Dodge 5500 Chassis Cab (2008 year). Manual

Hoses And Vacuum/Vapor Harnesses

Inspect surfaces of hoses and nylon tubing for evidence
of heat and mechanical damage. Hard or soft spots,
brittle rubber, cracking, tears, cuts, abrasions, and exces-
sive swelling indicate deterioration of the rubber.

Pay particular attention to those hoses nearest to high
heat sources such as the exhaust manifold. Inspect hose
routing to be sure hoses do not come in contact with any
heat source or moving component which may cause heat
damage or mechanical wear.

Insure nylon tubing in these areas has not melted or
collapsed.

Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.

Components should be replaced immediately if there is
any evidence of wear or damage that could cause failure.

Fuel System Connections

Electronic Fuel Injection high pressure fuel systems are
designed with tubes and special connects, connections
and clamps which have unique material characteristics to
provide adequate sealing and resist attack by deterio-
rated gasoline.

You are urged to use only the manufactures-specified
tubes, connections and clamps, or their equivalent in
material and specification, in any fuel system servicing.

Brake System

Power Disc Brakes (Front and Rear)
Disc brakes do not require adjustment; however, several
hard stops during the break-in period are recommended
to seat the linings and wear off any foreign material.

Brake And Power Steering Hoses
When the vehicle is serviced for scheduled maintenance,
inspect surface of hoses and nylon tubing for evidence of

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heat and mechanical damage. Hard and brittle rubber,
cracking, tears, cuts, abrasion, and excessive swelling
indicate deterioration of the rubber. Particular attention
should be made to examining those hose surfaces nearest
to high heat sources, such as the exhaust manifold.

Insure nylon tubing in these areas has not melted or
collapsed.

Inspect all hose connections such as clamps and cou-
plings to make sure they are secure and no leaks are
present.

NOTE:

Often, fluid such as oil, power steering fluid,

and brake fluid are used during assembly plant opera-
tions to facilitate the assembly of hoses to couplings.
Therefore, oil wetness at the hose-coupling area is not
necessarily an indication of leakage. Actual dripping of
hot fluid when systems are under pressure (during
vehicle operation), should be noted before hose is re-
placed based on leakage.

NOTE:

Inspection of brake hoses should be performed

whenever the brake system is serviced and every engine
oil change. Inspect hydraulic brake hoses for surface
cracking, scuffing, or worn spots. If there is any evidence
of cracking, scuffing, or worn spots, the hose should be
replaced immediately! Eventual deterioration of the hose
can take place resulting in a possibility of a burst failure.

WARNING!

Worn brake hoses can burst and cause brake failure.
You could have an accident. If you see any signs of
cracking, scuffing, or worn spots, have the brake
hoses replaced immediately.

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441

Brake Master Cylinder – Brake Fluid Level Check
The fluid level of the master cylinder should be checked
when performing under the hood service, or immedi-
ately if the brake system warning lamp indicates system
failure.

The brake master cylinder has a translucent plastic
reservoir. On the outboard side of the reservoir, there is a
“MAX” mark and an “MIN” mark (3500 vehicles only)
and a “FULL” and “ADD” mark (4500/5500 vehicles
only). The fluid level must be kept within these two
marks. Do not add fluid above the full mark because
leakage may occur at the cap.

With disc brakes the fluid level can be expected to fall as
the brake linings wear. However, an unexpected drop in
fluid level may be caused by a leak and a system check
should be conducted.

Refer to Fluids, Lubricants and Genuine Parts for the
correct Fluid type.

WARNING!

Use of a brake fluid that may have a lower initial
boiling point, or unidentified as to specification, may
result in sudden brake failure during hard prolonged
braking. You could have an accident.

WARNING!

Overfilling the brake fluid reservoir can result in
spilling brake fluid on hot engine parts and the
brake fluid catching fire.

Use only brake fluid that has been in a tightly closed
container to avoid contamination from foreign matter or
moisture.

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CAUTION!

Do not allow a petroleum-base fluid to contaminate
the brake fluid. Seal damage and loss of brake
performance may result.

Clutch Hydraulic System

The clutch hydraulic system is a sealed maintenance-free
system. In the event of leakage or other malfunction, the
system must be replaced.

Clutch Linkage

If the clutch pedal linkage begins to squeak or grunt, the
clutch pedal pivot bushings should be lubricated. Refer
to Fluids, Lubricants and Genuine Parts for the correct
lubricant type. Multipurpose Grease, NLGI Grade 2 E.P.

Rear Axle And 4x4 Front Driving Axle Fluid Level

For Models with 9.25 Front Axles and 11.5” Rear Axles
refer to Fluids, Lubricants and Genuine Parts for the
correct lubricant type. For normal service, periodic fluid
level checks are not required. When the vehicle is ser-
viced for other reasons, the exterior surfaces of the axle
assembly should be inspected.

