Dodge 3500 Diesel (2008 year). Manual

• Climatized Ultra Low Sulfur Diesel Fuel is a blend of

Number 2 Ultra Low Sulfur and Number 1 Ultra Low
Sulfur Diesel Fuels which reduces the temperature at
which wax crystals form in fuel.

NOTE:

The engine requires the use of “Ultra Low

Sulfur Diesel Fuel”

. Use of incorrect fuel could result in

engine and exhaust system damage. Refer to Fuel Re-
quirements in this section for further details on fuel
recommendations.

Engine Block Heater
The engine block heater warms engine coolant and
permits quicker starts in cold weather. Connect the heater
cord to a ground–fault interrupter protected 110–115 volt
AC electrical outlet with a grounded, three-wire exten-
sion cord.

The engine block heater cord is routed under the hood to
the right side and can be located just behind the grille
near the headlamp.

NOTE:

The engine block heater cord is a factory in-

stalled option. If your vehicle is not equipped, heater
cords are available from your authorized Mopar

t dealer.

The block heater must be plugged in at least one hour to
have an adequate warming effect on the coolant.

WARNING!

Remember to disconnect the cord before driving.
Damage to the 110–115 volt electrical cord could
cause electrocution.

NOTE:

The block heater will require 110 Volts AC and

6.5 Amps to activate the heater element.

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Block Heater Usage

A. Temperatures below 0°F (-18°C)

• Block Heater Required for 15W-40
• Block Heater Recommended for 5W-40

B. Temperatures below - 20°F (-29°C)

• Block Heater Required for 5W-40

Winter Front Usage
If a winter front or cold weather cover is to be used, a
percentage of the total grille opening area must be left
uncovered to provide sufficient air flow to the charge air
cooler and automatic transmission oil cooler. The per-
centage of opening must be increased with the increasing
ambient air temperature and/or engine load. If the
cooling fan can be heard cycling frequently, increase the
size of the opening in the winter front. A suitable cold
weather cover is available from your Mopar

t dealer.

Battery Blanket Usage
A battery loses 60% of its cranking power as the battery
temperature decreases to 0°F (-18°). For the same de-
crease in temperature, the engine requires twice as much
power to crank at the same RPM. The use of 120 VAC
powered battery blankets will greatly increase starting
capability at low temperatures. Suitable battery blankets
are available from your authorized Mopar

t dealer.

Arctic Operation
Where there are no provisions to keep the engine warm
when it is operating in ambient temperatures consistently
below (-10°F/-23°C), use 5W-40 synthetic engine oil and
fuel that meets the requirements in Section 7, “Mainte-
nance Procedures,” Engine Oil Selection.

Engine Warm-Up
Avoid full throttle operation when the engine is cold.
When starting a cold engine, bring the engine up to
operating speed slowly to allow the oil pressure to
stabilize as the engine warms up.

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277

NOTE:

High-speed, no-load running of a cold engine

can result in excessive white smoke and poor engine
performance. No-load engine speeds should be kept
under 1,200 rpm during the warm-up period, especially
in cold ambient temperature conditions.

If temperatures are below 32°F (0°C), operate the engine
at moderate speeds for 5 minutes before full loads are
applied.

Engine Idling

Avoid prolonged idling, long periods of idling may be
harmful to your engine because combustion chamber
temperatures can drop so low that the fuel may not burn
completely. Incomplete combustion allows carbon and
varnish to form on piston rings and injector nozzles.
Also, the unburned fuel can enter the crankcase, diluting
the oil and causing rapid wear to the engine.

CAUTION!

Extended periods of idle time may not allow the
vehicle’s exhaust aftertreatment system to properly
regenerate. This can lead to the illumination of the
Malfunction Indicator Light (MIL) or an Electronic
Vehicle Information Center (EVIC) warning message.
Operating the engine for extended periods with the
MIL illuminated or an EVIC warning message dis-
played can cause extensive engine and exhaust sys-
tem damage.

NOTE:

Your vehicle is equipped with a turbo speed

limiter, this feature limits the engine speed to 1200 rpm
when engine coolant temperatures are below 70°F (21°C).
This feature is designed to protect the turbo charger from
damage and will only operate in PARK or NEUTRAL.

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NOTE:

An optional driver-controlled high idle speed is

available on automatic transmission equipped vehicles
with speed control. This feature allows the driver to
select an elevated idle speed between 1100 and 1500
rpms. Your dealer can enable this feature.

