Dodge 2500 (2009 year). Manual

When adding engine coolant (antifreeze):

• The manufacturer recommends using MOPAR威

Antifreeze/Coolant 5 Year/100,000 Mile Formula
HOAT (Hybrid Organic Additive Technology).

• Mix a minimum solution of 50% HOAT engine coolant

(antifreeze) and distilled water. Use higher concentra-
tions (not to exceed 70%) if temperatures below -34°F
(-37°C) are anticipated.

• Use only high purity water such as distilled or deion-

ized water when mixing the water/engine coolant
(antifreeze) solution. The use of lower quality water
will reduce the amount of corrosion protection in the
engine cooling system.

Please note that it is the owner’s responsibility to main-
tain the proper level of protection against freezing ac-
cording to the temperatures occurring in the area where
the vehicle is operated.

NOTE:

Mixing engine coolant (antifreeze) types will

decrease the life of the engine coolant (antifreeze) and
will require more frequent engine coolant (antifreeze)
changes.

Cooling System Pressure Cap
The cap must be fully tightened to prevent loss of engine
coolant (antifreeze), and to ensure that engine coolant
(antifreeze) will return to the radiator from the coolant
recovery bottle.

The cap should be inspected and cleaned if there is any
accumulation of foreign material on the sealing surfaces.

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WARNING!

• The warning words “DO NOT OPEN HOT” on

the cooling system pressure cap are a safety pre-
caution. Never add engine coolant (antifreeze)
when the engine is overheated. Do not loosen or
remove the cap to cool an overheated engine. Heat
causes pressure to build up in the cooling system.
To prevent scalding or injury, do not remove the
pressure cap while the system is hot or under
pressure.

• Do not use a pressure cap other than the one

specified for your vehicle. Personal injury or en-
gine damage may result.

Disposal of Used Engine Coolant
Used ethylene glycol-based engine coolant (antifreeze) is
a regulated substance requiring proper disposal. Check
with your local authorities to determine the disposal

rules for your community. To prevent ingestion by ani-
mals or children do not store ethylene glycol-based
engine coolant (antifreeze) in open containers or allow it
to remain in puddles on the ground. If ingested by a
child, contact a physician immediately. Clean up any
ground spills immediately.

Coolant Level
The coolant bottle provides a quick visual method for
determining that the engine coolant (antifreeze) level is
adequate. With the engine cold, the level of the engine
coolant (antifreeze) in the coolant recovery bottle should
be between the ranges indicated on the bottle.
The radiator normally remains completely full, so there is
no need to remove the radiator cap unless checking for
engine coolant (antifreeze) freeze point or replacing en-
gine coolant (antifreeze). Advise your service attendant
of this. As long as the engine operating temperature is
satisfactory, the coolant bottle only needs to be checked
once a month.

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445

When additional engine coolant (antifreeze) is needed to
maintain the proper level, it should be added to the
coolant bottle. Do not overfill.

Points To Remember

NOTE:

When the vehicle is stopped after a few miles (a

few kilometers) of operation, you may observe vapor
coming from the front of the engine compartment. This is
normally a result of moisture from rain, snow, or high
humidity accumulating on the radiator and being vapor-
ized when the thermostat opens, allowing hot engine
coolant (antifreeze) to enter the radiator.

If an examination of your engine compartment shows no
evidence of radiator or hose leaks, the vehicle may be
safely driven. The vapor will soon dissipate.

• Do not overfill the coolant recovery bottle.
• Check the engine coolant (antifreeze) freeze point in

the radiator and in the coolant recovery bottle. If

engine coolant (antifreeze) needs to be added, the
contents of the coolant recovery bottle must also be
protected against freezing.

• If frequent engine coolant (antifreeze) additions are

required, or if the level in the coolant recovery bottle
does not drop when the engine cools, the cooling
system should be pressure tested for leaks.

• Maintain engine coolant (antifreeze) concentration at

50% HOAT engine coolant (antifreeze) (minimum)
and distilled water for proper corrosion protection of
your engine, which contains aluminum components.

• Make sure that the radiator and coolant recovery

bottle overflow hoses are not kinked or obstructed.

• Keep the front of the radiator clean. If your vehicle is

equipped with air conditioning, keep the front of the
condenser clean.