When checking the fluid level (3500 only), the vehicle
should be in a level position. The fluid level should be
1/4” ± 1/4” (6.4 mm ± 6.4 mm) below the fill hole on the
front axle. The fluid level should be 1/4” ± 1/4” (6.4 mm
± 6.4 mm) below the fill hole on the rear axle.

When checking the fluid level (4500/5500 only), the
vehicle should be in a level position. The fluid level
should be 1/4” ± 1/4” (6.4 mm ± 6.4 mm) below the fill
hole on the front axle. The fluid level should be level with
the bottom of the fill hole on the rear axle.

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443

Drain And Refill
On 3500 vehicles the differential cover must be removed
to drain the axle fluid.

On 4500/5500 vehicles remove the lower bolt to drain the
axle fluid.

Follow the appropriate Maintenance Schedule for recom-
mended front and rear axle fluid change intervals.

Lubricant Selection
Refer to Fluids, Lubricants and Genuine Parts for the
correct lubricant type.

NOTE:

The presence of water in the gear lubricant will

result in corrosion and possible failure of differential
components. Operation of the vehicle in water, as may be
encountered in some off-highway types of service, will
require draining and refilling the axle to avoid damage.

Limited-Slip Differentials DO NOT REQUIRE

any

limited slip oil additive (friction modifiers).

NOTE:

Slight noise and mild shuddering may be evi-

dent while turning a vehicle with limited slip differential
on concrete or dry pavement. These conditions should be
considered normal operation of the limited slip differen-
tial.

1 — 4500/5500 Rear Axle Fluid Fill Plug
2 — 4500/5500 Rear Axle Fluid Drain Plug

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Transfer Case — If Equipped

Drain And Refill
Follow the appropriate Maintenance Schedule for recom-
mended transfer case fluid change intervals.

Lubricant Selection
Refer to Fluids, Lubricants and Genuine Parts for the
correct lubricant type.

Fluid Level Check
This fluid level can be checked by removing the filler
plug. The fluid level should be to the bottom edge of the
filler plug hole with the vehicle in a level position.

Manual Transmission — If Equipped

Lubricant Selection for 6-Speed Manual
Transmission — If Equipped
If it becomes necessary to add fluid or change the fluid,
be sure to use the same lubricant or equivalent. Refer to
Fluids, Lubricants and Genuine Parts for the correct
lubricant type.

Follow the Maintenance Schedule for recommended
transmission fluid change intervals.

Fluid Level Check
This fluid level can be checked by removing the filler
plug. If the level of the lubricant is more than 1/4” below
the bottom of the filler hole while the vehicle is on level
ground, enough lubricant should be added to bring the
level to the bottom of the filler hole.

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445

Automatic Transmission (Gas Engine Only)

Selection Of Lubricant
Refer to Fluids, Lubricants and Genuine Parts for the
correct lubricant type. It is important that the transmis-
sion fluid be maintained at the prescribed level using the
recommended fluid.

CAUTION!

Using a transmission fluid other than the manufac-
turers recommended fluid may cause deterioration in
transmission shift quality and/or torque converter
shudder. Using a transmission fluid other than the
manufacturers recommended fluid will result in
more frequent fluid and filter changes. Refer to
Fluids, Lubricants and Genuine Parts for correct
fluid type.

Fluid Level Check – 545RFE Transmission
Check the fluid level while the transmission is at normal
operating temperature 180° F (82° C). This occurs after at
least 15 mi (25 km) of driving. At normal operating
temperature the fluid cannot be held comfortably be-
tween the fingertips.

Procedure For Checking Fluid Level
To properly check the automatic transmission fluid level,
the following procedure must be used:

1. Operate the engine at idle speed and normal operating
temperature.

2. The vehicle must be on level ground.

3. Fully apply parking brake.

4. Place the gear selector momentarily in each gear
position ending with the lever in P (Park).

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5. Remove the dipstick, wipe it clean and reinsert it until
seated.

6. Remove the dipstick again and note the fluid level on
both sides. The fluid level should be between the HOT
(upper) reference holes on the dipstick at normal operat-
ing temperature. Verify that a solid coating of oil is seen
on both sides of the dipstick. If the fluid is low, add as
required into the dipstick tube. Do not overfill. After
adding any quantity of oil through the dipstick tube, wait
a minimum of two (2) minutes for the oil to fully drain
into the transmission before rechecking the fluid level.