The optional driver-controlled high idle speed will help
increase cylinder temperatures and provide additional
cab heat, however, may still cause the exhaust aftertreat-
ment system to not properly regenerate. Extended peri-
ods of idle time should be avoided.

NOTE:

• If ambient temperatures are low and the coolant

temperature is below 200°F (93°C), the engine idle
speed will slowly increase to 1000 RPM after 2 minutes
of idle, if the following conditions are met:

• foot is off brake pedal and throttle pedal
• automatic transmission is in Park (P)
• vehicle speed is zero
• Applying the throttle will cancel fast idle
• If the engine is equipped with an exhaust brake,

operating the exhaust brake at idle will greatly im-
prove warm up rate and will help keep the engine
close to operating temperature during extended idle.

CAUTION!

Use of aftermarket exhaust brakes is not recom-
mended and could lead to engine damage

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279

Stopping The Engine

Idle the engine a few minutes before routine shutdown.
After full load operation, idle the engine 3 to 5 minutes
before shutting it down. This idle period will allow the
lubricating oil and coolant to carry excess heat away from
the combustion chamber, bearings, internal components,
and turbocharger. This is especially important for turbo-
charged, charge air cooled engines.

NOTE:

During engine shutdown on vehicles equipped

with manual transmissions, it is normal for the diesel
engine to resonate heavily for a moment during engine
shut off. When the engine is connected to a manual
transmission, this resonance causes loud gear rattle from
the transmission. This is commonly referred to as “shut
down rattle”. The manufacturer recommends performing
engine shut down with the clutch pedal pushed to the
floor (clutch disengaged). When engine shut down is
performed in this manner the rattle is reduced (not
eliminated).

Driving

Condition

Load

Turbo-

charger

Temperature

Idle Time

(min.) Be-

fore Engine

Shutdown

Stop and

Empty

Cool

Less than

One

Stop and

Medium

One

Highway

Speeds

Medium

Warm

Two

City Traffic

Maximum

GCWR

Three

Highway

Speeds

Maximum

GCWR

Four

Uphill

Grade

Maximum

GCWR

Hot

Five

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Engine Speed Control

CAUTION!

Prevent overspeeding the engine going down hill.
When descending steep grades, use a combination of
gears and service brakes to control vehicle/engine
speed. Overspeed can cause severe engine damage.

Operating Precautions

Avoid Overheating The Engine
The temperature of the coolant (a mixture of 50%
ethylene-glycol and 50% water) must not exceed the
normal range of the temperature gauge (240°F/116°C)
with a 16 psi (110 kPa) radiator cap.

Usually the coolant temperature indicated during opera-
tion will be to the left of center in the normal range of the
gauge.

Avoid Low Coolant Temperature Operation
Continual operation at low coolant temperature below
the normal range on the gauge (140°F/60°C) can be
harmful to the engine. Low coolant temperature can
cause incomplete combustion which allows carbon and
varnish to form on piston rings and injector nozzles.
Also, the unburned fuel can enter the crankcase, diluting
the lubricating oil and causing rapid wear to the engine.

Cooling System Tips — Automatic Transmission

To reduce potential for engine and transmission over-
heating in high ambient temperature conditions, take the
following actions:

• City Driving —
when stopped, put transmission in neutral and increase
engine idle speed.

• Highway Driving —
reduce your speed.

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281

• Up Steep Hills —
select a lower transmission gear, but try and keep the
torque converter clutch engaged.

• Air Conditioning —
turn it off temporarily.

Do Not Operate The Engine With Low Oil
Pressure
When the engine is at normal operating temperature, the
minimum oil pressures required are:

Idle 700 to 800 RPM . . . . . . . . . . . . . . . 10 psi (69 kPa)
Full speed and load . . . . . . . . . . . . . . 30 psi (207 kPa)

CAUTION!

If oil pressure falls to less than normal readings, shut
the engine off immediately. Failure to do so could
result in immediate and severe engine damage.