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MAINTAINING YOUR VEHICLE

• Do not change the thermostat for Summer or Winter

operation. If replacement is ever necessary, install
ONLY the correct type thermostat. Other designs may
result in unsatisfactory coolant performance, poor gas
mileage, and increased emissions.

Brake System

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
“FULL” mark and an “ADD” mark. 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” in this
section for the correct fluid type.

WARNING!

• Use of a brake fluid that may have a lower initial

boiling point, or is unidentified as to specification,
may result in sudden brake failure during hard
prolonged braking. You could have an accident.

• Overfilling the brake fluid reservoir can result in

spilling brake fluid on hot engine parts and the
brake fluid catching fire.

(Continued)

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447

WARNING! (Continued)

• Use only brake fluid that has been in a tightly-

closed container to avoid contamination from for-
eign matter or moisture.

CAUTION!

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

Rear Axle And 4x4 Front Driving Axle Fluid Level
For normal service, periodic fluid level checks are not
required. When the vehicle is serviced for other reasons
the exterior surfaces of the axle assembly should be
inspected. If gear oil leakage is suspected inspect the
fluid level. Refer to “Fluids, Lubricants, and Genuine
Parts” in this section for the correct fluid type.

This inspection should be made with the vehicle in a level
position. The fluid level should be even with the bottom
of the fill hole for the manufacturer’s C205F HD front
axles. The fluid level should be 5/8 in (16 mm) below the
fill hole on 9 1/4 in manufacturer’s rear axles.

For all 2500/3500 Model axles, the fluid level should be
1/4” ± 1/4 in (6.4 mm ± 6.4 mm) below the fill hole on
the 9.25 in front and 3/4 in ± 1/4 in (19 mm ± 6.4 mm) on
10.5 in rear axles. The 11.5 in rear axle level should be
1/4 in ± 1/4 in (6.4 mm ± 6.4 mm) below the fill hole.

Drain and Refill
Refer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.

Lubricant Selection
Refer to “Fluids, Lubricants, and Genuine Parts” in this
section for the correct fluid type.

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MAINTAINING YOUR VEHICLE

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.

2500/3500 Model Axles DO NOT REQUIRE any limited
slip oil additive (friction modifiers).

Transfer Case

Drain And Refill
Refer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.

Lubricant Selection
Refer to “Fluids, Lubricants, and Genuine Parts” in this
section for the correct fluid 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.

Automatic Transmission

Selection Of Lubricant
It is important that the proper lubricant is used in the
transmission to assure optimum transmission perfor-
mance. Use only the manufacturer’s recommended trans-
mission fluid. Refer to “Fluids, Lubricants, and Genuine
Parts” in this section for the correct fluid type. It is
important that the transmission fluid be maintained at
the prescribed level using the recommended fluid. No
chemical flushes should be used in any transmission;
only the approved lubricant may be used.

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449

CAUTION!

Using a transmission fluid other than the manufac-
turer’s recommended fluid may cause deterioration
in transmission shift quality and/or torque converter
shudder. Using a transmission fluid other than the
manufacturer’s recommended fluid will result in
more frequent fluid and filter changes. Refer to
“Fluids, Lubricants, and Genuine Parts” in this sec-
tion for correct fluid type.

Fluid Level Check
If your vehicle is equipped with a dipstick, use the
following procedure. If your vehicle has a capped dip-
stick tube, it is sealed and should not be tampered with.
Your authorized dealer has the proper tools to ensure that
the fluid level is set properly. The fluid level should be
checked when the engine is fully warmed up and the

fluid in the transmission is at normal operating tempera-
ture. Operation of the transmission with an improper
fluid level will greatly reduce the life of the transmission
and of the fluid. Check the fluid level whenever the
vehicle is serviced.

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

To check the automatic transmission fluid level properly,
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.

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

4. Place the shift lever momentarily into each gear posi-
tion ending with the lever in PARK.

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 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 oil fill tube, wait
a minimum of two 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 tem-
perature). 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 (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.

7. Check for leaks. Release parking brake.

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

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451

dipstick cap to spring back slightly from its fully seated
position, as long as its seal remains engaged in the
dipstick tube.

Automatic Transmission Fluid and Filter Change
Refer to the “Maintenance Schedule” in Section 8 for the
proper maintenance intervals.

NOTE:

If the transmission is disassembled for any

reason, the fluid and filter(s) should be changed.

It is important that the proper lubricant is used in the
transmission. Refer to “Fluids, Lubricants, and Genuine
Parts” in this section for the correct fluid type.