NOTE:

If it is necessary to check the transmission below

the operating temperature, the fluid level should be
between the two cold (lower) holes on the dipstick with
the fluid at approximately 70° F (21° C) (room tempera-
ture). If the fluid level is correctly established at room
temperature, it should be between the HOT (upper)

reference holes when the transmission reaches 180° F (21°
C). Remember it is best to check the level at the normal
operating temperature.

CAUTION!

Be aware that if the fluid temperature is below 50° F
(10° C), it may not register on the dipstick. Do not add
fluid until the temperature is elevated enough to
produce an accurate reading.

7. Check for leaks. Release the Parking Brake.

NOTE:

To prevent dirt and water from entering the

transmission after checking or replenishing fluid, make
certain that the dipstick cap is properly reseated. It is
normal for the dipstick cap to spring back slightly from
its fully seated positions, as long as its seal remains
engaged in the dipstick tube.

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447

Automatic Transmission Fluid and Filter Change
Follow the Maintenance Schedule for recommended
transmission fluid and filter change intervals.

NOTE:

If the transmission is disassembled for any

reason, the fluid and filter should be changed.

Special Additives
The manufacturer recommends against the addition of
any additives to the transmission. Exception to this
policy is the use of special dyes to aid in detecting fluid
leaks. The use of transmission sealers should be avoided,
since they may adversely affect seals.

Automatic Transmission (Diesel Engine Only)

CAUTION!

Using a transmission fluid other than the manufac-
turers recommended fluid may cause deterioration in
transmission shift quality and/or torque converter
shudder. Using a transmission fluid other than the
manufacturers recommended fluid will result in se-
rious damage to the transmission. Refer to Fluids,
Lubricants and Genuine Parts for correct fluid type.

Fluid Level Check – AS68RC Transmission
Check the fluid level while the transmission is at normal
operating temperature 167° F (76° C). This occurs after at
least 15 mi (25 km) of driving. At normal operating
temperature the fluid cannot be held comfortably be-
tween the fingertips.

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Procedure For Checking Fluid Level
To properly check the automatic transmission fluid level,
the following procedure must be used:

1. The vehicle must be on level ground.

2. Operate the engine at idle speed for a minimum of 60
seconds and normal operating temperature.

3. Fully apply parking brake and press the brake pedal.

4. Place the gear selector momentarily in each gear
position ending with the lever in P (Park). Make sure the
engine is running at idle speed.

5. Remove the dipstick and determine if the fluid is hot
or cold. Hot fluid is approximately 160° F - 175° F (70° C
– 82° C), Which is the normal operating temperature after
the vehicle has been driven at least 15 miles. The fluid can
not be comfortably held between the finger tips. Only use

the cold region on the dipstick as a rough reference when
doing initial oil level set after transmission rebuild or
transmission refill.

6. Wipe the dipstick clean and reinsert it until seated.

7. Remove the dipstick again and note the fluid level on
both sides. The fluid level should be between the HOT
(upper) reference holes on the dipstick at normal operat-
ing temperature. Verify that a solid coating of oil is seen
on both sides of the dipstick. If the fluid is low, add
Mopar

t A68SRC™ Automatic Transmission Fluid as

required into the dipstick tube. Do not overfill. Never
use any ATF other than Mopar

t AS68RC™ Automatic

Transmission Fluid.

After adding any quantity of oil

through the dipstick tube, wait a minimum of two (2)
minutes for the oil to fully drain into the transmission
before rechecking the fluid level.

NOTE:

If it is necessary to check the transmission below

the operating temperature, the fluid level should be

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449

between the two cold (lower) holes on the dipstick with
the fluid at approximately 70° F – 85° F (20° C – 30° C). If
the fluid level is correctly established at room tempera-
ture, it should be between the HOT (upper) reference
holes when the transmission reaches 160° F - 175° F (70°
C – 82° C). Remember it is best to check the level at the
normal operating temperature.

CAUTION!

Be aware that if the fluid temperature is below 50° F
(10° C), it may not register on the dipstick. Do not add
fluid until the temperature is elevated enough to
produce an accurate reading. Never use any ATF
other than Mopar

t AS68RC™ Automatic Transmis-

sion Fluid.

8. Check for leaks. Release the Parking Brake.

NOTE:

To prevent dirt and water from entering the

Automatic Transmission Fluid and Filter Change
To obtain best performance and long life for automatic
transmissions, the manufacturer recommends that they
be given regular maintenance service by an Authorized
Dodge Dealer or Service Center. It is important that the
transmission fluid is maintained at the correct level, and
that it be drained and refilled as specified.

It is important that proper lubricant is used in the
transmission. Refer to Fluids, Lubricants and Genuine
Parts for the correct lubricant type. A filter change should
be made at the time of the oil change.