Do Not Operate The Engine With Failed Parts
Practically all failures give some warning before the parts
fail. Be on the alert for changes in performance, sounds,
and visual evidence that the engine requires service.
Some important clues are:

• engine misfiring or vibrating severely
• sudden loss of power
• unusual engine noises
• fuel, oil or coolant leaks
• sudden change, outside the normal operating range, in

the engine operating temperature

• excessive smoke
• oil pressure drop

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DIESEL EXHAUST BRAKE (ENGINE BRAKING) –
IF EQUIPPED

The exhaust brake feature will only function when the
driver turns the exhaust brake switch to the ON position.
Once the switch is in the ON position and the vehicle is
moving faster than 5 mph (8 km/h); the exhaust brake
will automatically operate when the driver removes
pressure from the accelerator pedal. Exhaust braking is
most effective when the engine RPM is higher. The
automatic transmission has been programmed to down-
shift more aggressively when the exhaust brake is en-
abled to increase brake performance.

Exhaust Brake Switch

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283

WARNING!

Do not use the Exhaust Brake feature when driving
in icy or slippery conditions as the increased engine
braking can cause the rear wheels to slide and the
vehicle to swing around with the possible loss of
vehicle control, which may cause an accident possi-
bly resulting in personal injury or death.

NOTE:

For optimum braking power it is recommended

to use the Exhaust Brake while in Tow/Haul Mode.

The purpose of the exhaust brake (engine braking) fea-
ture is to supply negative (braking) torque to the engine.
Typically, the engine braking is used for, but not limited
to, vehicle towing applications where vehicle braking can
be achieved by the internal engine power, thereby spar-
ing the mechanical brakes of the vehicle.

Benefits of the exhaust brake are:

• vehicle driving control
• reduced brake fade
• longer brake life
• faster cab warm-up.

The exhaust brake feature can also be used to reduce the
engine warm up time. To use the exhaust brake as a
warm-up device, the vehicle must be moving less than 5
mph (8 km/h), the exhaust brake switch must be in the
ON position, and the coolant temperature must below
180°F (82°C) and ambient temperature below 60°F (16°C).

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TRANSMISSION SHIFTING

Automatic Transmission with Overdrive
(68RFE) — If Equipped

The gear selector lever display located in the instrument
panel cluster indicates the transmission gear range (the
selector is illuminated for night driving). The selector
lever is mounted on the right side of the steering column.
You must depress the brake pedal to pull the selector
lever out of PARK position (Brake Interlock System). To
drive, move the selector lever from PARK or NEUTRAL
to the desired DRIVE position. Pull the selector lever
toward you when shifting into REVERSE, SECOND,
FIRST or PARK, or when shifting out of PARK.

Gear Ranges
DO NOT race the engine when shifting from PARK or
NEUTRAL position into another gear range.

PARK
This gear position supplements the parking brake by
locking the transmission. The engine can be started in
this range. Never use PARK while the vehicle is in
motion. Apply the parking brake when leaving the
vehicle in this range. Always apply parking brake first,
then place the selector in PARK position. On 4-wheel
drive vehicles be sure that the transfer case is in a drive
position!

WARNING!

Never use PARK position on an automatic transmis-
sion as a substitute for the parking brake. Always
apply parking brake fully when parked to guard
against vehicle movement and possible injury or
damage.

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285

WARNING!

Your vehicle could move and injure you and others if
it is not completely in PARK. Check by trying to
move the shift lever back and forth without first
pulling it toward you after you have set it in PARK.
Make sure it is in PARK before leaving the vehicle.

WARNING!

It is dangerous to shift the shift lever out of PARK or
NEUTRAL if the engine speed is higher than idle
speed. If your foot is not firmly on the brake pedal,
the vehicle could accelerate quickly forward or in
reverse. You could lose control of the vehicle and hit
someone or something. Only shift into gear when the
engine is idling normally and when your right foot is
firmly on the brake pedal.

REVERSE
Use this range only after the vehicle has come to a
complete stop.

NEUTRAL
Shift to NEUTRAL when the vehicle is standing for
prolonged periods with the engine running. The engine
may be started in this range. Set the parking brake if you
must leave the vehicle.

DRIVE
Drive range provides underdrive 1st, 2nd and 3rd gears,
direct 4th gear and overdrive 5th and 6th gears. The shift
into overdrive 5th and 6th gear occurs only after the
transmission has completed the shift into 4th gear. No
other movement of the shift mechanism is required to
complete the 4–5 or 5–6 gear shifts.

The 4th and 5th gear upshifts occurs automatically unless
the Tow/Haul mode is enabled.

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Upshifts into both overdrive gears, 5th and 6th, will be
delayed when the transmission fluid temperature is
below 40° F (4.5° C) or above 240° F (115.5° C).

NOTE:

Use caution when operating a heavily loaded

vehicle in 2nd or 1st gear in high ambients as torque
converter slip can impose significant additional heat load
on the cooling system.

