Dodge Diesel (2004 year). Manual - part 24

2. Pull the housing straight out from the body, with a
quick motion, to separate the housing from the body. If
not pulled straight, locators may be damaged.

3. Push the red lock slide in on the connector and remove
the housing from the vehicle.

4. Remove the four (4) screws from the bulb strip in the
housing.

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5. Pull the appropriate bulb straight from the bulb strip.

• Top Bulb: Park/Turn/Hazard
• Center Bulb: Stop/Park/Sidemarker
• Bottom Bulb: Backup Lights

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

7. While holding the taillight firmly in place, fasten the
top screw first.

Center High-Mounted Stoplight With Cargo Light

1. Remove the two (2) screws holding the housing/lens
to the body as shown.

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2. Separate the connector holding the housing and wir-
ing harness to the body.

3. Turn desired bulb socket

⁄

turn and remove socket

and bulb from housing.

4. Pull desired bulb straight from the socket.

• Outside Bulbs: Cargo Lamps
• Inside Bulb: Center High Mount Stop Lamp

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

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Cab Top Clearance Lights — If Equipped

1. Remove the two screws from the top of the light.

2. Rotate the socket

⁄

turn and pull it from the light

assembly.

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3. Pull the bulb straight from it’s socket and replace.

Tailgate ID Lights (Dual Rear Wheels)

1. Remove the two screws and housing and access the
bulb sockets from the rear.

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2. Turn socket

⁄

turn counterclockwise to access the

bulb.

3. Pull bulb straight out from socket.

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

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Side Marker Lights (Dual Rear Wheels)

1. Push rearward on the side marker light assembly.

2. Pull the entire assembly from the fender.

3. Turn socket

⁄

turn counterclockwise and remove from

assembly to access the bulb.

4. Pull bulb straight out from socket.

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

Fog Lights

1. Reach under the vehicle, unlock and twist connector
counterclockwise

⁄

turn and remove connector and bulb

from housing.

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2. Pull bulb straight from the connector.

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

FLUID CAPACITIES

U.S.

Metric

Fuel

2500 Shortbed Models

34 gal.

128L

2500 Longbed Models

35 gal.

132L

3500 Shortbed Models

34 gal.

128L

3500 Longbed Models

35 gal.

132L

Engine Oil

5.9L Diesel Engine I-6

12.0 qts.

11.4L

Cooling System

5.9L Diesel Engine I-6

7 gal.

26.5L

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RECOMMENDED FLUIDS, LUBRICANTS AND GENUINE PARTS
Engine

Component

Fluids, Lubricants and Genuine Parts

Engine Coolant

Mopar

t Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Or-

ganic Additive Technology) P/N 5011764AB or equivalent.

Engine Oil

For the proper quality and SAE Grade oil for your engine, refer to the sec-
tion

9Maintenance Procedures.9

Engine Oil Filter

Mopar

t Engine Oil Filter, P/N 05083285AA or equivalent.

Engine Fuel Filter

Mopar

t Fuel Filter, P/N 05015581AB or equivalent.

Fuel Selection

Refer to the section

9Fuel Requirements9 for detailed information on fuel se-

lection.

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Chassis

Component

Fluids, Lubricants and Genuine Parts.

Automatic Transmission

Mopar

t ATF+4, Automatic Transmission Fluid

Transfer Case

Mopar

t ATF+4, Automatic Transmission Fluid

Manual Transmission Fluid NV 4500 Mopar

t 75W-85 Synthetic, API grade GL4, Mopar P/N 4874459,

Manual Transmission Fluid NV 5600 Mopar

t manual transmission fluid P/N 4874464.

Clutch Linkage

Multipurpose Grease, NLGI Grade 2 E.P.

Front and Rear Axle Fluid 2500/3500
Models

GL-5 SAE 75W-90 Synthetic Limited-Slip AAM Rear Axles DO NOT RE-
QUIRE

a limited slip additive.

Brake Master Cylinder

Mopar

t DOT 3 and SAE J1703 should be used. If DOT 3 brake fluid is not

available, then DOT 4 is acceptable. Use only recommended brake fluids.

