Dodge Diesel (2004 year). Manual

WARNING!

You or others could be injured if you leave the
vehicle unattended with the transfer case in the
Neutral (N) position without first fully engaging the
parking brake. The transfer case Neutral (N) position
disengages both the front and rear driveshafts from
the powertrain and will allow the vehicle to move
regardless of the transmission position. The parking
brake should always be applied when the driver is
not in the vehicle.

For additional information on the appropriate use of each
transfer case mode position see the information below:

2H
Rear Wheel Drive High Range - Normal street and
highway driving. Dry hard surfaced roads.

4H
4-Wheel-Drive High Range - Locks the front and rear
driveshafts together. Forces the front and rear wheels to
rotate at the same speed. Additional traction for loose,
slippery road surfaces only.

N
Neutral - Disengages both the front and rear driveshafts
from the powertrain. To be used for flat towing behind
another vehicle. See Recreational Towing for more infor-
mation.

4L
4-Wheel-Drive Low Range - Low speed 4-wheel-drive.
Locks the front and rear driveshafts together. Forces the
front and rear wheels to rotate at the same speed.
Additional traction and maximum pulling power for
loose, slippery road surfaces only. Do not exceed 25 mph
(40 km/h).

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Shifting Procedure - Manually Shifted Transfer
Case

⇔ 4H

Shifting between 2H and 4H can be made with the
vehicle stopped or in motion. If the vehicle is in motion,
shifts can be made up to 55 mph (88 km/h). With the

vehicle in motion, the transfer case will engage / disen-
gage faster if you momentarily release the accelerator
pedal after completing the shift. Apply a constant force
when shifting the transfer case lever.

2H or 4H

⇔ 4L

With the vehicle rolling at 2 to 3 mph (3 to 5 km/h), shift
an automatic transmission to N (Neutral) or depress the
clutch on a manual transmission. While the vehicle is
coasting at 2 to 3 mph (3 to 5 km/h), shift the transfer
case lever firmly to the desired position. Do not pause in
transfer case N (Neutral).

NOTE:

Pausing in transfer case N (Neutral) in vehicles

equipped with an automatic transmission may require
shutting the engine OFF to avoid gear clash while
completing the shift. If difficulty occurs, shift automatic
transmission to N (Neutral), hold foot on brake, and turn
engine OFF. Make shift to the desired mode.

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229

NOTE:

Shifting into or out of 4L is possible with the

vehicle completely stopped, however difficulty may oc-
cur due to the mating clutch teeth not being properly
aligned. Several attempts may be required for clutch
teeth alignment and shift completion to occur. The pre-
ferred method is with the vehicle rolling 2 to 3 mph (3 to
5 km/h). Avoid attempting to engage or disengage 4L
with the vehicle moving faster than 2 to 3 mph (3 to 5
km/h).

NOTE:

Do not attempt to shift to or from 4L while the

transmission is in gear or clutch is engaged.

Transfer Case Reminder Light

The four-wheel-drive operating light (4WD), located in
the instrument cluster, is used to alert the driver that the
front axle is fully engaged and all four wheels are
driving.

Electronically Shifted Transfer Case Operating
Information/Precautions

This is an electric shift transfer case and is operated by
the 4WD Control Switch (Transfer Case Switch), which is
located on the instrument panel.

The Electronically Shifted transfer case provides 4 mode
positions: 2 (rear) wheel drive high range or all wheel
drive high range, 4 wheel drive high range, 4 wheel drive
low range, and neutral.

The Electronically Shifted transfer case is designed to be
driven in the 2 wheel drive position (2WD) or all wheel
drive position (AWD) for normal street and highway
conditions (dry hard surfaced roads).

When additional traction is required, the transfer case
4HI and 4LO positions can be used to lock the front and
rear driveshafts together and force the front and rear
wheels to rotate at the same speed. This is accomplished
by rotating the 4WD Control Switch to the desired

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position - see Shifting Procedure section for specific
shifting instructions. The 4HI and 4LO positions are
designed for loose, slippery road surfaces only. Driving
in the 4HI and 4LO positions on dry hard surfaced roads
may cause increased tire wear and damage to the driv-
eline components.

NOTE:

The transfer case Neutral (N) position is selected

by depressing the recessed button located on the lower
left hand corner of the 4WD Control Switch. The transfer
case Neutral (N) position is to be used for recreational
towing only. See the Recreational Towing section for
specific procedures on shifting into and out of Neutral
(N).

