Service Publications
CF 500, CF 600
An Operator’s Manual is shipped with this vehicle for customer
use. Additional service publications can be purchased by Operator’s Manual
contacting International Printing and Distribution Services,
c/o Moore Wallace North America, 1750 Wallace Avenue, St. Form No. 3812586R1
Charles, Illinois 60174.
It is the policy of International Truck and Engine Corporation to
improve its products whenever it is possible and practical to do
so. We reserve the right to make changes or add improvements
at any time without incurring any obligation to make such
changes on products sold previously.
© 06/01/2007
3812586R1 i
Table of Contents
Locking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Hydraulic Brake Booster System (HydroBoost). . . . . . . . . . . .55
Sounding a Panic Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Replacing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Antilock Brake System (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Replacing Lost Remote Entry Transmitters. . . . . . . . . . . . . . . .40 Automatic Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Brake-Shift Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Section 4 – Vehicle Operation Understanding Shift Positions of the 5–speed
Automatic Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Vehicle Entry and Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 If Vehicle Gets Stuck In Mud Or Snow. . . . . . . . . . . . . . . . . . . . . .61
Seating and Occupant Restraints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Power Take Off Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Seat Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Gross Axle Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Axle Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Combination Lap and Shoulder Belts. . . . . . . . . . . . . . . . . . . . . . .44 Vehicle Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Vehicle Sensitive Retractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Jump Starting Your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Front Safety Belt Height Adjustment. . . . . . . . . . . . . . . . . . . . . . . .45 Preparing Your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Lap Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Connecting the Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Safety Belt Warning Light And Indicator Chime. . . . . . . . . . . .46 Jump Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Care of Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Removing the Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Towing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Positions Of The Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Towing Vehicle With Front Wheels Suspended. . . . . . . . . . . .65
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Towing Vehicle With Rear Wheels Suspended. . . . . . . . . . . .66
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Tow Hooks (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Restarting After Running Out Of Fuel. . . . . . . . . . . . . . . . . . . . . . .48
Optional Engine Protection System — 3 Way (08WPP). . .48 Section 5 – Vehicle Maintenance, Service
General Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Intervals and Specifications
Backing up/Electric Back-up Alarm. . . . . . . . . . . . . . . . . . . . . . . . . .50
Parking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Exhaust Filter Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Parked Regeneration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Supporting Your Vehicle for Service. . . . . . . . . . . . . . . . . . . . . . . . .69
Regeneration Inhibit Switch (Optional). . . . . . . . . . . . . . . . . . . . . .53 Chassis Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Cab Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Care Of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
If Brakes Do Not Grip Well. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Washing and Waxing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ii 3812586R1
Table of Contents
3812586R1 iii
Table of Contents
iv 3812586R1
Foreword
SECTION 1 — FOREWORD
Preface Study this manual carefully. Do not operate your vehicle until you
are completely familiar with the contents of this manual. Always
Your vehicle has been engineered and manufactured so that it retain this manual in your vehicle for reference. If you sell the
can provide economical and trouble-free service. However, it is vehicle, make sure the manual goes with it.
the owner’s responsibility to see that the vehicle receives proper
care and maintenance. Assistance Guide
Making modifications to various parts, components and
systems of your vehicle, such as brake and steering systems, When parts are required, always provide the unit code number,
can adversely affect the quality and reliability of your vehicle. vehicle model and Vehicle Identification Number (VIN). Request
Such modifications must be avoided. the salesperson to assist you in obtaining this information upon
delivery.
Cautions and Warnings For information not given in this manual, or if you require services
of trained service personnel, we urge you to contact a nearby
Throughout this manual you will find Cautions and Warnings: International® dealer, or phone 1-800-44-TRUCK (87825) for
assistance.
CAUTION
International® believes that every customer is entitled to the best
Cautions will advise you of the proper care to be service, both from the product itself and from the firm who sells
taken to avoid damage to your vehicle or property. and services that product.
If, for any reason, you do not feel you are receiving these
WARNING services in connection with the operation of your vehicle or
the sales transaction, you should return to your selling dealer
Warnings advise you of hazards, the so that these matters can be corrected to your satisfaction. If
consequences, and what to do to avoid the matter is not resolved at that time, it is suggested that the
them, not only to avoid damage to your vehicle following steps be taken:
or property, but to help avoid situations and
occurrences which could result in personal
injury or death.
3812586R1 1
Foreword
Contact a Member of Management at the Dealer. Line Set Ticket which is sometimes known as the vehicle
specification card or code sheet.
Discuss the details of the difficulty. In most instances any
problem can be resolved to your satisfaction by the owner or
manager in charge. Line Set Ticket
Contact Closest International® Sales Region Office or the Each vehicle is provided with a Line Set Ticket (code sheet)
Customer Relations Manager. which lists identification code numbers of component units used
to build the vehicle.
Addresses of Region Sales Offices and the Customer Relations
Manager are found on the first page of this manual. Should you One copy of the line set ticket is included in the literature
desire to contact any of these offices, it is important to include provided with the vehicle. When replacement parts are
the following information in your communication. required, take this copy with you to positively identify vehicle
components to be sure of getting the correct parts.
• Name under which new vehicle was purchased, address and
telephone number of purchaser Be Sure To Return Line Set Ticket To Vehicle After Obtaining
Parts.
• Vehicle model, year, vehicle identification number,
component code and serial numbers
Vehicle Storage Instructions
• Vehicle delivery date and present mileage
When a vehicle is not used for an extended period of time,
• Location where purchased
certain precautions must be taken to prevent deterioration of
• Details of the problem. some components. Contact your dealer for advice on vehicle
storage, as well as proper procedures to follow when you return
Component Code Numbers the vehicle to service.
Code numbers are the basis for identifying the components used Exterior Noise Emissions
on International trucks. They are used by sales personnel to
order the truck, by manufacturing to build that truck and by parts Many operators and owners of the type of vehicles described
personnel to service the truck. Many items in this manual are herein are subject to Federal Motor Carrier Safety Regulations
identified by codes. and Noise Emission Requirements. All owners and operators
are urged to obtain a copy and comply with these regulations.
Code numbers are a combination of numbers and/or
Copies of these regulations can be purchased from:
alphabetical letters. These codes are listed on the Vehicle
2 3812586R1
Foreword
3812586R1 3
Foreword
Reporting Safety Defects inform the National Highway Traffic Safety Administration
(NHTSA) in addition to notifying International Truck and Engine
U.S. REGISTERED VEHICLES Corporation. To notify International, see regional numbers,
listed in the front of the manual.
If you believe that your vehicle has a defect which could cause
a crash or could cause injury or death, you should immediately If NHTSA receives similar complaints, it may open an
investigation, and if it finds that a safety defect exists in a
4 3812586R1
Foreword
group of vehicles, it may order a recall and remedy campaign. To contact Transport Canada, Defect Investigation and Recalls,
However, NHTSA cannot become involved in individual you may call 800-333-0510. You can also write to: Transport
problems between you, your dealer, or International Truck and Canada, ASFAD, Place deVille Tower C, 330 Sparks Street,
Engine Corporation. Ottawa, Ontario K1A 0N5.
To contact NHTSA, you may either call the Auto Safety Hotline
SAFETY RECALLS AND AUTHORIZED FIELD CHANGES
toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation, Safety Recalls and Authorized Field Changes are two
Washington, D.C. 20590. You can also obtain other information campaigns that are used to notify owners of modifications
about motor vehicle safety from the Hotline. that may involve their vehicle. If you receive such notification,
PLEASE FOLLOW ALL INSTRUCTIONS PROVIDED IN THE
CANADIAN REGISTERED VEHICLES CUSTOMER LETTER. If your vehicle is part of a Safety Recall
campaign, the recall service procedure must be completed
If you believe that your vehicle has a defect which could cause
to assure safe operation of your vehicle. As a vehicle owner,
a crash or could cause injury or death, you should immediately
you must provide International Truck and Engine Corporation
contact International Truck and Engine Corporation Canada and
dealers with address corrections and changes to ensure that
then Transport Canada.
you receive all notifications. Please verify that your local dealer
To contact International Truck and Engine Corporation Canada, has your correct address. Dealers will also have a record of any
you may either call the Regional Service Manager (Canadian outstanding campaigns that affect your vehicle.
Sales Region) 905-332-2537 or write to: International Truck and
Engine Corporation Canada, 5500 North Service Road, Box
5337, Burlington, Ontario L7L 5H7.
3812586R1 5
Foreword
International Customer Security Guide • Drop a business card with your name on it between the glass
and doorframe. This can aid in identifying the truck when it’s
International has prepared this guide to help you protect recovered.
your vehicle investment from theft. We realize the financial
commitment you have made is significant, and that you depend • Keep a copy of the lineset ticket in a location other than your
on that vehicle to generate profits and a livelihood. Vehicle theft truck for reporting purposes and a copy of the VIN in your
can be more than an economic crime. Protecting your vehicle wallet.
from theft or hijacking can be crucial to the safety and security • Photograph the interior and exterior of your truck from
of the country and economy. While no system or device is 100% various angles and keep these photographs in a safe
effective, our intention is to provide some tips that you or your non-truck location, or send them to your insurance agent.
drivers can use to reduce the risk of theft.
• Report a theft as soon as it’s discovered to the local police
If you suspect vehicle theft activity, take a minute to tell the and to your insurance company.
National Insurance Crime Bureau (NICB) at 1–800–TEL-NICB.
You can make the free call anonymously and you might be • Post a driver has no cash sign on your door to discourage a
eligible for a reward. To learn more about vehicle theft and how robbery.
you can protect yourself, visit the NICB’s website, www.nicb.org • Permanently mount your C.B. radio or remove it when you
will be away from your truck.
Add Layers of Protection
• Do not discuss where your vehicle is located when you are
International recommends four layers of protection for your not on the road.
vehicle — the more layers of protection on your vehicle, the
more difficult it is to steal. • Do not share information about your specific destination, or
the load you are hauling.
Layer 1: Common Sense • Be conscious of other vehicles that may be following you
• Lock your doors. over long distances — call the police.
• Remove your keys from the ignition. • Be very suspicious of motorists that are signaling the driver
to stop or pull over. Call the police, report the incident, and
• Close your windows completely. let the police respond.
• Park in well-lit areas.
Layer 2: Visible or Audible Device
• Audible alarm system
6 3812586R1
Foreword
3812586R1 7
Foreword
8 3812586R1
Vehicle Inspection Guide
Tilting/Lowering Cab
WARNING
3812586R1 9
Vehicle Inspection Guide
LOWERING CAUTION
Refer to the Figure above when following these directions. Ensure that parking brake is applied before
starting engine.
