Dodge 3500 Diesel (2008 year). Manual

Truck models with manual transmission are equipped
with a clutch interlocking ignition system. The clutch
pedal must be fully depressed to start the vehicle.

Fully depress the clutch pedal before shifting gears. As
you release the clutch pedal, lightly depress the accelera-
tor pedal.

This transmission has a “creeper” 1st gear (L=low) which
should be used to start from a standing position when
carrying a payload or towing a trailer. Damage to the
clutch can result from starting in 2nd or 3rd gear with a
loaded vehicle. An unloaded vehicle may be launched in
2nd gear. Use each gear in numerical order – do not skip
a gear.

You should use 1st gear when starting from a standing
position if under heavy load or when pulling a trailer.

Recommended Vehicle Shift Speeds
To utilize your manual transmission efficiently for both
fuel economy and performance, it should be upshifted as
listed in recommended shift speed chart. Shift at the
vehicle speeds listed for acceleration. When heavily
loaded or pulling a trailer these recommended up-shift
speeds may not apply.

Maximum Recommended Up-shift Speeds

Gear

Selec-

tion

L to 2

2 to 3

3 to 4

4 to 5

5 to 6

Maxi-

mum

Speed

7 mph

(11

km/h)

15 mph

(24

km/h)

25 mph

(40

km/h)

40 mph

(64

km/h)

45 mph

(72

km/h)

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STARTING AND OPERATING

Downshifting

Moving from a high gear down to a lower gear is
recommended to preserve brakes when driving down
steep hills. In addition, downshifting at the right time
provides better acceleration when you desire to resume
speed. Downshift progressively. Do not skip gears to
avoid overspeeding the engine and clutch.

WARNING!

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

CAUTION!

When descending a hill, be very careful to downshift
one gear at a time to prevent overspeeding the engine
which can cause valve damage, and / or clutch disc
damage even if the clutch pedal is depressed.

Maximum Recommended Downshift Speeds

CAUTION!

Failure to follow the recommended downshifting
speeds may cause the engine to overspeed and/or
damage the clutch disc even if the clutch pedal is
depressed.

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293

Maximum Recommended Downshifting Speeds

Gear

Selec-

tion

6 to 5

5 to 4

4 to 3

3 to 2

2 to L

Maxi-

mum

Speed

68 mph

(109

km/h)

50 mph

(80

km/h)

32 mph

(51

km/h)

19 mph

(31

km/h)

10 mph

(16

km/h)

Reverse Shifting

To shift into REVERSE (R), bring the vehicle to a com-
plete stop. Depress the clutch and pause briefly to allow
the gear train to stop rotating. Beginning from the
NEUTRAL (N) position, move the shift lever in one quick
smooth motion straight across and into the REVERSE (R)
area (the driver will feel a firm “click” as the shifter
passes the “knock-over”). Complete the shift by pulling
the shift lever into REVERSE (R).

The “knock-over” prevents the driver from accidentally
entering the REVERSE (R) shift area and warns the driver

that they are about to shift the transmission into RE-
VERSE (R). Due to this feature, a slow shift to REVERSE
(R) can be perceived as a high shift effort.

To shift out of reverse bring the vehicle to a complete stop
and depress the clutch. Shifting out of reverse prior to a
complete stop may cause high shift effort.

FOUR–WHEEL DRIVE OPERATION — IF
EQUIPPED

Four-Wheel Drive trucks are equipped with either a
manually shifted transfer case or an electronically shifted
transfer case. See the operating instructions for your
transfer case, located within this section.

Manually Shifted Transfer Case Operating
Information/Precautions

The transfer case provides 4 mode positions - 2 (rear)-
wheel drive high range, 4-wheel drive high range, neu-
tral, and 4-wheel drive low range.

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STARTING AND OPERATING

This transfer case is intended to be driven in the 2-wheel
drive position (2H) for normal street and highway con-
ditions such as dry hard surfaced roads.

When additional traction is required the transfer case 4H
and 4L 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
simply moving the shift lever to the desired positions.
The 4H and 4L positions are intended for loose, slippery
road surfaces only. Driving in the 4H and 4L positions on
dry hard surfaced roads may cause increased tire wear
and damage to the driveline components.

The 4-wheel drive light (4WD), located in the instrument
cluster, alerts the driver that the vehicle is in 4-wheel
drive and that the front and rear driveshafts are locked
together. This light illuminates when the transfer case is
shifted to either the 4H or 4L positions. There is no light
for the 2H or NEUTRAL positions.

When operating your vehicle in 4L, the engine speed is
approximately three times that of the 2H or 4H positions
at a given road speed. Take care not to overspeed 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 will adversely affect shifting and can
cause damage to the transfer case.

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.