Transfer Case Position Indicator Lights —
Electronically Shifted Transfer Case Only
Transfer case position indicator lights are located on the
Four-Wheel-Drive Control Switch, found on your instru-
ment panel, and indicate the current and desired transfer

case selection. When you select a different transfer case
position, the indicator lights will do the following:

If All Shift Conditions are Met

1. The current position indicator light will turn OFF.

2. The selected position indicator light will flash until the
transfer case completes the shift.

3. When the shift is complete, the indicator light for the
selected position will stop flashing and remain ON.

If One or More Shift Conditions are not Met

1. The indicator light for the current position will remain
ON.

2. The newly selected position indicator light will con-
tinue to flash.

3. The transfer case will not shift.

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231

NOTE:

Before retrying a selection, make certain that all

the necessary requirements for selecting a new transfer
case position have been met. To retry the selection, turn
the control knob back to the current position, wait five (5)
seconds, and retry selection. To find the shift require-
ments, refer to the

9Shifting Procedure9 for your transfer

case, located in this section of the owner’s manual.

The “SERVICE 4WD” warning light monitors the electric
shift 4WD system. If this light remains on after engine
start up or illuminates during driving, it means that the
4WD system is not functioning properly and that service
is required.

WARNING!

Always engage the parking brake when powering
down the vehicle if the

(Service 4WD( light is illu-

minated. Not engaging the parking brake may allow
the vehicle to roll which may cause personal injury.

NOTE:

Do not attempt to make a shift while only the

front or rear wheels are spinning. The transfer case is not
equipped with a synchronizer and therefore the front and
rear driveshaft speeds must be equal for the shift to take
place. Shifting while only the front or rear wheels are
spinning can cause damage to the transfer case.

When operating your vehicle in 4LO, the engine speed is
approximately three times that of the 2WD/AWD or 4HI
positions at a given road speed. Take care not to over-
speed the engine and do not exceed 25 mph (40 km/h).

Proper operation of 4 wheel drive vehicles depends on
tires of equal size, type and circumference on each wheel.
Any difference in tire size can cause damage to the
transfer case.

Because 4 wheel drive provides improved traction, there
is a tendency to exceed safe turning and stopping speeds.
Do not go faster than road conditions permit.

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WARNING!

For additional information on the appropriate use of each
transfer case mode position see the information below:

2WD/AWD
Rear Wheel Drive High Range - Normal street and
highway driving. Dry hard surfaced roads.

4HI
4 Wheel Drive High Range - Locks the front and rear
driveshafts together. Forces the front and rear wheels to
rotate at the same speed. Additional traction for loose,
slippery road surfaces only.

4LO
4 Wheel Drive Low Range - Low speed 4 wheel drive.
Locks the front and rear driveshafts together. Forces the
front and rear wheels to rotate at the same speed.
Additional traction and maximum pulling power for
loose, slippery road surfaces only. Do not exceed 25 mph
(40 km/h).

N
Neutral - Disengages both the front and rear driveshafts
from the powertrain. To be used for flat towing behind
another vehicle. See Recreational Towing for more infor-
mation.

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233

Shifting Procedure - Electronically Shifted
Transfer Case

NOTE:

If any of the requirements to select a new

transfer case position have not been met, the transfer case
will not shift.The indicator light for the previous position
will remain ON and the newly selected position indicator
light will continue to flash until all the requirements for
the selected position have been met. To retry a shift:

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return the control knob back to the original position,
make certain all shift requirements have been met, wait
five (5) seconds and try the shift again.

NOTE:

If all the requirements to select a new transfer

case position have been met, the current position indica-
tor light will turn OFF, the selected position indicator
light will flash until the transfer case completes the shift.
When the shift is complete, the indicator light for the
selected position will stop flashing and remain ON.

2WD/AWD

⇔ 4HI

Rotate the 4WD Control Switch to the desired position.
Shifts between 2WD/AWD and 4HI can be done with the
vehicle stopped or in motion. With the vehicle in motion,
the transfer case will engage / disengage faster if you
momentarily release the accelerator pedal after turning
the control switch. If the vehicle is stopped, the ignition

key must be in the ON position with the engine either
RUNNING or OFF. This shift cannot be completed if the
key is in the accessory position.

NOTE:

The 4x4 system will not allow shifts between

(2WD/AWD)/4HI if the front and/or rear wheels are
spinning (no traction). In this situation the selected
position indicator light will flash and the original posi-
tion indicator light will remain ON. At this time, reduce
speed and stop spinning the wheels to complete the shift.

