Dodge 1500 (2012 year). Manual

WARNING!

• Exhaust gases can injure or kill. They contain

carbon monoxide (CO), which is colorless and
odorless. Breathing it can make you unconscious
and can eventually poison you. To avoid breathing
CO, refer to “Safety Tips/Exhaust Gas” in “Things
To Know Before Starting Your Vehicle” for further
information.

• A hot exhaust system can start a fire if you park

over materials that can burn. Such materials might
be grass or leaves coming into contact with your
exhaust system. Do not park or operate your ve-
hicle in areas where your exhaust system can
contact anything that can burn.

CAUTION!

• The catalytic converter requires the use of un-

leaded fuel only. Leaded gasoline will destroy the
effectiveness of the catalyst as an emissions con-
trol device and may seriously reduce engine per-
formance and cause serious damage to the engine.

• Damage to the catalytic converter can result if your

vehicle is not kept in proper operating condition.
In the event of engine malfunction, particularly
involving engine misfire or other apparent loss of
performance, have your vehicle serviced promptly.
Continued operation of your vehicle with a severe
malfunction could cause the converter to overheat,
resulting in possible damage to the converter and
vehicle.

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Under normal operating conditions, the catalytic con-
verter will not require maintenance. However, it is im-
portant to keep the engine properly tuned to assure
proper catalyst operation and prevent possible catalyst
damage.

NOTE:

Intentional tampering with emissions control

systems can result in civil penalties being assessed
against you.

In unusual situations involving grossly malfunctioning
engine operation, a scorching odor may suggest severe
and abnormal catalyst overheating. If this occurs, stop
the vehicle, turn off the engine and allow it to cool.
Service, including a tune-up to manufacturer’s specifica-
tions, should be obtained immediately.

To minimize the possibility of catalytic converter dam-
age:

• Do not shut off the engine or interrupt the ignition,

when the transmission is in gear and the vehicle is in
motion.

• Do not try to start the engine by pushing or towing the

vehicle.

• Do not idle the engine with any spark plug wires

disconnected or removed, such as when diagnostic
testing, or for prolonged periods during very rough
idle or malfunctioning operating conditions.

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637

Cooling System

WARNING!

You or others can be badly burned by hot coolant or
steam from your radiator. If you see or hear steam
coming from under the hood, do not open the hood
until the radiator has had time to cool. Never try to
open a cooling system pressure cap when the radiator
is hot.

Engine Coolant Checks
Check the engine coolant (antifreeze) protection every
12 months (before the onset of freezing weather, where
applicable). If the engine coolant (antifreeze) is dirty or
rusty in appearance, the system should be drained,
flushed and refilled with fresh coolant. Check the front of
the A/C condenser for any accumulation of bugs, leaves,
etc. If dirty, clean by gently spraying water from a garden
hose vertically down the face of the condenser.

Check the coolant recovery bottle tubing for brittle rub-
ber, cracking, tears, cuts and tightness of the connection
at the bottle and radiator. Inspect the entire system for
leaks.

With the engine at normal operating temperature (but
not running), check the cooling system pressure cap for
proper vacuum sealing by draining a small amount of
engine coolant (antifreeze) from the radiator drain cock.
If the cap is sealing properly, the engine coolant (anti-
freeze) will begin to drain from the coolant recovery
bottle. DO NOT REMOVE THE COOLANT PRESSURE
CAP WHEN THE COOLING SYSTEM IS HOT.

Cooling System – Drain, Flush, And Refill
If the engine coolant (antifreeze) is dirty or contains a
considerable amount of sediment, clean and flush with a
reliable cooling system cleaner. Follow with a thorough
rinsing to remove all deposits and chemicals. Properly
dispose of old engine coolant (antifreeze) solution.

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MAINTAINING YOUR VEHICLE

Refer to the “Maintenance Schedule” for the proper
maintenance intervals.

Selection Of Coolant
Use only the manufacturer’s recommended engine cool-
ant (antifreeze). Refer to “Fluids, Lubricants, and Genu-
ine Parts” in “Maintaining Your Vehicle” for further
information.

CAUTION!

• Mixing of engine coolant (antifreeze) other than

specified HOAT engine coolant (antifreeze), may
result in engine damage and may decrease corro-
sion protection. If a non-HOAT engine coolant
(antifreeze) is introduced into the cooling system
in an emergency, it should be replaced with the
specified engine coolant (antifreeze) as soon as
possible.

(Continued)

CAUTION! (Continued)

• Do not use water alone or alcohol-based engine

coolant (antifreeze) products. Do not use addi-
tional rust inhibitors or antirust products, as they
may not be compatible with the engine coolant
(antifreeze) and may plug the radiator.

• This vehicle has not been designed for use with

Propylene Glycol based engine coolant (anti-
freeze). Use of Propylene Glycol based engine
coolant (antifreeze) is not recommended.

Adding Coolant
Your vehicle has been built with an improved engine
coolant (antifreeze) that allows extended maintenance
intervals. This engine coolant (antifreeze) can be used up
to five years or 104,000 miles (169 000 km) before replace-
ment. To prevent reducing this extended maintenance
period, it is important that you use the same engine
coolant (antifreeze) throughout the life of your vehicle.

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639

Please review these recommendations for using Hybrid
Organic Additive Technology (HOAT) engine coolant
(antifreeze). When adding engine coolant (antifreeze):

• The manufacturer recommends using MOPAR威

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

• Mix a minimum solution of 50% HOAT engine coolant

and distilled water. Use higher concentrations (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 coolant changes.

