manual transmission Ram 5500 Chassis Cab 2016 Diesel Supplement

NOTE:
•The torque converter clutch will not engage (and
68RFE-equipped trucks will not shift to sixth gear),
until the transmission fluid and engine coolant are
warm [usually after 1 to 3 miles (2 to 5 km) of driving].
Because the engine speed is higher when the torque
converter clutch is not engaged, it may seem as if the
transmission is not shifting properly when cold. This is
normal. Using the Electronic Range Select (ERS) shift
control, when the transmission is sufficiently warm,
will demonstrate that the transmission is able to shift
into and out of Overdrive.
•
If the vehicle has not been driven for several days, the
first few seconds of operation after shifting the transmis-
sion into gear may seem sluggish. This is due to the fluid
partially draining from the torque converter into the
transmission. This condition is normal and will not cause
damage to the transmission. The torque converter will
refill within five seconds after starting the engine.
MANUAL TRANSMISSION — IF EQUIPPED
WARNING!
You or others could be injured if you leave the
vehicle unattended without having the parking
brake fully applied. The parking brake should al-
ways be applied when the driver is not in the vehicle,
especially on an incline.
CAUTION!
Never drive with your foot resting on the clutch
pedal, or attempt to hold the vehicle on a hill with the
clutch pedal partially engaged, as this will cause
abnormal wear on the clutch.
NOTE: During cold weather, you may experience in-
creased effort in shifting until the transmission fluid
warms up. This is normal.
234 STARTING AND OPERATING

Shifting
Truck models with manual transmission are equipped
with a clutch interlocking ignition system. The clutch
pedal must be fully pressed to start the vehicle.Fully press the clutch pedal before shifting gears. As you
release the clutch pedal, lightly press the accelerator
pedal.
This transmission has a “creeper” first gear which should
be used to start from a standing position when carrying
a payload or towing a trailer. Damage to the clutch can
result from starting in second or third gear with a loaded
vehicle. An unloaded vehicle may be launched in second
gear. Use each gear in numerical order – do not skip a
gear.
NOTE:
When loaded, pulling a trailer or on a grade, the
truck should always start in first gear and not skip gears.
Shift Pattern
5
STARTING AND OPERATING 235

Recommended Vehicle Shift Speeds
To utilize your manual transmission efficiently for both
fuel economy and performance, it should be upshifted as
listed in recommended shift speed chart. Shift at thevehicle speeds listed for acceleration. When heavily
loaded or pulling a trailer these recommended up-shift
speeds may not apply.
Maximum Recommended Up-Shift Speeds
Gear Selection 1 to 2
2 to 33 to 44 to 5 5 to 6
Maximum Speed 7 mph
(11 km/h) 15 mph
(24 km/h) 25 mph
(40 km/h) 40 mph
(64 km/h) 45 mph
(72 km/h)
Downshifting
Moving from a high gear down to a lower gear is
recommended to preserve brakes when driving down
steep hills. In addition, downshifting at the right time
provides better acceleration when you desire to resume
speed. Downshift progressively. Do not skip gears to
avoid overspeeding the engine and clutch.
WARNING!
Do not downshift for additional engine braking on a
slippery surface. The drive wheels could lose their
grip and the vehicle could skid.
236 STARTING AND OPERATING

switch. Connections to the switches are found under the
hood in the connectors attached to the auxiliary Power
Distribution Center.
You have the ability to configure the functionality of the
auxiliary switches via the Electronic Vehicle Information
Center (EVIC) or Driver Information Display (DID). All
switches can now be configured for setting the switch
type operation to latching or momentary, power source of
either battery or ignition, and ability to hold last state
across key cycles.
NOTE:Holding last state conditions are met when
switch type is set to latching and power source is set to
ignition.
For further information on using the auxiliary switches,
please refer to the Ram Body Builders Guide by accessing
www.rambodybuilder.comand choosing the appropri-
ate links.
POWER TAKE OFF OPERATION — IF EQUIPPED
(CHASSIS CAB ONLY)
This vehicle when equipped with PTO Prep and either
the AS69RC automatic six-speed or G-56 manual six-
speed transmissions, will allow for an aftermarket upfit
with a transmission driven PTO (power take off). The
customer will have the ability to operate the PTO in
either a “stationary” or “mobile” mode. The vehicles will
be factory set to the “stationary” mode. To select ’mobile
mode’ You will need to enter the commercial vehicle
menu on the EVIC/DID screen and select mobile PTO
mode. Details of the PTO selection modes and further
PTO information is available at the Ram Truck Body-
builders web site. www.rambodybuilder.com
AS69RC Six-Speed Automatic Transmission Only
The PTO drive gear (part of the AS69RC) operates at
torque converter turbine speed. The turbine speed will be
5
STARTING AND OPERATING 239