2WD/AWD or 4HI

⇔ 4LO

NOTE:

When shifting into or out of 4LO some gear

noise may be heard. This noise is normal and is not
detrimental to the vehicle or occupants.

Shifting can be performed with the vehicle rolling 2 to 3
mph (3 to 5 km/h) or completely stopped. USE EITHER
OF THE FOLLOWING PROCEDURES:

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235

Preferred Procedure

1. With engine RUNNING, slow vehicle to 2 to 3 mph (3
to 5 km/h).

2. Shift the transmission into NEUTRAL (depress clutch
on manual transmissions).

3. While still rolling, rotate the transfer case control
switch to the desired position.

4. After the desired position indicator light is ON (not
flashing), shift transmission back into gear (release clutch
on manual transmissions).

Alternate Procedure

1. Bring the vehicle to complete stop.

2. With the key ON and the engine either OFF or
RUNNING, shift the transmission into NEUTRAL (de-
press clutch on manual transmissions).

3. Rotate the transfer case control switch to the desired
position.

4. After the desired position indicator light is ON (not
flashing), shift transmission back into gear (release clutch
on manual transmissions).

NOTE:

If steps 1 or 2 of either the Preferred or Alternate

Procedure are not satisfied prior to attempting the shift or
if they no longer are being met while the shift attempt is
in process then the desired position indicator light will
flash continuously while the original position indicator
light is ON, until all requirements have been met.

NOTE:

The ignition key must be ON for a shift to take

place and for the position indicator lights to be operable.
If the key is not ON then the shift will not take place and
no position indicator lights will be on or flashing.

NOTE:

If your are leaving your vehicle stored for longer

than 21 days, refer to the section on “Vehicle Storage.”

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LIMITED-SLIP DIFFERENTIAL — IF EQUIPPED

The limited-slip differential provides additional traction
on snow, ice, mud, sand and gravel, particularly when
there is a difference between the traction characteristics
of the surface under the right and left rear wheels. During
normal driving and cornering, the limited-slip unit per-
forms similarly to a conventional differential. On slip-
pery surfaces, however, the differential delivers more of
the driving effort to the rear wheel having the better
traction.

The limited-slip differential is especially helpful during
slippery driving conditions. With both rear wheels on a
slippery surface, a slight application of the accelerator
will supply maximum traction. When starting with only
one rear wheel on an excessively slippery surface, slight
momentary application of the parking brake may be
necessary to gain maximum traction.

WARNING!

On vehicles equipped with a limited-slip differen-
tial, never run the engine with one rear wheel off the
ground, since the vehicle may drive through the rear
wheel remaining on the ground. You could lose
control of the vehicle.

Care should be taken to avoid sudden accelerations when
both rear wheels are on a slippery surface. This could
cause both rear wheels to spin, and allow the vehicle to
slide sideways on the crowned surface of a road or in a
turn.

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237

PARKING BRAKE

The foot operated parking brake is positioned below the
lower left corner of the instrument panel. To release the
parking brake, pull the parking brake release handle.

NOTE:

The instrument cluster red brake warning light

will come on and flash to indicate that the parking brake
is applied. You must be sure that the parking brake is
fully applied before leaving the vehicle.

Be sure the parking brake is firmly set when parked and
the gear shift lever is in the PARK position. When
parking on a hill you should apply the parking brake
before placing the gear shift lever in PARK, otherwise the
load on the transmission locking mechanism may make it
difficult to move the selector out of PARK.

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WARNING!

• Always fully apply the parking brake when leav-

ing your vehicle, or it may roll and cause damage
or injury. Also be certain to leave an automatic
transmission in Park, a manual transmission in
Reverse or first gear. Failure to do so may allow
the vehicle to roll and cause damage or injury.

• Leaving children in a vehicle unattended is dan-

gerous for a number of reasons. A child or others
could be injured. Children should be warned not
to touch the parking brake or the gear selector
lever. Don’t leave the keys in the ignition. A child
could operate power windows, other controls, or
move the vehicle.

• Be sure the parking brake is fully disengaged before

driving, failure to do so can lead to brake problems
due to excessive heating of the rear brakes.

When parking on a hill, turn the front wheels toward the
curb on a downhill grade and away from the curb on an
uphill grade.

The parking brake should always be applied whenever
the driver is not in the vehicle.

