be added to the
coolant bottle. Do not overfill.
Checking Coolant Level — 6.4L Engine
The level of the coolant in the pressurized coolant bottle
should be between the “MIN” and “MAX” range on the
bottle when the engine is cold.
The radiator normally remains completely full, so there is
no need to remove the cap unless checking for coolant
freeze point or replacing engine coolant (antifreeze).
Advise your service attendant of this. As long as the
engine operating temperature is satisfactory, the coolant
Coolant Reservoir Dipstick
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MAINTAINING YOUR VEHICLE 467

•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 emis-
sions.
Brake System
In order to assure brake system performance, all brake
system components should be inspected periodically.
Refer to the “Maintenance Schedule” for the proper
maintenance intervals.
WARNING!
Riding the brakes can lead to brake failure and
possibly a collision. Driving with your foot resting or
riding on the brake pedal can result in abnormally
(Continued)
WARNING! (Continued)
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.
7
MAINTAINING YOUR VEHICLE 469

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 pro-
longed braking, resulting in sudden brake failure.
This could result in a collision.
• 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)
WARNING! (Continued)
•Do not allow petroleum based fluid to contaminate
the brake fluid. Brake seal components could be
damaged, causing partial or complete brake failure.
This could result in a collision.
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 ¼ in±¼in(6.4 mm ± 6.4 mm) below the fill
7
MAINTAINING YOUR VEHICLE 471

Lubricant Selection
Refer to “Fluids, Lubricants, and Genuine Parts” in
“Maintaining Your Vehicle” for further information.
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.
Limited-Slip Differentials DO NOT REQUIRE any
limited slip oil additive (friction modifiers).
NOTE: Slight noise and mild shuddering may be evi-
dent while turning a vehicle with limited slip differential
on concrete or dry pavement. These conditions should be
considered normal operation of the limited slip differen-
tial.
Transfer Case
Drain And Refill
Refer to the “Maintenance Schedule” for the proper
maintenance intervals.
Lubricant Selection
Refer to “Fluids, Lubricants, and Genuine Parts” in
“Maintaining Your Vehicle” for further information.
Fluid Level Check
This 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.
7
MAINTAINING YOUR VEHICLE 473

CAUTION!
Do not use chemical flushes in your transmission as
the chemicals can damage your transmission compo-
nents. Such damage is not covered by the New
Vehicle Limited Warranty.
Fluid Level Check
Check the fluid level when the engine is fully warmed up
and the transmission fluid is at normal operating tem-
perature. Driving 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 — Procedure
It is best to check the fluid level when the transmission is
at normal operating temperature (170-180°F / 77-82°C for
66RFE transmission, or 158–176°F / 70–80°C for AS66RCtransmission). This normally occurs after at least 15 miles
(25 km) of driving. At normal operating temperature the
fluid cannot be held comfortably between the fingertips.
You can read the transmission sump temperature in the
EVIC display (see Electronic Vehicle Information Center
[EVIC] for further information).
Use the following procedure to check the transmission
fluid level properly:
1. Monitor the transmission temperature using the EVIC
display, and operate the vehicle as required to reach
the normal operating temperature.
2. Park the vehicle on level ground.
3. Run the engine at normal idle speed for at least 60 seconds, and leave the engine running for the rest of
this procedure.
4. Fully apply the parking brake and press the brake.
7
MAINTAINING YOUR VEHICLE 475

5. Place the shift lever momentarily into each gear posi-tion (allowing time for the transmission to fully en-
gage in each position), ending with the transmission in
PARK.
6. Wipe the area around the dipstick clean to prevent dirt from entering the transmission.
7. Remove the dipstick, wipe it clean and reinsert it until seated.
8. Remove the dipstick again and note the fluid level on both sides. The fluid level reading is only valid if there
is a solid coating of oil on both sides of the dipstick.
Note that the holes in the dipstick will be full of fluid
if the actual level is at or above the hole. The fluid level
should be between the “HOT” (upper) reference holes
on the dipstick at normal operating temperature. If the
fluid level is low, add fluid through the dipstick tube
to bring it to the proper level. Do not overfill.UseONLY the recommended fluid (see
Fluids, Lubri-
cants, and Genuine Parts for fluid specifications).
After adding any quantity of oil through the dipstick
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 60-70°F / 16-21°C for 66RFE transmis-
sion, or 68-86°F / 20-30°C for AS66RC transmission. Only
use the COLD region of the dipstick as a rough reference
when setting the fluid level after a transmission service
or fluid change. Re-check the fluid level, and adjust as
required, once the transmission reaches normal operating
temperature.
476 MAINTAINING YOUR VEHICLE

FUSES
WARNING!
•When replacing a blown fuse, always use an ap-
propriate replacement fuse with the same amp
rating as the original fuse. Never replace a fuse
with another fuse of higher amp rating. Never
replace a blown fuse with metal wires or any other
material. Failure to use proper fuses may result in
serious personal injury, fire and/or property dam-
age.
(Continued)
WARNING! (Continued)
•Before replacing a fuse, make sure that the ignition
is off and that all the other services are switched off
and/or disengaged.
• If the replaced fuse blows again, contact an autho-
rized dealer.
• If a general protection fuse for safety systems (air
bag system, braking system), power unit systems
(engine system, gearbox system) or steering system
blows, contact an authorized dealer.
484 MAINTAINING YOUR VEHICLE