1. Push the cab up using grip E. Pull handle G rearward while
holding grip E. With the engine stopped, check the following:
2. With handle B raised fully, hold grip E and lower the cab until Engine Compartment
hook D is locked.
3. Lower handle B securely to its original position.
WARNING
To avoid personal injury or death from hot coolant or steam use only the following procedure to remove the pressure cap
from the radiator or expansion tank. Allow the engine to cool first. Wrap a thick, heavy cloth around the cap. Unscrew the
cap slowly to allow pressure to release from under the cap. After the pressure has been released, the pressure cap may be
removed.
WARNING
Exercise great care when working on vehicles with an auxiliary A/C fan. The fan can start with no advance warning any time
the ignition is ON. Failure to observe this warning could result in vehicle damage, personal injury or death.
Oil Level: Use dipstick to verify that the oil level is between the full and refill mark.
Coolant Level: Look through the clear sight glass on the reservoir and make sure the fluid is within the minimum
and maximum fluid level range as marked on the reservoir. Do Not Remove Pressure Cap Until
Coolant Has Cooled.
Filter Minder: Inspect gauge, on the air cleaner, for filter element air restriction indication. For element replacement,
See “Air Cleaner Element Service” in the Maintenance section.
10 3812586R1
Vehicle Inspection Guide
Power Steering Fluid: Verify that the fluid level is between the full and refill mark.
Belt: With engine off, press belt to test that it is snug. Check for frays, cracks, loose fibers, or visible signs of
wear. If it deflects more than ½ to ¾ of an inch, slippage is probably excessive.
Any Leaks: Check for signs of fluid puddles, or dripping fluids on the ground under the engine, or the underside of
the engine.
HVAC Air Inlet: Check for debris, leaves, etc. that may have collected on the HVAC air inlet grille or inside the exterior
module, which could reduce system performance.
Transmission
WARNING
If vehicle is equipped with an automatic transmission, have a qualified technician regularly check operation of transmission
neutral start switch. If unit starts in gear, the vehicle may inadvertently move, which could result in property damage, personal
injury or death.
Fluid Level: Check fluid level and shift linkage for proper operation.
Cab/Fuel Area
WARNING
Maintain adequate clearance between all parts of the exhaust system and all hoses, wires for engine cooling, brake system,
fuel system, power steering system and electrical system. Heat damage to hoses, wires may cause vehicle malfunction that
could result in property damage, personal injury, or death.
Door, Mirror: Check for proper adjustment. Check for cracks or loose fittings. Make sure visibility is not impaired
due to dirty mirrors.
3812586R1 11
Vehicle Inspection Guide
Fuel Tank(s): Check to see that tank(s) is secure and that caps are secure. Make sure there is no damage to
the tank(s).
Leaks: Check for any fuel leaks from tank(s).
Windshield Washer Fluid Level: Inspect the reservoir and verify that the fluid level is up to the full mark. If additional fluid is required,
see “Lubricant and Sealer Specifications” chart, in the Maintenance section, for the correct fluid
type before filling.
Master Cylinder Brake Fluid: Inspect hydraulic brake fluid level and make sure it is between the MIN and MAX levels marked
on the reservoir.
WARNING
Exercise great care when working on vehicles with running engines that are equipped with an automatic fan clutch. The
fan engages when engine coolant reaches a predetermined temperature or the refrigerant pressure (if equipped with air
conditioning) reaches a predetermined setting. The fan will start with no advance warning. Failure to observe these
precautions could result in vehicle damage, personal injury or death.
Emergency Equipment: Prior to entering cab, verify that vehicle is equipped with spare electrical fuses (if used); 3 red
reflective triangles; and a properly charged and rated fire extinguisher, and wheel chocks. Walk
around vehicle and check that all steps and grab handles, inside and out as well as behind, are tight
and clean; use extreme caution and maintain 3 point contact at all times. Check door latches for
positive closing, latching and locking.
Starting the Engine: Verify the parking brake is set and the transmission is in P (Park). When the WAIT TO START
indicator light in the instrument cluster turns off, turn the key to START.
Engine Warning Indicators: Check to see that none of the engine warning indicators is on.
Accelerator: Depress accelerator pedal and verify that it operates smoothly without any binding or irregular feel.
Remove foot from accelerator and make sure engine returns to idle immediately.
12 3812586R1
Vehicle Inspection Guide
Steering Play: Check for smooth operation through complete rotation. Check for excessive looseness in the
steering linkages. The steering wheel should have less than 10 degrees free play (approximately 2
inches at rim of 18 inch steering wheel).
Seats: Be sure seats are firmly engaged to avoid forward or rearward movement when starting or stopping.
Make sure that anchor mounting fasteners to the floor as well as tether straps to floor or cab-back
are tight [25 – 35 lbf-ft (34 – 47.5 Nm)] and straps are not worn.
Seat Belts: Check the entire seat belt assembly for wear and proper operation. Make certain that anchor
mountings are tight.
Horn(s): Check to see that horn works.
Mirrors, Windshield: Check mirrors for proper adjustment; check for cracks or loose fittings. Make sure the mirrors
are clean.
Check the windshield for cracks, dirt, illegal stickers or other obstructions to view.
Wipers: Check the following: worn rubber on blades, blades securely mounted on wiper arms, and that
wipers work.
Lighting Indicators: Check to see that indicators illuminate when corresponding lights are turned on.
Heater/Defroster: Check to be sure that heater/defroster is working. Verify adequate air flow from louvers and vents.
Operate Temperature and Mode controls to verify proper operation.
Hydraulic Brake Check: Pump the brake pedal three times. Then apply firm pressure to the pedal and hold for five seconds.
The pedal should not move. If it does, there may be a leak or other problem. Do not drive vehicle
until problem is fixed.
Parking Brake: Check that parking brake will hold vehicle by gently trying to pull forward with parking brake on.
3812586R1 13
Vehicle Inspection Guide
Front of Vehicle
Lights: Check to see that all lights illuminate and are clean. Make sure headlights function on both high and
low beams. Check to see that reflectors are clean and unbroken and of proper color (red on rear,
amber elsewhere). Make sure that running lights are also clean and unbroken. Rear running lights
must be checked separately from signal, flasher and brake lights.
Steering Gear: Look for: missing or loose fasteners, power steering fluid leaks, and damage to power steering hoses.
Steering Linkage: Check to see that connecting links, arms, rods are not worn or cracked; joints, sockets and boot
seals are not worn or loose; that there are no loose or missing cotter keys, nuts or bolts.
Tow Hooks (optional): Front tow hooks should be inspected for damage or a loose mounting. This is particularly important
on vehicles where the tow hooks are frequently used.
Front Suspension
WARNING
Do not operate vehicle if any of the following conditions are evident. Loss of steering or suspension could cause loss of vehicle
control and result in property damage, personal injury or death.
Spring: Look for missing, broken or shifted leaves, or those that are in contact or nearly in contact
with tires, rim, brake drum, frame or body.
Spring Mount: Check/inspect spring hangers, bolts, bushings, axle mounting U-bolts and nuts for: cracks,
breaks, wear, damage, tightness, and correct component quantity.
Torsion Bar, Shock Absorbers: Make sure the torsion arm is not cracked, broken or missing. Check for cracks, leaks, and
missing or broken mounting bolts or bushings.
14 3812586R1
Vehicle Inspection Guide
Front Brakes
Hoses: Check for cracked, worn or frayed hoses; and for secure couplings.
Rotor and Brake Linings: Check to see there are no cracks, dents or holes; no loose or missing bolts. Check to see that
brake linings (where visible) are not worn dangerously thin or contaminated by lubricant.
Front Wheel
WARNING
If wheels or tires must be changed, obtain expert tire service help. Mounting and de-mounting of tires should only be
performed by qualified personnel using necessary safety procedures and equipment, otherwise the result could be property
damage, personal injury or death.
Tires: Check tread depth and tire inflation and note if tread is evenly worn. Look for cuts, or other
damage to the tread walls. See if valve caps and stem are missing, broken or damaged. Make
sure retread is not separating from tire. Retreads are not allowed on front axles of school buses,
nor are they recommended on front axles of trucks. NOTE: Minimum tread depth is 4/32 inch
on front tires, and 2/32 inch on other tires.
Rims: Check for damaged or bent rims. Rim should not have welding repairs or rust trails that indicate it
is loose on the wheel.
Lug Nuts: Check to see that all lug nuts are present and not loose (look for rust trails around nuts). There
should be no cracks radiating from lug bolt holes nor distortion of the bolt holes.
Hub Oil Seal: Check wheel hub oil seal for leaks.
3812586R1 15
Vehicle Inspection Guide
Under Vehicle
WARNING
Maintain adequate clearance between all parts of the exhaust system and all hoses, wires for engine cooling, brake system,
fuel system, power steering system and electrical system. Heat damage to hoses, wires may cause vehicle malfunction that
could result in property damage, personal injury or death.
Drive Shaft: Check to see that shaft is not bent or cracked. Ensure that all shaft couplings are secure.
Exhaust System: Check to see that outside visible parts are securely mounted. Check to see there are no cracks,
holes or severe dents.
Frame: Check for cracks or bends in longitudinal frame members. Make sure there are no loose, cracked,
bent, broken or missing crossmembers or crossmember fasteners.
Truck
WARNING
Maintain adequate clearance between all parts of the exhaust system and all hoses, wires for engine cooling, brake system,
fuel system, power steering system and electrical system. Heat damage to hoses, wires may cause vehicle malfunction that
could result in property damage, personal injury or death.
Electric Harnesses: Make sure wires are not tangled, crimped or pinched or being dragged against truck parts. Electrical
line insulation should not be cut, cracked, chafed or worn. None of the wires should be spliced
or taped. Check for corrosion on pins and in electrical sockets to ensure continuity and reduced
heat build-up potential.
16 3812586R1
Vehicle Inspection Guide
Turn Signals / Brake Lights: Make sure both brake lights illuminate when the brake pedal is applied and each turn signal flashes.
Make sure that the four-way hazard flashers work properly.
Lights, Reflectors: Check to see that reflectors are clean. Make sure none are missing or broken. Check for proper
color: red on rear, amber elsewhere. All running lights should be clean, not broken, and the proper
color. All running lights must be checked separately from signal flasher and brake lights.
Rear Springs
Springs: Check for broken leaves, leaves that have shifted and are in (or nearly in) contact with the tires, rim,
brake drum, frame or body. Check for missing or broken leaves in the leaf spring.
Spring Mounts: Check for cracked or broken spring hangers; broken, missing or loose bolts; missing or damaged
bushings; broken, loose or missing axle mounting parts.