Cooling System Pressure Cap
The cap must be fully tightened to prevent loss of engine
coolant (antifreeze), and to ensure that the 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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MAINTAINING YOUR VEHICLE

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 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
or pet, seek emergency assistance immediately. Clean up
any ground spills immediately.

Checking Coolant Level – 3.7L, 4.7L, And 5.7L
Engines
With the engine OFF and cold, the level of the engine
coolant should be between the MIN and MAX range on
the dipstick.

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641

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 need only be checked once
a month.

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 coolant 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 engine coolant (antifreeze) freeze point in the

radiator and in the coolant recovery bottle. If engine
coolant (antifreeze) needs to be added, contents of
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.

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643

• 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, also.

• 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 engine coolant (antifreeze)
performance, poor gas mileage, and increased
emissions.

Brake System

In order to assure brake system performance, all brake
system components should be inspected periodically.
Refer to the “Maintenance Schedule” for the proper
maintenance intervals.

WARNING!

Riding the brakes can lead to brake failure and
possibly a collision. Driving with your foot resting or
riding on the brake pedal can result in abnormally
high brake temperatures, excessive lining wear, and
possible brake damage. You would not have your full
braking capacity in an emergency.

Brake Fluid Level Check
The fluid level of the master cylinder should be checked
when performing under the hood service or immediately
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” dot and an “MIN” dot. The fluid level must be
kept within these two dots. Do not add fluid above the
MAX mark because leakage may occur at the cap.

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MAINTAINING YOUR VEHICLE

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.

Use only the manufacturer’s recommended brake fluid.
Refer to “Fluids, Lubricants, and Genuine Parts” in
“Maintaining Your Vehicle” for further information.

WARNING!

• Use only manufacturer’s recommended brake

fluid. Refer to “Fluids, Lubricants, and Genuine
Parts” in “Maintaining Your Vehicle” for further
information. Using the wrong type of brake fluid
can severely damage your brake system and/or
impair its performance. The proper type of brake
fluid for your vehicle is also identified on the
original factory installed hydraulic master cylin-
der reservoir.

(Continued)

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645

WARNING! (Continued)

• To avoid contamination from foreign matter or

moisture, use only new brake fluid or fluid that
has been in a tightly closed container. Keep the
master cylinder reservoir cap secured at all times.
Brake fluid in a open container absorbs moisture
from the air resulting in a lower boiling point.
This may cause it to boil unexpectedly during hard
or prolonged braking, resulting in sudden brake
failure. This could result in a collision.

• Overfilling the brake fluid reservoir can result in

spilling brake fluid on hot engine parts, causing
the brake fluid to catch fire. Brake fluid can also
damage painted and vinyl surfaces, care should be
taken to avoid its contact with these surfaces.

(Continued)

WARNING! (Continued)

• Do not allow petroleum based fluid to contami-

nate the brake fluid. Brake seal components could
be damaged, causing partial or complete brake
failure. This could result in a collision.

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 “Maintaining Your Vehicle” for further informa-
tion. This inspection should be made with the vehicle in
a level position.

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MAINTAINING YOUR VEHICLE

For 1500 Model axles, the fluid level should be even with
the bottom of the fill hole (within 1/4 in (6.4 mm) of edge
of hole) for the FDU215 HD front axle and C235FE rear
axle.

For all 2500/3500 Model axles, the fluid level should be
1/4 in ± 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” for the proper
maintenance intervals.

Lubricant Selection
Refer to “Fluids, Lubricants, and Genuine Parts” in
“Maintaining Your Vehicle” for further information.

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
1500 Model rear axles equipped with a Limited Slip
Differential require that 5 oz. (148 ml) MOPAR

威 Limited

Slip Additive or equivalent be added to the gear lubri-
cant. Refer to “Fluids, Lubricants, and Genuine Parts” in
“Maintaining Your Vehicle” for further information. The
MOPAR

威 Limited Slip Additive or equivalent should be

added to the gear lubricant whenever a fluid change is
made.

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

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647

Transfer Case

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

Lubricant Selection
Refer to “Fluids, Lubricants, and Genuine Parts” in
“Maintaining Your Vehicle” for further information.

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 “Maintaining Your Vehicle” for further informa-
tion. It is important that the transmission fluid be main-
tained at the prescribed level using the recommended
fluid.

CAUTION!

• Do not use chemical flushes in your transmission

as the chemicals can damage your transmission
components. Such damage is not covered by the
New Vehicle Limited Warranty.

(Continued)

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MAINTAINING YOUR VEHICLE

CAUTION! (Continued)

• Using a transmission fluid other than the manu-

facturer’s recommended fluid may cause deterio-
ration in transmission shift quality and/or torque
converter shudder. Using a transmission fluid
other than the manufacturer’s recommended fluid
will require more frequent fluid and filter
changes. Refer to “Fluids, Lubricants, and Genu-
ine Parts” in “Maintaining Your Vehicle” for fur-
ther information.

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.

Fluid Level Check
The fluid level should be checked when the engine is
fully warmed up and the fluid in the transmission is at
normal operating temperature. Operation of the trans-
mission 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.

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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649

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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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” 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 proper lubricant is used in the
transmission. Refer to “Fluids, Lubricants, and Genuine
Parts” in “Maintaining Your Vehicle” for further
information.

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.

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.

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Dodge 1500 (2012 year). Manual - part 40