Dodge Diesel (2004 year). Manual

• If a bearing assembly is accidentally separated when

servicing the brake rotors, it should be replaced.

Rear Wheel Bearings
Clean and repack when brake linings are replaced or
rotors resurfaced.

Selection Of Lubricating Grease

The National Lubricating Grease Institute (NLGI) has
developed a symbol (Certification Mark) to aid the
vehicle owner in the proper selection of grease for the
lubrication of wheel bearings and chassis components.
This symbol (an example shown below) is located on the
grease container and identifies the application and qual-
ity of the grease.

There are two groups
identified: those for wheel
bearings (Letter “G”) and
those for chassis (Letter
“L”) lubrication. Perfor-
mance categories within
these groups result in dual
letter

designations

for

each group. The letter des-
ignations shown in the ex-
ample are the highest

quality level available and when combined as shown can
be used for both wheel bearing and chassis lubrication.
Use only those greases that have the NLGI symbol on the
container along with the proper quality level for your
application.

356

MAINTAINING YOUR VEHICLE

Noise Control System Required Maintenance &
Warranty

For 3500 Two-Wheel Drive and Four-Wheel Drive mod-
els over 10,000 lbs. (4 535 kg) Gross Vehicle Weight
Rating.

All vehicles built over 10,000 lbs. (4 535 kg) Gross Vehicle
Weight Rating and manufactured for sale and use in the
United States are required to comply with the Federal
Government’s Exterior Noise Regulations. These vehicles
can be identified by the Noise Emission Control Label
located in the operator’s compartment.

Required Maintenance For Noise Control Systems
The following maintenance services must be performed
every 6 months or 6,000 miles (9 600 km), whichever
comes first, to assure proper operation of the noise
control systems. In addition, inspection and service
should be performed anytime a malfunction is observed

MAINTAINING YOUR VEHICLE

357

or suspected. Proper maintenance of the entire vehicle
will help the effectiveness of the noise control systems.

Exhaust System
Inspect the entire exhaust system for leaks and damaged
parts. Devices such as hangers, clamps, and U-bolts
should be tight and in good condition. Damaged compo-
nents, burned or blown out mufflers, burned or rusted
out exhaust pipes should be replaced according to the
procedures and specifications outlined in the appropriate
service manual.

Air Cleaner Assembly
Inspect air cleaner housing for proper assembly and fit.
Make certain that the air cleaner is properly positioned
and that the cover is tight. Check all hoses leading to the
cleaner for tightness. The air filter element must also be
clean and serviced according to the instructions outlined
in the Maintenance Schedule Section of this manual.

Tampering With Noise Control System Prohibited
Federal law prohibits the following acts or the causing
thereof: (1) the removal or rendering inoperative by any
person, other than for purposes of maintenance, repair, or
replacement, of any device or element of design incorpo-
rated into any new vehicle for the purpose of noise
control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or (2) the use of the vehicle
after such device or element of design has been removed
or rendered inoperative by any person.

Among those acts presumed to constitute tampering are
the acts listed below.

358

MAINTAINING YOUR VEHICLE

• AIR CLEANER

− Removal of the air cleaner.

− Removal of the air cleaner filter element from the air

cleaner housing.

− Removal of the air ducting.

• EXHAUST SYSTEM

− Removal or rendering inoperative exhaust system

components including the muffler or tailpipe.

• ENGINE COOLING SYSTEM

− Removal or rendering inoperative the fan clutch.

− Removal of the fan shroud.

Noise Emission Warranty
The manufacturer warrants that this vehicle as manufac-
tured by the manufacturer, was designed, built and
equipped to conform at the time it left the manufacturer’s
control with all applicable U.S. EPA Noise Control Regu-
lations.

This warranty covers this vehicle as designed, built and
equipped by the manufacturer, and is not limited to any
particular part, component or system of the vehicle
manufactured by the manufacturer. Defects in design,
assembly or in any part, component or system of the
vehicle as manufactured by the manufacturer, which, at
the time it left the manufacturer’s control, caused noise
emissions to exceed Federal standards, are covered by
this warranty for the life of the vehicle.

MAINTAINING YOUR VEHICLE

359

Maintenance Log and Service Chart — 24 Valve Cummins Turbo Diesel

Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest to
the mileage at which service was performed.
MILES

7,500

15,000

22,500

30,000

37,500

45,000

52,500

60,000

KILOMETERS

12 000

24 000

36 000

48 000

60 000

72 000

84 000

96 000

Exhaust system-
inspect
Air cleaner
assembly-inspect
ODOMETER
READING
PERFORMED
BY
PERFORMED
AT

360

MAINTAINING YOUR VEHICLE

Noise Systems Maintenance Chart and Service Log — Insert Month, Day, Year under column mileage closest to
the mileage at which service was performed.