Torque Rod and Shocks Absorbers: Check to see that torque rod is not cracked, broken or missing. Check shock absorbers for cracks or
leaks. There should be no missing or broken mounting bolts or worn bushings.
Rear Brakes
Hoses: Check for cracked, worn or frayed hoses; and for secure couplings.
Rotor and Brake Linings: Check to see there are no cracks, dents or holes; no loose or missing bolts. Check to see that brake
linings (where visible) are not worn dangerously thin or contaminated by lubricant.
Rear Wheels
Tires: Check the tread depth and tire inflation and note if tread is evenly worn. Look for cuts, or other
damage to the tread walls. See if valve caps and stem are missing, broken or damaged. Make sure
retread is not separating from tire. NOTE: Minimum tread depth is 4/32 inch on front tires,
and 2/32 inch on other tires.
Spacers: Check to see that dual wheels are evenly separated, and that tires are not touching one another.
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Vehicle Inspection Guide
Rims: Check for damaged or bent rims. Rims should not have welding repairs or rust trails that indicate it is
loose on the wheel.
Lug Nuts: Check to see that all lug nuts are present and not loose (look for rust trails around nuts). There
should be no cracks radiating from lug bolt holes nor distortion of the bolt holes.
Rear of Vehicle
Signal/Brake Lights: Check to see that both brake lights come on when brakes are applied. Make sure each signal light
flashes; and check that four-way hazard flashers work.
Lights, Reflectors: Check to see that reflectors are clean. Make sure none are missing or broken. Check for proper
color - red on rear, amber elsewhere. Rear running lights should be clean, not broken and proper
color. Rear running lights must be checked separately from signal, flasher and brake lights.
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Warning lights and gauges can alert you to a vehicle condition Many lights will illuminate when you start your vehicle to make
that may become serious enough to cause expensive repairs. A sure the bulb works. If any light remains on after starting the
warning light may illuminate when a problem exists with one of vehicle, have the respective system inspected immediately.
your vehicle’s functions.
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Vehicle Controls
Stop Engine:This red light momentarily illuminates when the ignition is in the ON position. If this red
warning light illuminates while driving, the vehicle’s cooling system may be overheating or the engine
oil pressure may be dangerously low. An audible tone will also sound when this light is illuminated.
Safely pull off the road as soon as possible and stop the engine. Continuing to drive while this
light is illuminated may result in extensive engine damage. If the warning light is flashing, it
indicates that critical limits have been reached or exceeded and the engine must be stopped
immediately. Contact your dealership or authorized service center as soon as possible.
NOTE: With the optional Engine Warning Protection System, the engine will automatically shut down
30 seconds after critical limits have been reached. The engine may be re-started in 30 seconds in
order to allow the vehicle to be moved to a safe location.
Check Engine:This amber light momentarily illuminates when the ignition is in the ON position. If
this amber warning light illuminates while driving, a problem in the electronic engine controls has
been detected. Contact your dealership or authorized service center as soon as possible.
Warn Engine:This amber light momentarily illuminates when the ignition is in the ON position. This
amber warning light will illuminate to display any emissions-related issues. Contact your dealership
or authorized service center as soon as possible.
WARNING
When an alarm sounds, stop normal vehicle operation and determine the source
of the alarm condition. Failure to observe this warning could result in property
damage, personal injury, or death.
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Wait to start: With the key in the ON position, this amber light will illuminate if glow plug heat is
necessary as a starting aid. Wait until the light goes off before starting. The light should always
illuminate briefly, when the ignition key is in the ON position. If the light does not illuminate, there
may be a problem. Refer to Starting the engine and Cold weather operation in the Vehicle Operation
chapter. After the engine starts, the light should remain off. The light should always illuminate at least
momentarily when the engine is cold and the ignition is turned to ON. If it does not illuminate, the
glow plug system should be checked and repaired promptly to avoid difficulty in cold starting.
WARNING
Explosion Hazard. Do not use volatile starting aids such as ether, propane, or
gasoline in the engine air intake system. Glow plugs and/or grid heater will ignite
vapors, which can cause severe engine damage, personal injury, or death.
Diesel Particulate Filter (DPF) Warning: The amber light will illuminate to indicate that the DPF is
plugged or has a sensor malfunction.
Water in fuel: During refueling it is possible for water-contaminated diesel fuel to be pumped into
your fuel tank. Your vehicle fuel system is equipped with a fuel filter/water separator to remove water
from the fuel. The amber WATER IN FUEL light will illuminate when the Horizontal Fuel Conditioner
Module (HFCM) has a significant quantity of water in it. If the light illuminates when the engine is
running, stop the vehicle as soon as safely possible, shut off the engine and drain the HFCM. Refer
to Fuel filter/water separator in the Engine Operation and Maintenance Manual section for the drain
procedure. Allowing water to stay in the system could result in extensive damage to, or failure of, the
fuel injection system. If the WATER IN FUEL light comes on frequently, water should be drained
from the fuel tank(s) every 3 months.
Brake fluid: This red light illuminates when the brake fluid is low. An audible tone will also sound
when this light is illuminated. Check the brake master cylinder reservoir to make sure the fluid
level is OK, add if necessary (refer to Brake fluid in the Vehicle Maintenance, Service Intervals and
Specifications chapter for proper checking and adding procedure). If the level is OK, but the light
stays illuminated, do not drive the vehicle as loss of braking ability may occur. Have the vehicle towed
to your local dealership or authorized service center.
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Parking brake warning: This red light illuminates when the parking brake is engaged.
Anti-lock brake system: This amber light momentarily illuminates when the ignition is in the ON
position. If the ABS light stays illuminated or continues to flash, a malfunction has been detected:
have the system serviced immediately. If the ABS light is not functioning, the odometer display will
show “No ABS Ind” and the Check Electrical System light will illuminate.
Check trans: This amber light momentarily illuminates when the ignition is in the ON position. If this
light stays illuminated, a problem has been detected and the shift pattern may be in default operation
(starts in 5th gear or Drive). Operating limitations may be placed on the transmission upshifting and
downshifting patterns. Have the system serviced immediately as transmission damage may occur.
Safety belt: This red light illuminates to remind you to fasten your safety belt. A chime may also
sound to remind you to fasten your safety belt.
Trans temp: This red light momentarily illuminates when the ignition is in the ON position. This light
will stay illuminated when the transmission fluid temperature is too high. An audible tone will also
sound when this light is illuminated. Normal operating temperature range is 70°F — 248°F (21°C —
120°C). Temperatures above 275°F (135°C) can cause transmission fluid to break down and result in
internal component damage. Have the system serviced immediately.
Check electrical system: This amber light momentarily illuminates when the ignition is in the ON
position. If this light stays illuminated, there is a communication problem between the cluster and an
electronic module. Check the odometer display for a failure message.
Change oil: This amber light momentarily illuminates when the ignition is in the ON position. If
enabled, this light will illuminate when the engine oil life is low and requires changing (refer to the
Engine Operation and Maintenance Manual for resetting).
Tow/Haul: This green light illuminates when the Tow/Haul feature has been activated. Refer to the
Vehicle Operation chapter for transmission function and operation.
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PTO enable: This amber light illuminates when power take-off (PTO) mode is being used.
Charging system: This red light illuminates when the battery is not charging properly.
Turn signal: This green light illuminates when the left or right turn signal or the hazard lights are
turned on. If the indicators stay on or flash faster than normal, check for a burned out bulb.
High beams: This blue light illuminates when the high beam headlamps are on.
Safety belt not fastened warning chime: Sounds for five Headlamps on warning chime: Sounds when the headlamps
seconds each time the ignition is turned to the ON position and or parking lamps are on, the ignition is off (and the key is not in
the safety belt is not fastened. the ignition) and either door is opened. The odometer display
will show “Lights ON”.
Key-in-ignition warning chime (if equipped): Sounds when
the key is left in the ignition (in the ON or ACC position) and
either door is opened. The odometer display will show “Key In
IGN”.
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Vehicle Controls
Gauges
Tachometer: Indicates the engine speed in revolutions per minute. Continuous driving at high RPMs
may damage the engine. If there is an electrical problem between the gauge and the engine control
module, the gauge pointer will fall below the 0 position to rest on the pointer stop.
Speedometer: Indicates the current vehicle speed. If there is an electrical problem between the gauge
and the engine control module, the gauge pointer will fall below the 0 position to rest on the pointer stop.
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Engine coolant temperature gauge: Indicates engine coolant temperature. Readings above 230°F
(110°C) indicate the engine may be overheating; a red warning light will illuminate on the gauge
indicating this condition. If there is an electrical problem between the gauge and the engine control
module, the gauge pointer will drop to the six o’clock position and the red warning light will flash.
Fuel gauge: Indicates approximately how much fuel is left in the fuel tank (when the ignition is in
the ON position). If your vehicle is equipped with dual fuel tanks, the engine will draw fuel from the
driver-side fuel tank only. With dual fuel tanks, the vehicle will be equipped with a fuel transfer pump
system that will draw fuel from the passenger-side fuel tank and send fuel to the driver-side fuel tank.
The driver-side fuel tank must have fuel in it at all times otherwise the vehicle may stall and may be
difficult to restart. The fuel gauge reads the fuel level only from the driver-side fuel tank. When the
fuel level reaches 1/8 full, a red warning light on the fuel gauge will illuminate and an audible alarm
will sound. This warning light will stay on until the tank(s) is filled above 1/8 full. If there is an electrical
problem between the gauge and the engine control module, the gauge pointer will drop to the six
o’clock position and the red warning light will flash.
Odometer/Trip Odometer Display: The odometer registers the total miles (kilometers) of the vehicle.
The trip odometer registers the miles (kilometers) of individual journeys. There are two modes for the
trip odometer, Trip 1 and Trip 2. Pressing Select/Reset for less than two seconds will switch between
Trip 1 and Trip 2. Pressing and holding Select/Reset for longer than two seconds will clear the trip
odometer for the setting it is on (Trip 1 or Trip 2).
Air filter restriction gauge (located on air cleaner housing): Measures the vacuum inside the air
cleaner. The more the air cleaner is restricted (dirty, clogged), the higher the vacuum reading. Change
the air filter when the gauge reads 25 inches (635 mm). After installation of the new filter element, reset
the gauge to by pressing the reset button on top of the gauge.
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Distributes air through the instrument panel vents and the floor vents.
Distributes air through the windshield defroster vents and floor vents.
Operating tips • Remove any snow, ice or leaves from the air intake area at
the base of the windshield.