BRAKE SYSTEM

If power assist is lost for any reason (for example,
repeated brake applications with the engine off), the
brakes will still function. However, you will experience a
substantial increase in braking effort to stop the vehicle.

If either the front or rear hydraulic systems lose normal
capability, the remaining system will still function with
some loss of overall braking effectiveness. This will be
evident by increased pedal travel during application,
greater pedal force required to slow or stop, and activa-
tion of the BRAKE warning lamp and the ABS lamp (if
equipped) during brake use.

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239

Brake Noise

During normal operation of the brake system certain
noises may be present from time to time. Occasional

9groan9 or 9squeal9 noises may occur during normal
operation of the brake system which may not be indica-
tive of a problem. These noises may be heard at any time
the brakes are applied but may be more noticeable during
the first few brake applications in the morning. Moisture,
hot or cold temperature, dust, and or other debris may
also contribute to the noise condition. Repeated or con-
tinuous noises during braking may be an indication that
the brake linings are worn and in need of replacement.

Four-Wheel Anti-Lock Brake System

WARNING!

Anti-Lock Brake Systems contain sophisticated elec-
tronic equipment. It may be susceptible to interfer-
ence caused by improperly installed or high output
radio transmitting equipment. This interference can
cause possible loss of anti-lock braking capability.
Installation of such equipment should be performed
by qualified professionals.

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WARNING!

• Anti-lock system (ABS) cannot prevent the natu-

ral laws of physics from acting on the vehicle, nor
can it increase braking or steering efficiency be-
yond that afforded by the condition of the vehicle
brakes and tires or the traction afforded.

• The ABS cannot prevent accidents, including

those resulting from excessive speed in turns,
following another vehicle too closely, or hydro-
planing. Only a safe, attentive, and skillful driver
can prevent accidents.

• The capabilities of an ABS equipped vehicle must

never be exploited in a reckless or dangerous
manner which could jeopardize the user’s safety
or the safety of others.

This Anti-lock Brake System is designed to aid the driver
in maintaining vehicle control under adverse braking
conditions. The system operates with a separate com-
puter to modulate hydraulic pressure to prevent wheel
lockup and help avoid skidding on slippery surfaces.

The system’s pump motor runs during an ABS stop to
provide regulated hydraulic pressure. The pump motor
makes a low humming noise during operation. This is
normal.

When you are in a severe braking condition involving
use of the Anti-lock Brake System, you will experience
some pedal drop as the vehicle comes to a complete stop.
This is the result of the system reverting to the base brake
system and is normal.

Engagement of the Anti-lock Brake System may be
accompanied by a pulsing sensation. You may also hear a
clicking noise. These occurrences are normal, and indi-
cate that the system is functioning.

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241

ABS Warning Light
The Anti-lock Brake System includes an amber warning
light, located in the instrument cluster. When the light is
illuminated, the Anti-lock Brake System is not function-
ing. The system reverts to standard non-anti-lock brakes.

WARNING!

Pumping of the anti-lock brakes will diminish their
effectiveness and may lead to an accident. Pumping
makes the stopping distance longer. Just press firmly
on your brake pedal when you need to slow down or
stop.

POWER STEERING

Your power steering system will provide mechanical
steering capability if power assist is lost.

If for any reason the hydraulic pressure is interrupted, it
will still be possible to steer your vehicle. Under these
conditions you will experience a substantial increase in
steering effort.

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TIRE SAFETY INFORMATION

Tire Markings

NOTE:

• P(Passenger)-Metric tire sizing is based on U.S. design

standards. P-Metric tires have the letter “P” molded
into the sidewall preceding the size designation. Ex-
ample: P215/65R15 95H.

• European Metric tire sizing is based on European

design standards. Tires designed to this standard have
the tire size molded into the sidewall beginning with
the section width. The letter

9P9 is absent from this tire

size designation. Example: 215/65R15 96H

• LT(Light Truck)-Metric tire sizing is based on U.S.

design standards. The size designation for LT-Metric
tires is the same as for P-Metric tires except for the
letters “LT” that are molded into the sidewall preced-
ing the size designation. Example: LT235/85R16.

• Temporary Spare tires are high pressure compact

spares designed for temporary emergency use only.
Tires designed to this standard have the letter “T”
molded into the sidewall preceding the size designa-
tion. Example: T145/80D18 103M.

• High Flotation tire sizing is based on U.S. design

standards and begins with the tire diameter molded
into the sidewall. Example: 31x10.5 R15 LT.

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Dodge Diesel (2004 year). Manual - part 15