Power Steering Reservoir

Mopar

t ATF+4, Automatic Transmission Fluid

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MAINTENANCE SCHEDULES

CONTENTS

m Emission Control System Maintenance . . . . . . . . 384
m Maintenance Schedules — 24–Valve Cummins

Turbo Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . 384

▫ Schedule “B” . . . . . . . . . . . . . . . . . . . . . . . . 387
▫ Schedule “A” . . . . . . . . . . . . . . . . . . . . . . . . 396

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EMISSION CONTROL SYSTEM MAINTENANCE

The “Scheduled” maintenance services, listed in bold
type

in this section (Section 8) must be done at the times

or mileages specified to assure the continued proper
functioning of the emission control system. These, and all
other maintenance services included in this manual,
should be done to provide best vehicle performance and
reliability. More frequent maintenance may be needed for
vehicles in severe operating conditions such as dusty
areas and very short trip driving.

Inspection and service also should be done any time a
malfunction is suspected.

NOTE:

Maintenance, replacement, or repair of the emis-

sion control devices and systems on your vehicle may be
performed by any automotive repair establishment or
individual using any automotive part which has been
certified pursuant to U.S. EPA or, in the State of Califor-
nia, California Air Resources Board regulations.

MAINTENANCE SCHEDULES — 24–VALVE
CUMMINS TURBO DIESEL

There are two maintenance schedules that show the
required

service for your vehicle.

First is Schedule “B”. It is for vehicles that are operated
under the conditions that are listed below and at the
beginning of the schedule.

• Frequent short trips where the engine does not achieve

full operating temperature (operating temperature de-
fined as 190° F (66° C ) coolant temperature).

• Extensive engine idling (over 10 minutes per hour of

operation) at ambient temperatures less than 32° F (0°
C).

• Driving in dusty conditions.
• Frequent trailer towing.
• Taxi, police, or delivery service (commercial service).

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• Off-road or desert operation.
• Extensive operation at high engine speeds (greater

than 2900 rpm) and loads (greater than 70% throttle).

NOTE:

Most vehicles are operated under the conditions

listed for Schedule

9B9.

Second is Schedule “A”. It is for vehicles that are not
operated under any of the conditions listed under Sched-
ule

9B9.

Use the schedule that best describes your driving condi-
tions. Where time and mileage are listed, follow the
interval that occurs first.

CAUTION!

Failure to perform the required maintenance items
may result in damage to the vehicle.

At Each Stop for Fuel

• Check the engine oil level about 15 minutes after a

fully warmed engine is shut off. Checking the oil level
while the vehicle is on level ground will improve the
accuracy of the oil level reading. Add oil only when
the level is at or below the ADD or MIN mark.

• Check the windshield washer solvent and add if

required.

• Drain water from the fuel filter.

Once a Month

• Check tire pressure and look for unusual wear or

damage.

• Inspect the batteries and clean and tighten the termi-

nals as required.

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• Check the fluid levels of coolant reservoir, brake

master cylinder, and transmission and transfer case (if
equipped), add as needed.

• Check Filter Minder™. Replace air cleaner filter

element if necessary.

• Check all lights and all other electrical items for correct

operation.

At Each Oil Change

• Change the engine oil filter.
• Inspect the exhaust system.

• Inspect the brake hoses.
• Inspect the CV joints (if equipped) and front suspen-

sion components.

• Check the automatic transmission fluid level.
• Check the manual transmission fluid level.
• Check the coolant level, hoses, and clamps.

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Schedule “B”

Follow schedule “B” if you usually operate your vehicle
under one or more of the following conditions.

• Frequent short trips where the engine does not achieve

full operating temperature (operating temperature de-
fined as 190° F (66° C ) coolant temperature).

• Extensive engine idling (over 10 minutes per hour of

operation) at ambient temperatures less than 32° F (0°
C).

• Driving in dusty conditions.
• Frequent trailer towing.
• Taxi, police, or delivery service (commercial service).
• Off-road or desert operation.
• Extensive operation at high engine speeds (greater

than 2900 rpm) and loads (greater than 70% throttle).

SCHEDULE “B”

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