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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295

NOTE:

Delayed shifts out of four-wheel drive may be

experienced due to uneven tire wear, low or uneven tire
pressures, excessive vehicle loading, or cold tempera-
tures.

WARNING!

You or others could be injured if you leave the
vehicle unattended with the transfer case in the
NEUTRAL position without first fully engaging the
parking brake. The transfer case NEUTRAL 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 drive-
shafts from the powertrain. To be used for flat towing
behind another vehicle. See Recreational Towing for
more information.

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STARTING AND OPERATING

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).

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

Manual Transfer Case Shifter

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297

vehicle in motion, the transfer case will engage/
disengage faster if you momentarily release the accelera-
tor 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 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 NEUTRAL.

NOTE:

Pausing in transfer case 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 NEUTRAL, hold foot on brake, and turn
engine OFF. Make shift to the desired mode.

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.

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STARTING AND OPERATING

Electronically Shifted Transfer Case Operating
Information/Precautions (4 Position Switch) — If
Equipped

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.

This Electronically Shifted transfer case provides four
mode positions: 2 (rear)-wheel drive high range, 4-wheel
drive lock range, 4-wheel drive low range, and NEU-
TRAL.

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

When additional traction is required, the transfer case
4WD LOCK and 4WD LOW 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 position - refer to “Shifting Procedure” in this
section. The 4WD LOCK and 4WD LOW positions are
designed for loose, slippery road surfaces only. Driving

Transfer Case Switch

STARTING AND OPERATING

299

in the 4WD LOCK and 4WD LOW positions on dry hard
surfaced roads may cause increased tire wear and dam-
age to the driveline components.

NOTE:

The transfer case NEUTRAL position is selected

by depressing the recessed button located on the lower
left hand corner of the 4WD Control Switch. The transfer

case NEUTRAL position is to be used for recreational
towing only. Refer to “Recreational Towing” in this
section.

Transfer Case Position Indicator Lights —
Electronically Shifted Transfer Case Only
Transfer case position indicator lights are located in the
instrument cluster and indicate the current and desired
transfer case selection. When you select a different trans-
fer case position, the indicator lights will do the follow-
ing:

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.

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STARTING AND OPERATING

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.

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
seconds, and retry selection. To find the shift require-
ments, refer to the

9Shifting Procedure9 for your transfer

case, located in this section.

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

illuminated. 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, as this can cause
damage to driveline components.

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301

When operating your vehicle in 4WD LOW, the engine
speed is approximately three times that of the 2WD or
4WD LOCK positions at a given road speed. Take care
not to overspeed 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.

WARNING!

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

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

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STARTING AND OPERATING

4WD LOCK
4-Wheel Drive Lock 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.

4WD LOW
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. Refer to “Recreational Towing” in this
section.

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

Transfer Case Switch

STARTING AND OPERATING

303

light will continue to flash until all the requirements for
the selected position have been met. To retry a shift:
return the control knob back to the original position,
make certain all shift requirements have been met, wait
five 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

⇔ 4WD LOCK

Rotate the 4WD control switch to the desired position.
Shifts between 2WD and 4WD LOCK 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 turn-
ing 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 ACC position.

NOTE:

The 4x4 system will not allow shifts between

2WD/4WD LOCK 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 or 4WD LOCK

⇔ 4WD LOW

NOTE:

When shifting into or out of 4WD LOW 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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STARTING AND OPERATING

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 (depress
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
then the desired position indicator light will flash con-
tinuously 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 “Vehicle Storage” in section 7.

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305

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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DRIVING ON SLIPPERY SURFACES

When driving on wet or slushy roads, it is possible for a
wedge of water to build up between the tire and road
surface. This is known as hydroplaning and may cause
partial or complete loss of vehicle control and stopping
ability. To reduce this possibility, the following precau-
tions should be observed:

1. Slow down during rainstorms or when roads are
slushy.

2. Slow down if road has standing water or puddles.

3. Replace tires when tread wear indicators first become
visible.

4. Keep tires properly inflated.

5. Maintain sufficient distance between your vehicle and
the car in front to avoid a collision in a sudden stop.

DRIVING THROUGH WATER

Driving through water more than a few inches/
centimeters deep will require extra caution to ensure
safety and prevent damage to your vehicle.

Flowing/Rising Water

WARNING!

Do not drive on, or cross, a road or a path where
water is flowing and/or rising (as in storm run-off).
Flowing water can wear away the road or path’s
surface and cause your vehicle to sink into deeper
water. Furthermore, flowing and/or rising water can
carry your vehicle away swiftly. Failure to follow this
warning may result in injuries that are serious or
fatal to you, your passengers, and others around you.

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307

Dodge 3500 Diesel (2008 year). Manual - part 19