• To reduce fog build up on the windshield during humid
weather, place the air flow selector in the defrost position. To aid in side window defogging/demisting in cold weather:
• To reduce humidity build up inside the vehicle: do not drive 1. Select panel vent
with the recirculated air selector in the recirc position.
2. Set the temperature control to full heat
• Under normal weather conditions, do not leave the
3. Set the fan speed to its highest setting
recirculated air selector in recirc when the vehicle is
parked. This allows the vehicle to “breathe” using the 4. Direct the outer instrument panel vents towards the side
outside air inlet vents. windows
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4. Used to manually enable or disable recirculated air operation. When activated (control
moved all the way to the left), recirculates air in the cabin thereby reducing the amount
of time to cool down the interior of the vehicle when used with the A/C control. May
also help reduce undesired outside odors from reaching the interior of the vehicle.
To reduce humidity inside the vehicle, turn recirculation off (control moved all the
way to the right).
5. Air flow selections: Controls the direction of the airflow in the vehicle. See the following for a brief
description on each control.
Distributes air through the instrument panel vents.
Distributes air through the instrument panel vents and the floor vents.
Distributes air through the windshield defroster vents and floor vents.
Operating Tips • Remove any snow, ice or leaves from the air intake area at
the base of the windshield.
• To reduce fog build up on the windshield during humid
weather, place the air flow selector in the defrost position To aid in side window defogging/demisting in cold weather:
and turn on the A/C.
1. Select panel vent
• To reduce humidity build up inside the vehicle: do not drive
2. Press A/C
with the recirculated air selector in the recirc position.
3. Adjust the temperature control to maintain comfort.
• Under normal weather conditions, do not leave the
recirculated air selector in recirc when the vehicle is 4. Set the fan speed to its highest setting
parked. This allows the vehicle to “breathe” using the
5. Direct the outer instrument panel vents towards the side
outside air inlet vents.
windows
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Vehicle Controls
Lights
Headlamp Control
High beams/Flash-to-pass
To turn on the high beams, push the lever
away from you. Pull the lever towards you
to deactivate.
Refer to the VEHICLE MAINTENANCE section for Headlight Aim Daytime Running Lamps (DRL) (If Equipped)
Adjustment.
Turns the headlamps on with a reduced output when the ignition
is in the ON position and the headlamp control is in the OFF or
parking lamp position.
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Fog Lamps
Turn the ring on the headlamp control to turn the fog lamps on and off.
The fog lamps will only operate when the low beam headlamps are on.
This is located on the bottom edge of the instrument panel to the left of
the steering column and is used to adjust the brightness of the instrument
panel and all applicable switches in the vehicle during headlamp and
parklamp operation.
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Driver Controls
• MIST: For a single wipe (without washer), push the control up once.
Pull the control toward you to activate washer. Pull and hold for a longer wash cycle.
CAUTION WARNING
Do not operate the washer for more than 10
seconds as damage to the washer motor may Do not use the washers in freezing weather
occur. without first warming the windshield with the
defrosters; otherwise, the washer solution may
freeze on the windshield and obscure your
vision and could cause an accident, resulting in
property damage, personal injury, or death.
Do not use radiator coolant or anti-freeze in the
windshield washer reservoir. Radiator coolant
in the washer reservoir can severely reduce
visibility when sprayed on the windshield.
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Vehicle Controls
Tilt/Telescope Steering
Pull the tilt steering control toward you to move the steering
wheel up or down, or to push/pull the steering wheel
toward/away from you. Push the control back down fully
to lock the steering wheel in position.
WARNING
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Vehicle Controls
• Push the switches down to open the windows and pull the switches up to close
the windows.
• One-touch down driver’s window: To open the driver window without holding
the control, press the control marked AUTO completely down and release quickly.
The driver’s window will open fully. To stop the window partway down, pull the
control up, then release it.
The window lock feature allows only the driver to operate the power
windows.
To lock out the passenger window control, press the control down. Press
the control again to restore the window controls.
Mirrors
With the doors closed, move the mirrors to maximize rear viewing area
by adjusting the mirrors left or right as required.
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Vehicle Controls
Do not use the cruise control system when Once speed control is switched off,
unpredictable driving conditions are present. the previously programmed engine
Such conditions include heavy traffic, roads RPM will be erased.
that are winding, icy, snow covered, slippery,
or with a loose surface. These conditions may
cause wheel slippage and loss of vehicle control, To set a speed (with speed control
resulting in property damage, personal injury or on)
death.
Press SET - If the vehicle is moving,
To turn speed control on this will set the vehicle speed. If the
vehicle is stationary, this will set the
Press CRUISE RPM. If the vehicle vehicle idle RPM.
is moving, speed control will be
enabled; if the vehicle is stationary,
engine RPM can be controlled. If you drive up or down a steep hill, your vehicle speed may vary
momentarily slower or faster than the set speed; this is normal.
Speed control cannot reduce the vehicle speed if it increases
above the set speed on a downhill. If your vehicle speed is faster
Do not shift the gearshift lever into N (Neutral) with the
than the set speed while driving on a downhill, you may want to
speed control on.
shift to the next lower gear or apply the brakes to reduce your
vehicle speed.
If the vehicle speed falls below 35 mph (56 km/h) or engine RPM
falls below 1,000 RPM, your speed control will disengage; this is
normal. Pressing RESUME + will re-engage it.
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Press and hold SET - If the vehicle Depress the brake pedal.
is moving, this will decrease vehicle Disengaging the speed control
speed; if the vehicle is stationary, this will not erase the previously
will decrease engine RPM. Release programmed set speed or engine
the control when the desired vehicle RPM.
speed/engine RPM is reached.
Pressing the top portion of the
Press and release SET - to operate control will erase the previously
the tap-down function. Each press programmed engine RPM.
will decrease the set speed by 1 mph
(1.6 km/h) or engine RPM in idle
To return to a previously set
mode.
speed
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Vehicle Controls
Keys
The regeneration control panel is located on the center dash Power Door Locks (if equipped)
panel. For operation instructions refer to Exhaust Filter
Regeneration. WARNING
HEST Lamp: Both doors lock automatically when the driver’s door lock button
is pushed down, and unlock when it is pulled up.
This amber lamp warns
the driver that exhaust
temperatures are high.
INHIBT REGEN:
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Remote Entry System (if equipped) Your vehicle has an all-door remote entry system.
The all-door remote entry system allows you to:
• lock or unlock both vehicle doors without a key.
• activate the panic alarm.
The remote entry features only operate with the ignition in the 1
(LOCK) position.
If there are problems with the remote entry system, make sure to
take ALL remote entry transmitters with you to the dealership
in order to aid in troubleshooting the problem.
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Vehicle Controls
Sounding a Panic Alarm COVER AND CIRCUIT BOARD OFF THE FRONT HOUSING
OF THE REMOTE ENTRY TRANSMITTER.
Press “!” to activate the alarm. Press “!” again, or turn the ignition
to the 3 (ON) position to deactivate. 2. Do not wipe off any grease on the battery terminals on the
back surface of the circuit board.
NOTE: The panic alarm will only operate when the ignition is in 3. Remove the old battery. NOTE: Please refer to local
the 1 (LOCK) position. regulations when disposing of transmitter batteries.
Replacing the Battery 4. Insert the new battery. Refer to the diagram inside the remote
entry transmitter for the correct orientation of the battery. Press
The remote entry transmitter uses one button type three-volt the battery down to ensure that the battery is fully seated in the
lithium battery CR2025 or equivalent. battery housing cavity.
5. Snap the two halves back together.
To replace the battery: If the remote entry transmitters are lost, replacements can be
1. Twist a thin coin between the two halves of the remote entry ordered and programmed for the vehicle by an authorized dealer.
transmitter near the key ring. DO NOT TAKE THE RUBBER
40 3812586R1
Vehicle Operation
3812586R1 41
Vehicle Operation
42 3812586R1
Vehicle Operation
WARNING
3812586R1 43
Vehicle Operation
WARNING
To avoid personal injury or death, do not ride The front safety restraints in the vehicle are combination lap and
in the vehicle cargo area or on the outside of shoulder belts. The passenger outboard safety belt has vehicle
the vehicle. Ride only in designated seating sensitive emergency locking retractors.
positions or sleeper berth with seat belts or bunk
restraints fastened and properly adjusted.
44 3812586R1
Vehicle Operation
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Vehicle Operation
46 3812586R1
Vehicle Operation
STARTING THE ENGINE 1. Ensure headlamps and all accessories are turned off, the
parking brake is applied and the transmission is in the P
(Park) position.
WARNING
2. Turn the key to ON, but do not start the engine. In cooler
Operation of a diesel engine near flammable weather, the glow plugs may activate the WAIT TO START
vapors in the air may cause the engine speed light in the instrument cluster.
to increase uncontrollably and over speed. If
this situation occurs, mechanical damage, fire, If the WAIT TO START light illuminates, do not crank
explosion, personal injury or death could result. the engine until the light goes off.
Turning off the ignition key will not slow or
stop the engine due to uncontrollable fueling 3. When the WAIT TO START light turns off, turn the
of the engine through flammable vapors being key to START; when the engine starts, release the
drawn into the engine air inlet. Operation of key.
components such as starter, alternator, electric If the engine does not start within 20 seconds of cranking,
motors, etc. and static electricity could also release the key and allow two or three minutes for the starter to
ignite flammable vapors. cool before trying again. Excessive cranking may damage the
Do not operate the truck in the possible presence starter and/or engine.
of flammable vapors unless both a complete After the engine starts:
hazard analysis is performed and necessary
additional safety processes and/or equipment • Idle the engine for at least five minutes before operating with
such as vapor testing, air intake shutoff devices, a full load.
ventilation, etc. are utilized. The operator is • Try to limit engine idle to 10 minutes. Excessive idling
responsible for using those processes and/or reduces fuel economy.
equipment to ensure that the diesel engine
and all other components on the truck can be • When starting a cold engine, increase the engine speed
operated safely under the specific conditions (RPM) slowly to make sure adequate lubrication is available
and hazards that may be encountered. to the bearings.