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The fluid and filter(s) should be changed as specified in
the Maintenance Schedule (Section 8).

NOTE:

If the transmission is disassembled for any

reason, the fluid and filter should be changed, and the
bands adjusted (if equipped).

Front and Rear Wheel Bearings

Front Wheel Bearings
Front wheel bearings for all Dodge Ram Trucks are
sealed-for-life. They do not require greasing or seal
replacement. In some instances, these bearings will

“purge” excess grease and the bearing will look slightly
wet. This is normal. Periodic inspection for excess play is
recommended.

Rear Wheel Bearings — Manufacturer’s Axles
These bearings are normally considered permanently
lubricated. Cleaning and repacking is required only
when axle shafts are removed or in case of extreme water
or dust contamination.

Noise Control System Required Maintenance &
Warranty

For 3500/4500/5500 Two-Wheel Drive and Four-Wheel
Drive models over 10,000 lbs. (4 535 kg) Gross Vehicle
Weight Rating.

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451

All vehicles built over 10,000 lbs. (4 535 kg) Gross Vehicle
Weight Rating and manufactured for sale and use in the
United States are required to comply with the Federal
Government’s Exterior Noise Regulations. These vehicles
can be identified by the Noise Emission Control Label
located in the operator’s compartment.

Required Maintenance For Noise Control Systems
The following maintenance services must be performed
every 6 months or 6,000 miles (9 600 km) whichever
comes first, to assure proper operation of the noise
control systems. In addition, inspection and service
should be performed anytime a malfunction is observed
or suspected. Proper maintenance of the entire vehicle
will help the effectiveness of the noise control systems.

Exhaust System
Inspect the entire exhaust system for leaks and damaged
parts. Devices such as hangers, clamps, and U-bolts
should be tight and in good condition. Damaged compo-
nents, burned or blown out mufflers, burned or rusted
out exhaust pipes should be replaced according to the
procedures and specifications outlined in the appropriate
service manual.

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Air Cleaner Assembly
Inspect air cleaner housing for proper assembly and fit.
Make certain that the air cleaner is properly positioned
and that the cover is tight. Check all hoses leading to the
air cleaner for tightness. The air filter element must also
be clean and serviced according to the instructions out-
lined in the Maintenance Schedule Section of this
manual.

Tampering With Noise Control System Prohibited
Federal law prohibits the following acts or the causing
thereof: (1) the removal or rendering inoperative by any
person, other than for purposes of maintenance, repair, or
replacement, of any device or element of design incorpo-
rated into any new vehicle for the purpose of noise
control prior to its sale or delivery to the ultimate
purchaser or while it is in use, or (2) the use of the vehicle
after such device or element of design has been removed
or rendered inoperative by any person.

Among those acts presumed to constitute tampering are
the acts listed below.

• AIR CLEANER

− Removal of the air cleaner.

− Removal of the air cleaner filter element from the air

cleaner housing.

− Removal of the air ducting.

• EXHAUST SYSTEM

− Removal or rendering inoperative exhaust system

components including the muffler or tailpipe.

• ENGINE COOLING SYSTEM

− Removal or rendering inoperative the fan clutch.

− Removal of the fan shroud.

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453

Noise Emission Warranty
The manufacturer warrants that this vehicle as manufac-
tured by the manufacturer, was designed, built and
equipped to conform at the time it left the manufacturer’s
control with all applicable U.S. EPA Noise Control Regu-
lations.

This warranty covers this vehicle as designed, built and
equipped by the manufacturer, and is not limited to any

particular part, component or system of the vehicle
manufactured by the manufacturer. Defects in design,
assembly or in any part, component or system of the
vehicle as manufactured by the manufacturer, which, at
the time it left the manufacturer’s control, caused noise
emissions to exceed Federal standards, are covered by
this warranty for the life of the vehicle.

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Noise Systems Maintenance Chart and Service Log Maintenance Log and Service Chart (Gas Engines) Insert
Month, Day, Year under column mileage closest to the mileage at which service was performed.
MILES

6,000

12,000

18,000

24,000

30,000

36,000

42,000

48,000

KILOMETERS

9 600

19 000

29 000

36 000

48 000

58 000

67 000

77 000

Exhaust system-inspect
Air cleaner assembly-inspect
ODOMETER READING
PERFORMED BY
PERFORMED AT

MILES

54,000

60,000

66,000

72,000

78,000

84,000

90,000

96,000

KILOMETERS

87 000

96 000

106 000 116 000 126 000 135 000 145 000 154 000

Exhaust system-inspect
Air cleaner assembly-inspect
ODOMETER READING
PERFORMED BY
PERFORMED AT

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Dodge 5500 Chassis Cab (2008 year). Manual - part 28