less than engine speed when the torque converter clutch
is not engaged and will be same as engine speed when
the torque converter clutch is engaged.
Stationary Mode
To operate the PTO in this mode the vehicle must meet
the following conditions:
•Be in PARK position (vehicles equipped with auto-
matic transmission.)
• PTO switch has been activated.
• Parking brake applied (vehicles equipped with
manual transmission).
• Brake pedal must not be applied.
• Vehicle engine must be running.
• No vehicle, brake or clutch switch faults present. •
PTO must be correctly installed using the vehicle
provided circuits.
The Electronic Vehicle Information Center (EVIC) or
Driver Information Display (DID) will display a PTO
On message for five seconds if the above conditions are
met. Otherwise, the EVIC/DID will display a message
To Operate PTO Shift To Park indicating what operator
action should be taken to engage the PTO mode.
The customer has the choice to operate the PTO by
utilizing the cruise control switches or by utilizing a
remote control (provided by the PTO supplier). To oper-
ate the feature using the cruise control switches, the
customer must first activate the PTO switch which will
turn on the PTO. In order to increase or decrease the
engine idle speed, to optimize the PTO function, the
“RESUME/ACCEL” and “DECEL” cruise switches can
240 STARTING AND OPERATING

JUMP STARTING
WARNING!
•To prevent personal injury or damage to clothing,
do not allow battery fluid to contact eyes, skin or
fabrics. Do not lean over a battery when connecting
jumper cables or allow cable clamps to touch each
other. Keep open flames or sparks away from
battery vent holes. Always wear eye protection
when working with batteries.
• Do not use a booster battery or any other booster
source that has a greater than 12 Volt system, i.e., do
not use a 24 Volt power source.
NOTE: Replacement batteries should both be of equal
size to prevent damage to the vehicle’s charging system.
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 an automatic transmis-
sion in PARK (or NEUTRAL for a manual transmission).
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.
262 WHAT TO DO IN EMERGENCIES

▫Manual Transmission — If Equipped ........298
▫ Automatic Transmission — If Equipped ......299
▫ Noise Control System Required Maintenance &
Warranty .......................... .303
 FLUID CAPACITIES ....................308 
FLUIDS, LUBRICANTS AND GENUINE
PARTS ............................. .309
▫ Engine ............................ .309
▫ Chassis ............................311
268 MAINTAINING YOUR VEHICLE

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 an accident.
Clutch Hydraulic System
The clutch hydraulic system is a sealed maintenance-free
system. In the event of leakage or other malfunction, the
system must be replaced.
Transfer Case — If Equipped
Drain And Refill
Refer to the “Maintenance Schedule” for the proper
maintenance intervals.
Selection of Lubricant
Refer to “Fluids, Lubricants, and Genuine Parts” in
“Maintaining Your Vehicle” for fluid specifications.
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.
Manual Transmission — If Equipped
Selection of Lubricant
Refer to “Fluids, Lubricants, and Genuine Parts” in
“Maintaining Your Vehicle” for fluid specifications.
Fluid Level Check
The fluid level can be checked by removing the filler
plug. If the level of the lubricant is more than 1/2 in
(12 mm) below the bottom of the filler hole while the
298 MAINTAINING YOUR VEHICLE

ComponentFluid, Lubricant, or Genuine Part
Front and Rear Axle Fluid (2500/3500) We recommend you use Synthetic, GL-5 SAE 75W-85.
Limited slip additive is not required for Limited-Slip
Rear Axles.
Front and Rear Axle Fluid (4500/5500) We recommend you use Synthetic, GL-5 SAE 75W-90.
Limited slip additive is not required for Limited-Slip
Rear Axles.
Clutch Linkage We recommend you use MOPAR Multi-Purpose Grease,
NLGI Grade 2 E.P. or equivalent.
Manual Transmission (G-56) – If Equipped
We recommend you use MOPAR ATF+4 Automatic Trans-
mission Fluid or equivalent licensed ATF+4 product.
312 MAINTAINING YOUR VEHICLE

Mileage or time passed
(whichever comes first):
7,500
15,000
22,500
30,000
37,500
45,000
52,500
60,000
67,500
75,000
82,500
90,000
97,500
105,000 112,500
120,000
127,500
135,000
142,500
150,000
Or Months: 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
Or Kilometers:
12,000
24,000
36,000
48,000
60,000
72,000
84,000
96,000
108,000
120,000
132,000
144,000
156,000
168,000
180,000
192,000
204,000
216,000
228,000
240,000
Change automatic transmission
fluid and filter(s) if using your ve-
hicle for any of the following: po-
lice, fleet, or frequent trailer tow-
ing (68RFE transmission only). XX
Change automatic transmission
fluid and filter(s). X
Change the manual transmission
fluid if using your vehicle for any
of the following: police, fleet, or
frequent trailer towing. XX
Replace Crankcase Ventilation
Filter (CCV). XX
8
MAINTENANCE SCHEDULE 321