3812586R1 47
Vehicle Operation
COLD WEATHER OPERATION This system includes the 3–way engine warning system. In
addition, if engine oil pressure, excessive engine speed, engine
coolant temperature or engine coolant level conditions exceed
WARNING
the warning limits, the appropriate fault codes are set and
Explosion Hazard. Do not use volatile starting the Red Engine Warning Light is turned ON. If the engine oil
aids such as ether, propane, or gasoline in the pressure, engine coolant temperature or engine coolant level
engine air intake system. Glow plugs and/or grid conditions exceed the preset critical limit, the engine is shut
heater will ignite vapors, which can cause severe down. After an automatic shutdown, the engine can be restarted
engine damage, personal injury, or death. and will operate in a de-rated mode for an additional 30 seconds
if the conditions causing the shutdown are still present, allowing
In order to correctly operate the engine in cold and hot the vehicle to be moved to a safe location.
temperatures, it is important to read and follow the instructions
in the Engine Operation and Maintenance Manual. General Operating Instructions
RESTARTING AFTER RUNNING OUT OF FUEL • Accelerate smoothly and evenly; rapid acceleration
increases fuel consumption without increasing engine
Avoid running out of fuel as this can allow air to enter the fuel
performance.
system, which will make restarting difficult. Refer to the Engine
Operation and Maintenance Manual for specific restarting • When approaching a hill, depress the accelerator smoothly
instructions. to start the incline at full power, then shift down as needed
to maintain vehicle speed.
OPTIONAL ENGINE PROTECTION SYSTEM — 3 WAY
• When going down a hill, or long steep grades, prevent
(08WPP)
over-speeding of the engine. The engine governor has no
control over engine speed when it is being pushed by a
WARNING loaded vehicle.
48 3812586R1
Vehicle Operation
WARNING WARNING
In the event engine shutdown occurs, make Operating an engine beyond the maximum
certain that vehicle is safely off the roadway, the governed speed could result in engine failure
4–way emergency flashers are on, and traffic and cause vehicle damage, personal injury or
warning devices are properly placed. Failure to death.
remove vehicle from roadway could cause an
accident and result in property damage, personal
WARNING
injury or death.
Always use the ashtray(s) provided for disposing
WARNING of cigar, cigarette, or pipe ashes and tobacco.
Failure to use an ashtray is a fire hazard and
Exhaust gases from engines contain hazardous could result in property damage, personal injury,
compounds. Do not operate engines in enclosed or death.
areas without abundant forced ventilation (with
garage doors and windows wide open). Maintain WARNING
exhaust system in good operating condition.
Breathing exhaust gases could result in personal All vehicles have blind spots. Make sure your
injury or death. way is clear in all directions before moving your
vehicle. Failure to follow these procedures could
result in property damage, personal injury or
death.
3812586R1 49
Vehicle Operation
BACKING UP/ELECTRIC BACK-UP ALARM check the intended path is clear; back up slowly as to allow
others time to move, if necessary.
WARNING
PARKING
Before backing up, check to see that area behind
vehicle is clear of people, animals and objects. WARNING
Use a spotter whenever possible and always
keep that person in sight. Failure to do so may When parking your vehicle, do not leave
result in property damage, personal injury, or transmission in gear; if vehicle rolls, engine
death. If so desired, backup alarms are available could start by heat of compression. Always
through your International dealer. However, they use parking brake. When parking on a grade,
are never a substitute for the above procedures. chock wheels and turn front wheels to keep the
vehicle from rolling into the traveled portion of
Before backing your vehicle, be sure you can do so safely. If
the roadway. Failure to follow these procedures
anything behind the cab limits your view, do not rely on mirrors
could cause an unattended vehicle to move,
alone to ensure that your intended path is clear. If other people
resulting in property damage, personal injury or
are in the vicinity, have someone standing well behind your
death.
vehicle and outside of your intended path (visible through an
exterior mirror) guide you as you back up. Always use the parking brake. When parking on a grade, block
the wheels and turn the front wheels to one side so that if the
Although OSHA or some governmental regulations may require
vehicle rolls, the front tires will act against the curb to stop the
the use of an electrical or mechanical back-up alarm to warn
vehicle. The front wheels will be more effective at stopping a
bystanders, such an alarm does not ensure that the intended
rolling vehicle than the rear wheels.
path is clear. When in doubt, get out of the vehicle and visually
50 3812586R1
Vehicle Operation
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Vehicle Operation
Pull vehicle safely off roadway and start Parked Regeneration to prevent
2 Exhaust filter is full.
loss of engine power.
Flashing
WARNING
Solid
NOTE: When this indicator is illuminated, the exhaust system and exhaust gases are extremely HOT. Extreme care must be taken to avoid
people and flammable materials, vapors and structures when the vehicle is stationary or moving slowly.
52 3812586R1
Vehicle Operation
PARKED REGENERATION PROCEDURE The engine speed will automatically ramp up to a preset RPM
and the switch indicator will illuminate solidly when the cycle
Perform the following steps to initiate Parked Regeneration is started. If the indicator is blinking, check to be sure that all
(cleaning) of the exhaust filter: conditions in step 2 are met. Once started, the regeneration
1. Park the vehicle safely off the roadway and away from cycle will last approximately 20 minutes.
flammable materials.
NOTE: In the event of an emergency situation where the vehicle
2. Before initiating parked regeneration (pressing must be moved after beginning Parked Regeneration, press
the PARKD REGEN switch), the following conditions PARKD REGEN switch to cancel Parked Regeneration.
must be in place:
4. When the regeneration cycle is complete, the switch light will
a. Park brake must be set go off, the engine rpm will return to normal idle and all exhaust
b. Transmission must be in Neutral (N) or Park filter indicators will be off. The vehicle may now be driven
(P), if available normally.
c. Accelerator, foot brake and clutch (if present) REGENERATION INHIBIT SWITCH (OPTIONAL)
pedals must not be depressed.
The Regeneration Inhibit switch is used to prevent the Active
NOTE: If any of the above conditions are altered during the Regeneration or Parked Regeneration process.
Parked Regeneration process, regeneration will be halted, and
must be restarted. Regeneration Inhibit Switch
3. Press the PARKD REGEN switch to initiate the regeneration Pressing the ON position of the ON/INHIBT
cycle. REGEN switch will inhibit both Active and Parked
Regeneration. Regeneration will be inhibited
NOTE: The engine must be at normal operating temperature (latched) when in this position and the switch
before the parked regeneration will initiate. indicator is turned on.
3812586R1 53
Vehicle Operation
54 3812586R1
Vehicle Operation
requiring use of the brakes, short applications (three to five Under normal operating conditions, noise of the fluid flowing
seconds duration) should be made rather than long, continuous through the booster may be heard whenever the brake is applied.
applications. This minimizes temperature rise, brake fade and This is normal and should be no reason for concern.
air consumption of air brake system.
If braking performance or pedal response becomes very poor,
even when the pedal is strongly applied, this may indicate
IF BRAKES DO NOT GRIP WELL
the presence of air in the hydraulic system or fluid leakage.
• If you have been driving through deep water, gently apply Safely stop the vehicle as soon as possible and seek service
the brakes several times while the vehicle is moving slowly. immediately.
• Let the brakes cool if you have been using them excessively,
as in mountain driving or after several fast, high-speed stops.
• Check brake linings for excessive wear.
If the brake fluid warning light in the instrument cluster remains
HYDRAULIC BRAKE BOOSTER SYSTEM (HYDROBOOST)
illuminated after engine start-up, and an audible tone is heard
while the light is illuminated, this indicates a system failure in the
The HydroBoost system receives fluid pressure from the power
brake system. Stop the vehicle as soon as safely possible and
steering pump to provide power assist during braking.
seek service immediately.
The HydroBoost booster includes a hydraulic accumulator that
holds a reserve of brake fluid under pressure that will provide two
or more power assisted brake applications in the event of power WARNING
steering fluid pressure loss. The accumulator will also deliver a
Stopping distance may increase under the failed
limited number of power assisted brake applications when the
condition since only one section of the brake
engine is off.
system is operating. Reduce speed and employ
The HydroBoost’s reserve accumulator provides reduced safe driving practices. Have brake system
braking power, and the number or reserve stops is limited repaired immediately. Loss of braking capability
(depending on the severity and duration of the brake could cause an accident and result in property
applications). damage, personal injury or death.
3812586R1 55
Vehicle Operation
PARKING BRAKE the parking brake only applies braking power to the rear wheels,
the vehicle’s stopping distance will increase greatly and the
handling of your vehicle will be adversely affected.
WARNING
Driving with the parking brakes applied can lead ANTILOCK BRAKE SYSTEM (ABS)
to excessive heat build up and fire resulting in
property damage, personal injury, or death. WARNING
56 3812586R1
Vehicle Operation
observed during ABS braking and the brake pedal may suddenly
WARNING
travel a little further as soon as ABS braking is done and normal
brake operation resumes. These are normal characteristics of If the ABS warning light comes on, your stopping
the ABS and should be no reason for concern. distances may increase under certain braking
conditions. Have the ABS system repaired
Using ABS immediately. Take every precaution to avoid
When hard braking is required, apply continuous force on the wheel lockup, which could result in loss of
brake pedal; do not pump the brake pedal since this will reduce vehicle control causing property damage,
the effectiveness of the ABS and will increase your vehicle’s personal injury or death.
stopping distance. The ABS will be activated immediately,
allowing you to retain full steering control during hard braking Automatic Transmission
and on slippery surfaces. However, the ABS does not decrease
stopping distance.
WARNING
ABS Warning Lamp To avoid sudden, unexpected vehicle movement
and property damage, personal injury or death,
The ABS lamp in the instrument always use the parking brake. Do not leave
cluster momentarily illuminates when transmission in gear instead of using parking
the ignition is turned on. If the light brake.
does not illuminate during start up,
remains on or flashes, the ABS may BRAKE-SHIFT INTERLOCK
be disabled and may need to be
serviced. This vehicle is equipped with a brake-shift interlock feature that
Even when the ABS is disabled, normal braking is still effective. prevents the gearshift lever from being moved from P (Park)
(If your BRAKE warning lamp illuminates with the parking brake when the ignition is in the ON position unless brake pedal is
released, have your brake system serviced immediately.) depressed.
If you cannot move the gearshift lever out of P (Park) with ignition
in the ON position and the brake pedal depressed, or if a vehicle
without battery power needs to be moved:
3812586R1 57
Vehicle Operation
58 3812586R1
Vehicle Operation
If it is necessary to use the above procedure to move the This vehicle is equipped with an adaptive Transmission Shift
gearshift lever, it is possible that a fuse has blown or the Strategy. Adaptive Shift Strategy offers the optimal transmission
vehicle’s brakelamps are not operating properly. operation and shift quality. When the vehicle’s battery has been
disconnected for any type of service or repair, the transmission
will need to relearn the normal shift strategy parameters, much
WARNING
like having to reset your radio stations when your vehicle battery
has been disconnected. The Adaptive Transmission Strategy
To prevent unexpected vehicle movement, hold
allows the transmission to relearn these operating parameters.
the brake pedal down while you move the
This learning process could take several transmission upshifts
gearshift from position to position. Failure to
and downshifts; during this learning process, slightly firmer shifts
follow this warning could result in property
may occur. After this learning process, normal shift feel and shift
damage, personal injury, or death.
scheduling will resume.