MILES

67,500

75,000

82,500

90,000

97,500

84,000

105,00

112,500

KILOMETERS

108 000

120 000

132 000

144 000

126 000

156 000

168 000

181 000

Exhaust system-
inspect
Air cleaner
assembly-inspect
ODOMETER
READING
PERFORMED
BY
PERFORMED
AT

MAINTAINING YOUR VEHICLE

361

Appearance Care and Protection from Corrosion

Protection of Body and Paint from Corrosion
Vehicle body care requirements vary according to geo-
graphic locations and usage. Chemicals that make roads
passable in snow and ice, and those that are sprayed on
trees and road surfaces during other seasons, are highly
corrosive to the metal in your vehicle. Outside parking,
which exposes your vehicle to airborne contaminants,
road surfaces on which the vehicle is operated, extreme
hot or cold weather and other extreme conditions will
have an adverse effect on paint, metal trim, and under-
body protection.

The following maintenance recommendations will enable
you to obtain maximum benefit from the corrosion
resistance built into your vehicle.

What Causes Corrosion?
Corrosion is the result of deterioration or removal of
paint and protective coatings from your vehicle.

The most common causes are:

• Road salt, dirt and moisture accumulation.
• Stone and gravel impact.
• Insects, tree sap and tar.
• Salt in the air near seacoast localities.
• Atmospheric fallout/industrial pollutants.

Washing

• Wash your vehicle regularly. Always wash your ve-

hicle in the shade using a mild car wash soap, and
rinse the panels completely with clear water.

• If insects, tar or other similar deposits have accumu-

lated on your vehicle, wash it as soon as possible.

• Use Mopar auto polish to remove road film and stains

and to polish your vehicle. Take care never to scratch
the paint.

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MAINTAINING YOUR VEHICLE

• Avoid using abrasive compounds and power buffing

that may diminish the gloss or thin out the paint
finish.

CAUTION!

Do not use abrasive or strong cleaning materials
such as steel wool or scouring powder, which will
scratch metal and painted surfaces.

Special Care

• If you drive on salted or dusty roads or if you drive

near the ocean, hose off the undercarriage at least once
a month.

• It is important that the drain holes in the lower edges

of the doors, rocker panels and tailgate be kept clear
and open.

• If you detect any stone chips or scratches in the paint,

touch them up immediately. The cost of such repairs is
considered the responsibility of the owner.

• If your vehicle is damaged due to an accident or

similar cause which destroys the paint and protective
coating have your vehicle repaired as soon as possible.
The cost of such repairs is considered the responsibil-
ity of the owner.

• All wheels and wheel trim, especially aluminum and

chrome plated wheels should be cleaned regularly
with mild soap and water to prevent corrosion. To
remove heavy soil, select a nonabrasive, non-acidic
cleaner. Do not use scouring pads, steel wool, a bristle
brush or metal polishes. Only Mopar cleaners are
recommended. Do not use oven cleaner. Avoid auto-
matic car washes that use acidic solutions or harsh
brushes that may damage the wheels’ protective fin-
ish.

MAINTAINING YOUR VEHICLE

363

• If you carry special cargo such as chemicals, fertilizers,

de-icer salt, etc., be sure that such materials are well
packaged and sealed.

• If a lot of driving is done on gravel roads, consider

mud or stone shields behind each wheel.

• Use Mopar touch up paint on scratches as soon as

possible. Your dealer has touch up paint to match the
color of your vehicle.

Interior Care
Use Mopar Fabric Cleaner to clean fabric upholstery and
carpeting.

Use Mopar Vinyl Cleaner to clean vinyl upholstery and
trim.

Mopar Total Clean is specifically recommended for
leather upholstery.

Your leather upholstery can be best preserved by regular
cleaning with a damp soft cloth. Small particles of dirt
can act as an abrasive and damage the leather upholstery
and should be removed promptly with a damp cloth.
Stubborn soils can be removed easily with a soft cloth
and Mopar Total Clean. Care should be taken to avoid
soaking your leather upholstery with any liquid. Please
do not use polishes, oils, cleaning fluids, solvents, deter-
gents, or ammonia based cleaners to clean your leather
upholstery. Application of a leather conditioner is not
required to maintain the original condition.

WARNING!

Do not use volatile solvents for cleaning purposes.
Many are potentially flammable, and if used in
closed areas they may cause respiratory harm.

