Content .. 23 24 25 26 ..

Dodge 2500 Diesel (2005 year). Manual - part 25

3. Pull the housing out from the fender to allow room to
disconnect the electrical connectors.

4. Unlock and pull connector straight from the base of
the headlight halogen bulb.

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.

388

MAINTAINING YOUR VEHICLE

Tail, Stop, Turn and Backup Lights

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

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.

MAINTAINING YOUR VEHICLE

389

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

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

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

390

MAINTAINING YOUR VEHICLE

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.

MAINTAINING YOUR VEHICLE

391

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.

392

MAINTAINING YOUR VEHICLE

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.

MAINTAINING YOUR VEHICLE

393

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.

394

MAINTAINING YOUR VEHICLE

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.

MAINTAINING YOUR VEHICLE

395

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.

396

MAINTAINING YOUR VEHICLE

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

MAINTAINING YOUR VEHICLE

397

RECOMMENDED FLUIDS, LUBRICANTS AND GENUINE PARTS
Engine

Component

Fluids, Lubricants and Genuine Parts

Engine Coolant

Mopar

威 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 section

⬙Maintenance Procedures.⬙

Engine Oil Filter

Mopar

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

Engine Fuel Filter

Mopar

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

Fuel Selection

Refer to the section

⬙Fuel Requirements⬙ for detailed information on fuel se-

lection.

398

MAINTAINING YOUR VEHICLE

Chassis

Component

Fluids, Lubricants and Genuine Parts.

Automatic Transmission

Mopar

威 ATF+4, Automatic Transmission Fluid or equivalent.

Transfer Case

Mopar

威 ATF+4, Automatic Transmission Fluid or equivalent.

Manual Transmission Fluid NV 4500 Mopar

威 75W-85 Synthetic, API grade GL4, Mopar P/N 4874459 or equiva-

lent

Manual Transmission Fluid NV 5600 Mopar

威 manual transmission fluid P/N 4874464 or equivalent.

Manual Transmission Fluid G-56

Mopar

威 ATF+4, Automatic Transmission Fluid or equivalent

Clutch Linkage

Multipurpose Grease, NLGI Grade 2 E.P. or equivalent

Front and Rear Axle Fluid 2500/3500
Models

GL-5 SAE 75W-90 Synthetic or equivalent Limited-Slip AAM Rear Axles
DO NOT REQUIRE

a limited slip additive.

Brake Master Cylinder

Mopar

威 DOT 3 and SAE J1703 should be used or equivalent. If DOT 3

brake fluid is not available, then DOT 4 is acceptable. Use only recom-
mended brake fluids.

Power Steering Reservoir

Mopar

威 ATF+4, Automatic Transmission Fluid or equivalent.

MAINTAINING YOUR VEHICLE

399

MAINTENANCE SCHEDULES

CONTENTS

䡵 Emission Control System Maintenance . . . . . . . . 402
䡵 Maintenance Schedules — 24–Valve Cummins

Turbo Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . 402

▫ Schedule “B” . . . . . . . . . . . . . . . . . . . . . . . . 405
▫ Schedule “A” . . . . . . . . . . . . . . . . . . . . . . . . 416

T
E

N
A
N
C

S
C
H
E
D
U
L
E
S

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).

402

MAINTENANCE SCHEDULES

T
E

N
A
N
C

S
C
H
E
D
U
L
E
S

• 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

⬙B⬙.

NOTE:

If ANY of these apply to you then change your

coolant every 102,000 miles (163 000 km) or 60 months,
whichever comes first and follow schedule “B” of the

⬙Maintenance Schedules⬙ section of this manual.

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

⬙B⬙.

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.

MAINTENANCE SCHEDULES

403

T
E

N
A
N
C

S
C
H
E
D
U
L
E
S

Content .. 23 24 25 26 ..