UNDERSTANDING SHIFT POSITIONS OF THE 5–SPEED P (Park)
AUTOMATIC TRANSMISSION
This position locks the transmission and prevents the rear
wheels from turning.
To put your vehicle in gear:
• Start the engine
• Depress the brake pedal
• Move the gearshift lever into the desired gear
To put your vehicle in P (Park):
• Come to a complete stop
• Move the gearshift lever and securely latch it in P (Park)
3812586R1 59
Vehicle Operation
R (Reverse)
With the gearshift lever in R (Reverse), the vehicle will move
backward. Always come to a complete stop before shifting into
and out of R (Reverse).
N (Neutral)
With the gearshift lever in N (Neutral), the vehicle can be started
and is free to roll. Hold the brake pedal down while in this
position.
D (Overdrive) with Tow/Haul OFF
D (Overdrive) with Tow/Haul OFF is the normal driving position
for the best fuel economy. The overdrive function allows
automatic upshifts and downshifts through gears one through
five.
D (Overdrive) with Tow/Haul ON To activate Tow/Haul, press the button on the side of the gearshift
The Tow/Haul feature improves transmission operation when lever.
towing a trailer or a heavy load. All transmission gear ranges
are available when using Tow/Haul.
WARNING
60 3812586R1
Vehicle Operation
Tow/Haul delays upshifts to reduce frequency of transmission • The transmission will not downshift into 1 (First) at high
shifting. Tow/Haul also provides engine braking in all forward speeds; it will downshift to a lower gear and then shift into 1
gears when the transmission is in the D (Overdrive) position; (First) when the vehicle reaches slower speeds.
this engine braking will slow the vehicle and assist the driver
in controlling the vehicle when descending a grade. Depending
on driving conditions and load conditions, the transmission may
downshift, slow the vehicle and control the vehicle speed when
descending a hill, without the accelerator pedal being pressed.
The amount of downshift braking provided will vary based upon Forced downshifts
the amount the brake pedal is depressed.
To deactivate the Tow/Haul feature and return to normal driving
mode, press the button on the side of the gearshift lever. The
TOW HAUL light will no longer be illuminated.
• Allowed in (Overdrive) or Drive.
When you shut off and restart the engine, the transmission will
automatically return to normal D (Overdrive) mode (Tow/Haul • Depress the accelerator to the floor.
OFF). • Allows transmission to select an appropriate gear.
3 (Third)
IF VEHICLE GETS STUCK IN MUD OR SNOW
Transmission starts and operates in third gear only.
If your vehicle gets stuck in mud or snow, it may be rocked out by
Used for improved traction on slippery roads. Selecting 3 (Third)
shifting between forward and reverse gears, stopping between
provides engine braking.
shifts in a steady pattern. Press lightly on the accelerator in each
2 (Second) gear.
Use 2 (Second) to start-up on slippery roads or to provide Do not rock the vehicle if the engine is not at normal
additional engine braking on downgrades. operating temperature or damage to the transmission may
occur.
1 (First)
Do not rock the vehicle for more than a minute or damage
• Provides maximum engine braking.
to the transmission and tires may occur, or the engine may
• Allows upshifts by moving gearshift lever. overheat.
3812586R1 61
Vehicle Operation
If your vehicle is equipped with a power take off (PTO), refer to It is not recommended, or approved, for axle conversions to be
the PTO equipment manufacturer’s instructions. performed.
NOTE: PTO applications draw auxiliary horsepower from the Under no circumstances should your vehicle be loaded in
powertrain, often while the vehicle is stationary. In this condition, excess of the GVWR or GAWR. It is the operator’s responsibility
there may be limited cooling air flow through the radiator and to ensure that neither the axle capacities, spring capacities, tire
around the vehicle that normally occurs when a vehicle is capacities nor the vehicle rated GVWR is exceeded.
moving. Depending on the level and duration of PTO use,
vehicle conditions, surrounding environmental conditions and Jump Starting Your Vehicle
other factors, this can contribute to elevated transmission fluid
temperatures and result in accelerated fluid deterioration, fuel
vapor over-pressurization and other concerns. WARNING
62 3812586R1
Vehicle Operation
CAUTION 3. Park the booster vehicle close to the disabled vehicle making
sure the two vehicles do not touch. Set the parking brake
To avoid damage to vehicle electronic
on both vehicles and stay clear of the engine cooling fan and
components, voltage supplied to a vehicle’s
other moving parts.
electrical system must never exceed 16.0 volts.
This voltage must not be exceeded when the 4. Check all battery terminals and remove any excessive
ignition switch is in the LOCK, ACC, or ON corrosion before you attach the battery cables. Ensure the
position, or during engine cranking. The most vent caps are tight and level.
reliable means for jump starting a vehicle is to
5. Turn the heater fan on in both vehicles to protect any
use batteries connected so as to provide 12
electrical surges. Turn all other accessories off.
volts. Never use an electric welder.
Connecting the Jumper Cables
CAUTION
Do not attempt to push-start your vehicle.
Automatic transmissions do not have push-start
capability; doing so may damage the torque
converter.
3812586R1 63
Vehicle Operation
64 3812586R1
Vehicle Operation
3. Remove the jumper cable from the positive (+) terminal of the
WARNING
booster vehicle’s battery.
Always chock the wheels when manually
releasing the parking brakes, or the vehicle can
roll causing property damage, personal injury, or
death.
For towing, make sure the vehicle is securely
connected to tow vehicle and tow vehicle parking
brakes are applied before releasing the disabled
4. Remove the jumper cable from the positive (+) terminal of the
vehicle’s parking brakes.
disabled vehicle’s battery.
After the disabled vehicle has been started and the jumper Towing Vehicle With Front Wheels Suspended
cables removed, allow it to idle for several minutes so the
engine computer can relearn its idle conditions. CAUTION
To avoid transmission damage, vehicles should
Towing Instructions not be towed even short distances without
suspending rear wheels or removing the axle
WARNING shafts or propeller shaft.
The wheel hub ends must be covered to
This vehicle may be equipped with (optional) dual prevent loss of axle lubricant and entrance
tow hooks. Always use both tow hooks to prevent of contaminants. Use extreme care in securing
possible overloading and breaking of individual the chains or U-bolts to avoid possible damage
hooks. Failure to follow this warning could result of brake lines, hoses or other components.
in property damage, personal injury, or death.
When it is necessary to tow a vehicle with the front wheels
Before moving the towed vehicle, check for adequate road suspended, extra precautions must be taken to avoid
clearance of vehicle components. International recommends transmission or differential damage. Proceed as follows.
unloading the towed vehicle prior to towing to reduce any
abnormal loads to the vehicle components resulting from the Remove axle shafts from axle assembly to prevent the wheels
towing procedures. Before towing, be sure to fully release the from driving the differential and the transmission. The wheel
parking brake. hub ends must be covered to prevent loss of axle lubricant and
entrance of contaminants.
3812586R1 65
Vehicle Operation
If axle shafts are not removed, removal of propeller shaft at rear Tow Hooks (optional)
axle will be required.
Your vehicle may be equipped with front and rear tow hooks.
Some vehicles may require front bumper removal to avoid The tow hooks should only be used in case of an emergency
damage. (retrieving a vehicle out of a ditch or snow bank, for example).
When using the tow hook, always pull the lead or chains in a
Towing Vehicle With Rear Wheels Suspended straight direction with respect to the hook; do not apply sideways
force.
Whenever possible, it is preferable to tow a disabled vehicle from
the rear by raising the rear of the chassis.
When towing a vehicle with rear of the chassis suspended the
front wheels must be locked in the straight ahead position.
66 3812586R1
Vehicle Maintenance, Service Intervals and Specifications
3812586R1 67
Vehicle Maintenance, Service Intervals and Specifications
CAUTION
WARNING
Always disconnect the ground battery terminal
Use only genuine International service parts. first, then the positive cable prior to electric
The use of inferior parts can adversely affect welding. Attach the welder ground cable as close
the quality and reliability of your vehicle, which as possible to the part being welded. If welding
could result in property damage, personal injury close to an electronic component, temporarily
or death. remove that component.
When servicing your vehicle always:
WARNING
1. Turn off the ignition switch unless the procedure calls for a
To avoid property damage, personal injury running engine.
or death, take care when performing any 2. Set the parking brake and chock the wheels.
maintenance or making any check or repair.
Some of the materials in this vehicle may also 3. Use support stands, not a jack, whenever you must be under
be hazardous if used, serviced, or handled a raised vehicle.
improperly. If you have any questions pertaining 4. Do not smoke.
to the service, have the work done by a skilled
technician. 5. Wear safety glasses for eye protection.
6. Operate engine only in a well ventilated area.
WARNING 7. Do not work on brakes or clutch unless proper precautions
are taken to avoid inhaling friction material dust.
To avoid property damage, personal injury or
death when servicing the vehicle, park on a flat 8. Do not wear loose clothing, hanging jewelry, watches or
level surface, set the parking brake, turn off the rings. Tie up long hair and avoid rotating machinery.
engine, and chock the wheels.
9. Avoid contact with hot metal parts; allow hot components to
cool before working on them.
10. Correct any defects that were revealed during inspection,
prior to operating the vehicle.
68 3812586R1
Vehicle Maintenance, Service Intervals and Specifications
3812586R1 69
Vehicle Maintenance, Service Intervals and Specifications
Cab Lubrication
Care Of Vehicle
Frequent and regular washing will lengthen the life of your new
vehicle’s painted finish and bright metal trim.
Wash your vehicle often with warm or cold water to remove dirt
and preserve the original luster of the paint. Never wash the
vehicle in the direct rays of the hot sun or when the sheet metal
is hot to the touch, as this may cause streaks on the finish. Do
not use hot water or strong soaps or detergents or wipe off dirt
when the surface is dry, as this will scratch the paint.
Always make certain that steps and grab handles are clean and
free of road grime, grease, ice, and other debris.
Prior to using any wax or polish, the vehicle must be thoroughly
washed.
70 3812586R1
Vehicle Maintenance, Service Intervals and Specifications
To preserve the bright look of your vehicle’s trim (grilles, To better protect plastic surfaces from fading, use Meguiar’s
bumpers, etc). Use only mild detergents and lukewarm water #40 vinyl and rubber cleaner/ conditioner. Spread evenly with
for cleaning. Damage to these parts can occur if cleaning sponge or towel and allow to penetrate. Buff off excess product
solutions having excessive acidity or alkalinity (pH) are used. with clean cloth.