364

MAINTAINING YOUR VEHICLE

Glass Surfaces
All glass surfaces should be cleaned on a regular basis
with any commercial household-type glass cleaner.
Never use an abrasive type cleaner. Use caution when
cleaning inside rear windows equipped with electric
defrosters or windshields equipped with a windshield
wiper de-icer. Do not use scrapers or other sharp instru-
ments which may scratch the elements.

When cleaning the rear view mirror, spray cleaner on the
towel or rag that you are using. Do not spray cleaner
directly on the mirror.

Cleaning Plastic Instrument Cluster Lenses
The lenses in front of the instruments in this vehicle are
molded in clear plastic. When cleaning the lenses, care
must be taken to avoid scratching the plastic.

1. Clean with a wet soft rag. A mild soap solution may be
used, but do not use high alcohol content or abrasive
cleaners. If soap is used, wipe clean with a clean damp
rag.

2. Dry with a soft tissue.

Seat Belt Maintenance
Do not bleach, dye or clean the belts with chemical
solvents or abrasive cleaners. This will weaken the fabric.
Sun damage will also weaken the fabric.

If the belts need cleaning, use a mild soap solution or
lukewarm water. Do not remove the belts from the car to
wash them.

Replace the belts if they appear frayed or worn or if the
buckles do not work properly.

MAINTAINING YOUR VEHICLE

365

FUSE AND RELAY CENTER

Your vehicle is equipped with a fuse and relay center
located in the engine compartment near the battery.
Located on the underside of the cover is a label that
identifies each component.

1. Disconnect the battery negative (-) cables from the
right and left batteries before removing the cover.

2. Use specified fuses only.

3. Always properly reinstall the cover.

VEHICLE STORAGE

If you are storing your vehicle for more than 21 days, we
recommend that you take the following steps to mini-
mize the drain on your vehicle’s battery:

• Disconnect the Ignition-Off Draw fuse (I.O.D.) fuse

located in the Fuse and Relay Center, located in the
engine compartment. The I.O.D. cavity includes a
snap-in retainer that allows the fuse to be discon-
nected, without removing it from the fuse block.

• The electronic shift transfer case should be placed in

the 4HI mode and kept in this position to minimize the
battery drain.

• As an alternative to the above steps you may, discon-

nect the negative cables from both batteries.

366

MAINTAINING YOUR VEHICLE

REPLACEMENT LIGHT BULBS

LIGHT BULBS — Inside

Bulb No.

Overhead Console Lights . . . . . . . . . . . . . . . TS 212-2
Dome Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7679

All of the inside bulbs are brass or glass wedge base.
Aluminum base bulbs are not approved.

LIGHT BULBS — Outside

Bulb No.

Back-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057
Center High Mounted Stop Lamp . . . . . . . . . . . . . 912
Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 9006LL
Headlamp (Halogen) . . . . . . . . . . . . . . . . . . . 9007QL
Park & Turn Signal . . . . . . . . . . . . . . . . . . . 3157NAK
Rear License Plate Lamp . . . . . . . . . . . . . . . . . . . 168
Rear Cargo Light. . . . . . . . . . . . . . . . . . . . . . . . . 912
Tail & Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3057
Cab Clearance Lights . . . . . . . . . . . . . . . . . . . . . . 168
Dual Rear Wheel Sidemarker Light . . . . . . . . . . . . 168
Dual Rear Wheel Tailgate ID Lights (3) . . . . . . . . . 168

BULB REPLACEMENT

Headlight (Halogen)/Front Park and Turn Lights

CAUTION!

This is a halogen bulb. Avoid touching the glass
with your fingers. Reduced bulb life will result.

1. Remove the expanding fastener from the headlight
welt.

MAINTAINING YOUR VEHICLE

367

2. Remove the three (3) bolts from the headlight housing.

NOTE:

The lower bolt on the driver side headlight also

retains the ambient temperature sensor between the
headlight assembly and the frame.

MAINTAINING YOUR VEHICLE

369

5. Twist connector on turn signal/park light bulb

⁄

turn

and remove connector and bulb from housing.

6. Remove housing from vehicle with headlight halogen
bulb in housing.

7. Twist collar on headlight halogen bulb

⁄

turn and

remove headlight bulb from the housing.

8. Replace headlight or turn signal bulb. Do not touch
the headlight halogen bulb.

9. Reverse procedure for installation of bulbs and hous-
ing.

10. Tighten the outboard fastener first.

Tail, Stop, Turn and Backup Lights

1. Remove the two (2) screws that pass through the bed
sheetmetal.

MAINTAINING YOUR VEHICLE

371

Dodge Diesel (2004 year). Manual - part 23