Special Additives
Automatic Transmission Fluid (ATF) is an engineered
product and its performance may be impaired by supple-
mental additives. Therefore, do not add any fluid addi-
tives to the transmission. The only exception to this

policy is the use of special dyes to aid in detecting fluid
leaks. In addition, avoid using transmission sealers as
they may adversely affect seals.

Appearance Care and Protection from Corrosion

Protection of Body and Paint from Corrosion
Vehicle body care requirements vary according to geo-
graphic locations and usage. Chemicals that make roads
passable in snow and ice, and those that are sprayed on
trees and road surfaces during other seasons, are highly
corrosive to the metal in your vehicle. Outside parking,
which exposes your vehicle to airborne contaminants,
road surfaces on which the vehicle is operated, extreme
hot or cold weather and other extreme conditions will
have an adverse affect on paint, metal trim, and under-
body protection.

The following maintenance recommendations will enable
you to obtain maximum benefit from the corrosion
resistance built into your vehicle.

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What Causes Corrosion?
Corrosion is the result of deterioration or removal of
paint and protective coatings from your vehicle.

The most common causes are:

• Road salt, dirt and moisture accumulation.
• Stone and gravel impact.
• Insects, tree sap and tar.
• Salt in the air near seacoast localities.
• Atmospheric fallout/industrial pollutants.

Washing

• Wash your vehicle regularly. Always wash your ve-

hicle in the shade using MOPAR

威 Car Wash or a mild

car wash soap, and rinse the panels completely with
clear water.

• If insects, tar or other similar deposits have accumu-

lated on your vehicle, use MOPAR

威 Super Kleen Bug

and Tar Remover to remove.

• Use MOPAR威 Cleaner Wax to remove road film, stains

and to protect your paint finish. Take care never to
scratch the paint.

• Avoid using abrasive compounds and power buffing

that may diminish the gloss or thin out the paint
finish.

CAUTION!

Do not use abrasive or strong cleaning materials such
as steel wool or scouring powder, which will scratch
metal and painted surfaces.

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453

Special Care

• If you drive on salted or dusty roads, or if you drive

near the ocean, hose off the undercarriage at least once
a month.

• It is important that the drain holes in the lower edges

of the doors, rocker panels and trunk be kept clear and
open.

• If you detect any stone chips or scratches in the paint,

touch them up immediately. The cost of such repairs is
considered the responsibility of the owner.

• If your vehicle is damaged due to an accident or

similar cause which destroys the paint and protective
coating, have your vehicle repaired as soon as pos-
sible. The cost of such repairs is considered the respon-
sibility of the owner.

• If you carry special cargo such as chemicals, fertilizers,

de-icer salt, etc., be sure that such materials are well
packaged and sealed.

• If a lot of driving is done on gravel roads, consider

mud or stone shields behind each wheel.

• Use MOPAR威 Touch Up Paint on scratches as soon as

possible. Your authorized dealer has touch up paint to
match the color of your vehicle.

Wheel and Wheel Trim Care
All wheels and wheel trim, especially aluminum and
chrome plated wheels should be cleaned regularly with a
mild soap and water to prevent corrosion. To remove
heavy soil and/or excessive brake dust, use MOPAR

威

Wheel Cleaner (05066247AB) or equivalent, or select a
nonabrasive, non-acidic cleaner. Do not use scouring
pads, steel wool, a bristle brush, or metal polishes. Only
MOPAR

威 or equivalent is recommended. Do not use

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oven cleaner. Avoid automatic car washes that use acidic
solutions or harsh brushes that may damage the wheels’
protective finish.

Stain Repel Fabric Cleaning Procedure — If
Equipped
You can identify if your vehicle has Stain Repel Seat
Fabric that makes spills easy to clean, reduces odor from
spills and reduces static by the presence of a tag on the
side of the seat.

Stain Repel seats may be cleaned in the following man-
ner:

• Remove as much of the stain as possible by blotting

with a clean, dry towel.

• Blot any remaining stain with a clean, damp towel.
• For tough stains, apply MOPAR威 Total Clean or a mild

soap solution to a clean, damp cloth and remove the
stain. Use a fresh, damp towel to remove soap residue.

• For grease stains, apply MOPAR威 Multi-Purpose

Cleaner to a clean, damp cloth and remove the stain.
Use a fresh, damp towel to remove soap residue.