Also, the higher the solution temperature ranges, the more
caustic the cleaner’s chemical compounds become. However, Air Conditioning System Checks
if high-pressure washing equipment and washing compounds
are used, satisfactory results can be achieved if the solution Have your air conditioning system checked each spring. The
has a pH value between 4 and 8, and the temperature does not refrigerant charge, cleanliness of the condenser-evaporator
exceed 160 degrees F (71 degrees C). Solutions that are more cores and belt condition are essential to air conditioning
acid or more alkaline will attack the anodic coating. performance.
If you are having difficulty with your washing compound, contact
your local supplier for the acidity/alkalinity (pH) specification. Front Axle - General Service Information
A non-abrasive chrome cleaner may be used sparingly to clean Maintaining the front axle alignment to specifications is very
the bright metal. Do not use steel wool. Use of automobile important and should only be performed by a qualified
wax or polish on bright metal usually will restore the original technician. Toe-in adjustment is particularly important with
brightness. radial tires.
Check to make sure that the axle mounting U-bolt nuts, attaching
UPHOLSTERY CARE
or mounting bolts and nuts are securely tightened. Regularly
Use a whisk broom and vacuum cleaner to remove loose dust check front axle for damage, binding, worn parts and adequate
and dirt from upholstery and floor. Vinyl and woven plastic lubrication.
upholstery can be washed with warm water and mild soap. At regular intervals, or during other scheduled maintenance,
Wipe dry. If commercial cleaners are used, follow instructions (tire rotation/service, wheel bearing service, alignment, etc.) the
supplied with cleaner. kingpins should be checked for excessive wear. Refer to the
service manual for proper procedures.
3812586R1 71
Vehicle Maintenance, Service Intervals and Specifications
Toe-In Setting - General Inspection oil level should be at the lower edge of the level inspection hole
when the vehicle is on level ground. Add oil as necessary.
Inspecting steer axle tires in the first 3,000–10,000 service
miles (4,800–16,000 service km) will generally show if tires are
REAR AXLE LUBRICANT
wearing normally.
Rapid outside shoulder wear on both tires indicates too much Refer to Vehicle Maintenance, Service Intervals and
toe-in. Rapid inside shoulder wear on both tires indicates too Specifications chapter for rear axle lubricant level checks and
much toe-out. In P&D-type service, left-to-right steer tire tread lubricant change intervals.
life differentials up to 40% can be observed depending on routes
and other variables. NOTE: Axle operating temperature normally will not exceed
100°F (38°C). If the operating temperature exceeds 230°F
Follow the tire manufacturer’s recommended cold inflation (110°C), the rate of axle lubrication oxidation will increase
pressure for the tire size, load range (ply rating) and steer axle and shorten the life of the lubricant and seals, requiring axle
loading typical for their operation (each steer axle tire will equal lubrication changes to become more frequent to preserve the
½ steer axle loading). axle. Extreme Pressure (EP) lubricants should not be run
Special applications may warrant a setting based on past consistently above 230°F (110°C).
experience with the type of tire operating loads and conditions. The rear axle may be filled with an optional synthetic lubricant
Radial tires are more sensitive to toe-in setting than bias ply which allows the use of extended service intervals. A tag on the
tires. filler plug will identify the use of synthetic lubricant.
It is essential that correct toe-in and tire pressure be maintained Use only a lubricant that meets manufacturer specifications
for optimum tire wear. (refer to Lubricant specifications in this chapter).
Rear Axle - General Inspection Use of a non-approved rear axle lubricant may cause
internal axle component damage.
Check to make sure that the axle mounting U-bolts, attaching or Check your rear axle lubricant level using the following
mounting bolts and nuts are securely tightened. Refer to U-bolt procedure:
nut torque chart in this chapter. Regularly check the rear axle for
damaged, binding or worn parts. 1. Park the vehicle on level ground.
Check the rear axle oil level. Proper oil level minimizes gear 2. Set the parking brake and shift into P (Park) and turn the
wear, heat and damage to the wheel bearings and seals. The engine off.
3. Clean any dirt from around the rear axle filler plug.
72 3812586R1
Vehicle Maintenance, Service Intervals and Specifications
4. Remove the filler plug and inspect the lubricant level. Brake System - General Inspection
5. The lubricant level should be up to the bottom of the filler
plug opening. WARNING
6. If necessary, add enough lubricant through the filler plug
Always check and maintain brakes in proper
opening so that the lubricant level is at the bottom of the
condition and adjustment. Out of adjustment
opening.
brakes could cause reduced braking ability and
7. Clean and install the filler plug securely. result in property damage, personal injury, or
death.
Drain and refill your rear axle lubricant using the following
procedure: Your vehicle is equipped with non-asbestos brake linings.
However, exposure to excessive amounts of brake material
Note: The rear axle lubricant should only be drained when the
(whether asbestos or non-asbestos, fiberglass, mineral wool,
lubricant is warm.
aramid or carbon) may be a potentially serious health hazard.
1. Park the vehicle on level ground.
2. Set the parking brake and shift into P (Park) and turn the WARNING
engine off.
Avoid breathing brake lining fiber dust as it
3. Clean any dirt from around the rear axle filler plug and may be hazardous to your health. Always use a
remove. respirator while performing brake maintenance.
4. Remove the two lower carrier to housing bolts from their Follow precautions listed below.
through holes and drain the lubricant into a suitable A. Always wear a respirator approved by the National
container. Dispose all used automotive fluids in a Institute of Occupational Studies of Health (NIOSH)
responsible manner following your local authorized or Mine Safety and Appliance (MSA) during all brake
standards. service procedures. Wear the respirator from removal
5. Re-install the two bolts removed. Use Loctite 270 and of the wheels through assembly.
torque to 142 — 158 lbf-ft (193 — 214 Nm). B. Never use compressed air or dry brushing to clean
6. Add enough lubricant through the filler plug opening so brake parts or assemblies.
that the lubricant level is up to the bottom of the opening.
7. Clean and install the filler plug securely.
3812586R1 73
Vehicle Maintenance, Service Intervals and Specifications
C. Clean brake parts and assemblies in open air. During This inspection should be performed by a qualified technician
assembly, carefully place all parts on the floor to avoid and must be in accordance with instructions provided by the
getting dust in the air. Use an industrial vacuum cleaner service manual.
with a HEPA filter system to clean dust from the brake
drums, backing plates and other brake parts. After Hydraulic Brakes - Fluid Level
using the vacuum, remove any remaining dust with a
rag soaked in water and wrung until nearly dry. Fluid level should be between the MIN and MAX lines as marked
on the reservoir. Do not fill the master cylinder to the top of the
D. Never use compressed air or dry sweeping to clean the reservoir.
work area. Use an industrial vacuum cleaner with a
HEPA filter system and rags soaked in water until wrung NOTE: If brake fluid requires attention to maintain a proper
until nearly dry. Dispose of used rags with care to avoid master cylinder level, this is an indication of either severe
getting dust in the air. Use an approved respirator when operation (pad wear) or fluid system leakage. A more frequent
emptying vacuum cleaners and handling used rags. and thorough brake inspection will be required.
E. Worker clean-up: Wash your hands before eating,
drinking or smoking. Vacuum your work clothes after Hydraulic brakes - Fluid Precautions
use and then launder them separately, without shaking
them, to prevent fiber dust getting into the air. The Hydroboost brake system consists of two completely
separate hydraulic systems operating with two different
Hydraulic Brakes - General Inspection And Adjustment and incompatible fluids; power steering fluid and hydraulic
brake fluid. Failure to observe precautions preventing the
A regular schedule for periodic cleaning, lubrication, adjustment contamination of either system with fluid from the other will
and inspection should be established based on the type of result in swelling and deterioration of rubber parts leading to
vehicle operation. It is difficult to predetermine an exact reduced brake performance and eventual brake failure.
maintenance interval (time or mileage), since vehicles will be To avoid fluid contamination, the following should always be
used in a wide variety of applications and conditions. If you observed:
are uncertain of the proper schedule and procedures for your
vehicle, contact your dealer. A. Use only fluids specified (or equivalent) and properly
identified.
Inspect the brake lining every maintenance interval. Establish
inspection intervals that provide for lining replacement before B. Add fluids only to the following locations:
damage to the disc occurs. Excessive lining wear may expose C. Power steering fluid to the power steering fluid pump
the backing plate to the disc causing scoring of the disc faces. reservoir.
74 3812586R1
Vehicle Maintenance, Service Intervals and Specifications
D. Brake fluid to the brake master cylinder. 3. If necessary, add brake fluid from a clean unopened
container until the level reaches the bottom of the fill
Brake Fluid Reservoir ports. Do not fill above this line.
The reservoir is located behind a panel on the far left side of the 4. Use only a DOT 3 brake fluid certified to meet
instrument panel, accessible by opening the driver’s door and manufacturer specifications. Refer to Lubricant
removing the end panel. specifications in this chapter.
Parking Brake
Check and refill the brake fluid reservoir using the following Parking brake adjustment should only be performed by a
procedure. qualified technician, and in accordance with the instructions in
1. Clean the reservoir caps before removal to prevent dirt the service manual.
or water from entering the reservoir. See VEHICLE INSPECTION GUIDE section for proper parking
2. Visually inspect the fluid level; the level should be brake inspection procedure.
between the MIN/MAX marks on the reservoir.
3812586R1 75
Vehicle Maintenance, Service Intervals and Specifications
NOTE: Never lower handle B when cab is tilted (see the Figure
WARNING
below).
Either the rapid release or the forced release of
the parking brake hand lever can cause the cable TILTING
to kink at the connection to the hand lever and
Remove all loose objects from cab, close doors, and chock
result in early cable failure. A damaged or failed
wheels.
cable could result in a vehicle roll-away that could
cause property damage, personal injury, or death.
WARNING
Tilting/Lowering Cab
76 3812586R1
Vehicle Maintenance, Service Intervals and Specifications
2. With handle B raised fully, hold grip E and lower the cab until 5. Wipe the dipstick clean. Insert the dipstick fully, then remove
hook D is locked. it again.
3. Lower handle B securely to its original position. • If the oil level is between ADD and OPERATING RANGE,
the oil level is acceptable. DO NOT ADD OIL.
Engine Oil • Maintain the oil level between ADD and OPERATING
RANGE on the dipstick by adding oil as required.
CHECKING ENGINE OIL LEVEL
• The distance from ADD to OPERATING RANGE on the
Engine oil level should be checked daily. dipstick represents 1.0 quart (1.0L).
1. Park the vehicle on level ground. • Oil levels above OPERATING RANGE may cause engine
damage. Some oil must be removed from the engine by a
2. Set the parking brake and shift into P (Park).
qualified service technician.