WARNING!

Never use Park position on an automatic transmis-
sion as a substitute for the parking brake. Always
apply parking brake fully when parked to guard
against vehicle movement and possible injury or
damage.

Overdrive Operation
The overdrive automatic transmission contains an elec-
tronically controlled 5th and 6th (Overdrive). The trans-
mission will automatically shift from Drive to Overdrive
if the following conditions are present:

• the transmission selector is in DRIVE;
• the engine coolant has reached normal operating tem-

perature;

• vehicle speed is above approximately 30 mph (48

km/h);

• the “TOW HAUL O/D OFF” switch has not been

activated;

• transmission has reached normal operating tempera-

ture.

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287

NOTE:

If the vehicle is started in extremely cold tem-

peratures, the transmission may not shift into Overdrive
and will automatically select the most desirable gear for
operation at this temperature. Normal operation will
resume when the transmission fluid temperature has
risen to a suitable level. Refer also to the Note under
torque converter clutch, later in this section.

If the transmission temperature gets extremely hot, the
transmission will automatically select the most desirable
gear for operation at this temperature. If the transmission
temperature becomes hot enough the TRANS TEMP light
may illuminate and the transmission may downshift out
of Overdrive until the transmission cools down. After
cooldown, the transmission will resume normal opera-
tion.

The transmission will downshift from Overdrive to Drive
if the accelerator pedal is fully depressed at vehicle
speeds above approximately 35 mph (56 km/h).

When To Use TOW HAUL

When driving in hilly areas, towing a trailer, carrying a
heavy load, etc., and frequent transmission shifting oc-
curs, press the TOW HAUL button once to select TOW
HAUL. In TOW HAUL mode, 4th to 5th gear upshifts are

1 — Tow/Haul Switch
2 — AUTO-6 (ERS) Switch

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delayed. Shifts into 5th and 6th gear are still allowed
under steady cruise conditions. Closed throttle down-
shifts (for improved engine braking) may occur during
steady braking maneuvers. Pressing the switch a second
time restores normal operation. Normal operation is
always the default at engine start-up.

The TOW HAUL light will illuminate in the instrument
cluster to indicate when the switch has been activated. If
the TOW HAUL modes are desired, the button must be
pressed each time the engine is started.

Electronic Range Select (ERS) Operation
The Auto–6 Electronic Range Select (ERS) shift control
allows you to move the switch down (-) or up (+) when
the shifter is in the D (Drive) position, allowing the
selection of the desired top gear. For example, if the
driver shifts the transmission into 3rd gear, the transmis-
sion will never shift above 3rd gear, but can shift down to
2nd or 1st gear, when needed.

Switching from ERS to D-Mode can be done at any
vehicle speed. To switch from “Drive” mode to “ERS”
mode, press the switch down (-) once. The current gear
will be maintained as the top gear. To disable ERS, simply
press and hold the switch up (+) until “D” is displayed in
the instrument cluster odometer.

WARNING!

Do not downshift for additional engine braking on a
slippery surface. The drive wheels could lose their
grip and the vehicle could skid.

Screen Display

Actual Gear(s)
Allowed

1-2

1-3

1-4

1-5

1-6

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289

NOTE:

To select the proper gear position for maximum

deceleration (engine braking), simply press and hold the
switch down (-). The transmission will shift to the range
from which the vehicle can best be slowed down.

Torque Converter Clutch
A feature designed to improve fuel economy has been
included in the automatic transmission on your vehicle.
A clutch within the torque converter engages automati-
cally at calibrated speeds. This may result in a slightly
different feeling or response during normal operation in
the upper gears. When the vehicle speed drops or during
acceleration when the transmission downshifts to second
gear, the clutch automatically disengages.

NOTE:

The torque converter clutch will not engage

until the transmission fluid and engine coolant are warm
[usually after 1-3 miles (1.6 - 4.8 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 into Overdrive when cold. This is normal.
Pressing the TOW HAUL O/D OFF button, when the
transmission is sufficiently warm, will demonstrate that
the transmission is able to shift into and out of Overdrive.

NOTE:

If the vehicle has not been driven in several

days, the first few seconds of operation after shifting the
transmission 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 of shifting from PARK into
any other gear position.

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MANUAL TRANSMISSION

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.

Shifting

Shift Pattern

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Dodge 3500 Diesel (2008 year). Manual - part 18