• Do not use any solvents or protectants on Stain Repel

products.

Interior Care
Use MOPAR

威 Total Clean to clean fabric upholstery and

carpeting.

Use MOPAR

威 Total Clean to clean vinyl upholstery.

MOPAR

威 Total Clean is specifically recommended for

leather upholstery.

Your leather upholstery can be best preserved by regular
cleaning with a damp soft cloth. Small particles of dirt
can act as an abrasive and damage the leather upholstery
and should be removed promptly with a damp cloth.
Stubborn soils can be removed easily with a soft cloth
and MOPAR

威 Total Clean. Care should be taken to avoid

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455

soaking your leather upholstery with any liquid. Please
do not use polishes, oils, cleaning fluids, solvents, deter-
gents, or ammonia-based cleaners to clean your leather
upholstery. Application of a leather conditioner is not
required to maintain the original condition.

WARNING!

Do not use volatile solvents for cleaning purposes.
Many are potentially flammable, and if used in
closed areas they may cause respiratory harm.

Cleaning Headlights
Your vehicle has plastic headlights that are lighter and
less susceptible to stone breakage than glass headlights.

Plastic is not as scratch resistant as glass and therefore
different lens cleaning procedures must be followed.

To minimize the possibility of scratching the lenses and
reducing light output, avoid wiping with a dry cloth. To
remove road dirt, wash with a mild soap solution fol-
lowed by rinsing.

Do not use abrasive cleaning components, solvents, steel
wool or other aggressive material to clean the lenses.

Glass Surfaces
All glass surfaces should be cleaned on a regular basis
with MOPAR

威 Glass Cleaner or any commercial

household-type glass cleaner. Never use an abrasive type
cleaner. Use caution when cleaning the inside rear win-
dow equipped with electric defrosters or the right rear
quarter window equipped with the radio antenna. Do
not use scrapers or other sharp instruments which may
scratch the elements. When cleaning the rearview mirror,
spray cleaner on the towel or rag that you are using. Do
not spray cleaner directly on the mirror.

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Cleaning Plastic Instrument Cluster Lenses
The lenses in front of the instruments in this vehicle are
molded in clear plastic. When cleaning the lenses, care
must be taken to avoid scratching the plastic.

1. Clean with a wet, soft rag. A mild soap solution may
be used, but do not use high alcohol content or abrasive
cleaners. If soap is used, wipe clean with a clean damp
rag.

2. Dry with a soft tissue.

Seat Belt Maintenance
Do not bleach, dye or clean the belts with chemical
solvents or abrasive cleaners. This will weaken the fabric.
Sun damage can also weaken the fabric.

If the belts need cleaning, use a mild soap solution or
lukewarm water. Do not remove the belts from the car to
wash them.

Replace the belts if they appear frayed or worn or if the
buckles do not work properly.

Dry with a soft tissue.

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FUSES

Integrated Power Module
The integrated power module is located in the engine
compartment near the battery. This center contains car-
tridge fuses and mini fuses. A description of each fuse
and component may be stamped on the inside cover,
otherwise the cavity number of each fuse is stamped on
the inside cover that corresponds to the following chart.

Integrated Power Module

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Cavity Cartridge

Fuse

Mini

Fuse

Description

20 Amp
Yellow

Power Outlet Console

20 Amp
Yellow

Cabin Compartment
Node (CCN) Door
Locks

—

15 Amp
Blue

Aisin Transmission
Controls (Diesel Only)

20 Amp
Yellow

Power Sunroof

10 Amp
Red

Vistronic Fan/
Wastegate Solenoid

—

10 Amp
Red

Heated Mirrors

Cavity Cartridge

Fuse

Mini

Fuse

Description

30 Amp
Pink

Off Road Module
Power

5 Amp
Orange

Trx-Off Rd Pkg Sen
(Gas Engine Only)
NOTE: Insert 5 amp
fuse in this cavity to
enable the TRX capa-
bility (If Equipped).

20 Amp
Yellow

Ignition Off Draw
(IOD)-Cabin Com-
partment Node
(CCN)/Radio/Under
Hood Lamp/Wireless
Control Module
(WCM)/Satellite Digi-
tal Audio Receiver
(SDARS)/Hands Free
Module (HFM)/EOM

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Dodge 2500 (2009 year). Manual - part 28