3. Turn off engine.
6. Put the dipstick back into the engine and ensure it is fully
seated.
3812586R1 77
Vehicle Maintenance, Service Intervals and Specifications
• Change your engine oil and filter more frequently if your NOTE: The engine coolant reservoir requires air space for
vehicle operation includes extended periods of idling expansion volume. The proper fill level is identified on the
or low-speed operation, driving for a long time in cold reservoir; do not overfill the reservoir.
temperatures or short driving distances.
CAUTION
Engine Coolant If the coolant should get extremely low and
the engine very hot, let the engine cool for
CHECKING ENGINE COOLANT approximately 15 minutes before adding coolant.
After the engine has cooled, start the engine
The engine coolant reservoir is located behind the passenger
and add coolant slowly. Adding coolant to a hot
side of the cab.
engine may crack the cylinder head or crankcase.
Never use only water to fill the cooling system.
WARNING
78 3812586R1
Vehicle Maintenance, Service Intervals and Specifications
Fill the coolant reservoir slowly with the proper coolant mixture COOLANT CONCENTRATION FREEZE POINT
(see above), to the appropriate level (top indicator).
Cooling systems should be checked twice a year to assure
Replace the cap. Turn until tightly installed. (Cap must be tightly proper coolant/water concentrations.
installed to prevent coolant loss.)
After any coolant has been added, check the coolant CAUTION
concentration. If the concentration is not 50/50 (protection to Always use premixed ELC or equivalent to top
–34° F/–36° C), drain some coolant and adjust the concentration. off the cooling system. Failure to do so may
It may take several drains and additions to obtain a 50/50 coolant result in the loss of extended life properties and
concentration. will require testing for SCA levels. Should top
Whenever coolant has been added, the coolant level in the off occur with conventional coolant(s) exceeding
coolant reservoir should be checked the next few times you 10% of the total cooling system capacity, either
drive the vehicle. If necessary, add enough 50/50 concentration drain and refill with ELC or maintain as a
of engine coolant and distilled water to bring the liquid level to conventional coolant system using SCA’s at
the proper level. the recommended levels.
If you have to add more than 1.0 liter (1.0 quart) of engine coolant RECYCLED ENGINE COOLANT
per month, have your dealer check the engine cooling system.
Your cooling system may have a leak. Operating an engine The use of recycled engine coolant is not recommended.
with a low level of coolant can result in engine overheating and
possible engine damage. Used engine coolant should be disposed of in an appropriate
manner. Follow your community’s regulations and standards for
EXTENDED LIFE COOLANT recycling and disposing of automotive fluids.
The cooling system of your new vehicle is filled at the factory ENGINE COOLANT CAPACITIES AND PART NUMBERS
with Shell Rotella Extended Life Coolant (ELC). Refer to the
Engine Operation and Maintenance Manual for specific coolant For cooling system capacities, refer to Refill capacities in
requirements and for maintaining/servicing the cooling system. this chapter. For coolant part numbers, refer to Lubricant
specifications in this chapter.
3812586R1 79
Vehicle Maintenance, Service Intervals and Specifications
FAN CLUTCHES
WARNING
The engine cooling system is equipped with an electronically
Exercise great care when working on vehicles
controlled fan drive that turns the fan off when not required for
with an auxiliary A/C fan. The fan can start with
engine cooling.
no advance warning any time the ignition is ON.
The fan drive is controlled electronically by the Engine Control Failure to observe this warning could result in
Module, which monitors the engine coolant temperatures. When vehicle damage, personal injury, or death.
the engine coolant temperature reaches a specified limit, the fan
drive will engage. Do not tamper with or disable the fan drive as Windshield Washer Fluid
it could cause the engine to overheat.
WARNING
80 3812586R1
Vehicle Maintenance, Service Intervals and Specifications
WARNING WARNING
Do not use the washers in freezing weather Whenever disconnecting battery terminals,
without first warming the windshield with the always disconnect ground terminal first. When
defrosters; otherwise, the washer solution may reconnecting, always connect ground terminal
freeze on the windshield and obscure your last. Failure to follow this procedure could result
vision and could cause an accident, resulting in in a short to ground and cause property damage,
property damage, personal injury, or death. personal injury, or death.
Do not use radiator coolant or anti-freeze in the Always wear eye protection when working
windshield washer reservoir. Radiator coolant around batteries. Do not attempt to jump-start a
in the washer reservoir can severely reduce vehicle with a frozen battery because the battery
visibility when sprayed on the windshield. may rupture or explode. If a frozen battery is
suspected, thaw out battery and recharge.
Battery
WARNING
WARNING
Do Not Check Battery Condition By Shorting
Keep lighted tobacco, flames, sparks or other (Flashing) Across Terminals.
ignition sources away from the batteries. Gas Failure to observe these warning could result in
from the battery cells is flammable and can ignite personal injury and/or damage to the vehicle.
and/or explode. This is particularly true when
jumper cables are being used. Battery fires or Battery cable terminals must be clean and tight. Use hot water
explosions could cause severe injury to the face, and common baking soda for removing terminal corrosion and
eyes, limbs and body. for cleaning the top of the battery. Brighten the contact surface
with steel wool, apply a light coat of lubricant sealing grease such
In addition, inhaling the hydrogen gas produced as Fleetrite® 472141-C1 or equivalent and reassemble. Be sure
by the normal operation of the battery could the terminals are clamped tightly and that the battery is clamped
result in partial or permanent damage to the securely in the battery box.
respiratory system.
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When working around the terminals and battery, use extra care
WARNING
to avoid shorting. A good practice is to insulate pliers and
screwdrivers. Do Not Check Battery Condition By Shorting Always follow recommended procedures for
(Flashing) Across Terminals. steering system maintenance. Failure to maintain
the steering system in proper condition can
Steering - General Inspection cause reduced steering ability resulting in
property damage, personal injury or death.
• Ask your service technician to examine the steering
mechanism. Only minor adjustments may be necessary. TIGHTENING STEERING COLUMN JOINT BOLTS
• Check tie rod ends, drag link end clamp bolts and king pins.
Joints and fasteners must be tight. Articulating joints must As a good maintenance practice, it is recommended that
be well lubricated. steering column joint bolts be checked for tightness every
60,000 miles (96,000 km) or annually, whichever occurs first.
• Check for installation and spread of cotter pins and tightness Do not overtighten.
of nuts at both ends of the tie rod and drag link.
• Check that pitman arm (steering arm at steering gear) POWER STEERING
mounting is tight and locked. Check system for leaks or
Whenever the power steering system has been drained and
hose chafing. Repair at once, if necessary.
refilled for any reason, air must be bled from the system before
• Maintain proper steering gear and power steering pump returning the vehicle to service. Failure to properly bleed the
lubricant levels. system can result in degradation of power steering performance.
• Regularly inspect steering column joint bolts and steering Consult your dealer who is aware of the proper procedures for
linkage, particularly for body-to-chassis clearance. filling and bleeding the system.
Note: Have any steering problems corrected at once by a
qualified service technician.
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3. With the parking brake engaged and your foot on the You can check the fluid without driving if the ambient temperature
brake pedal, start the engine and move the gearshift is above 50°F (10°C). However, if fluid is added at this time, an
lever through all of the gear ranges. Allow sufficient time overfill condition could result when the vehicle reaches normal
for each gear to engage. operating temperature.
4. Latch the gearshift lever in park, set the park brake, and
leave the engine running.
5. Remove the dipstick, and wipe it clean with a clean, dry
lint free rag.
6. Install the dipstick making sure it is fully seated in the The transmission fluid should be in this range if at normal
tube. operating temperature (150°F-170°F [66°C-77°C]).
7. Remove the dipstick and inspect the fluid level. The fluid
should be in the designated area for normal operating
temperature or ambient temperature.
Do not drive the vehicle if the fluid level is at the bottom of the
dipstick and the ambient temperature is above 50°F (10°C).
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Engine and Subsystem Maintenance For information regarding routine scheduled maintenance such
as replacement of oil, filters, coolant, belts, belt tensioners, etc.,
CAUTION and inspection and adjustment of items such as valve lash, etc.
refer to the Engine Operation and Maintenance Manual supplied
To prevent damage to the International Engine
with the vehicle.
Control Module it should never be spray-washed
directly. Never spray any connector.
AIR INDUCTION SYSTEM
For effective emissions control and low operating cost, it is
important that maintenance operations listed in this section and
WARNING
those in the Engine Operation and Maintenance Manual be
performed at the specified periods or mileage intervals indicated To avoid property damage, personal injury or
(kilometers, miles, hours, or months, whichever comes first). death when performing maintenance and repairs
Service intervals are based upon average operating conditions. to any turbocharged engine with engine air inlet
Where dusty, frequent start-and-stop or heavily laden operations piping disconnected, a turbocharger compressor
are encountered, more frequent servicing will be required. air inlet protective shield should be installed over
the turbocharger air inlet. Order protective shield
The vehicle owner is responsible for the performance of J-26554 for International engines from your local
all scheduled maintenance. The required maintenance International dealer.
operations may be performed by the owner at a service
establishment of the owner’s choosing. Any replacement parts Once each year, perform a complete inspection of the air
used for required maintenance services or repairs should be induction system. In areas where road salt is used, the
genuine manufacturer service parts or equivalent in quality and inspection consists of disassembling the joints of each aluminum
performance to genuine manufacturer service parts. Use of component and inspecting for salt build-up and presence of
inferior parts hinders operations of the engine and emissions chlorine that can cause aluminum particles to flake off and enter
controls and can reduce engine life and/or jeopardize the the engine combustion chambers.
warranty. If evidence of corrosion is found (usually at the pipe
Receipts covering the performance of regular maintenance connections), use a wire brush to clean the inside of the
should be retained in the event questions arise concerning pipes and inside the rubber hoses.
maintenance. The receipts should be transferred to each If the intake pipes are pitted at the joint ends, use RTV silicone to
subsequent owner of the vehicle. seal the joints. Be certain that no excess material is on the inside
of the pipes that can be pulled into the engine. If the service
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condition of the pipes, hoses or clamps is questionable, replace 1. Remove the cover by releasing the clamp and turning
the defective part(s). the cover counterclockwise and pulling it off.
Be sure that prior to reassembly all dust and debris has been 2. Remove the dirty filter and discard it.
cleaned out of the pipes and couplings with a clean, damp rag.
3. Clean any accumulation of dirt from the housing using
a damp rag. Do not use compressed air to clean the
AIR FILTER REPLACEMENT
housing.
4. Inspect the housing for damage or distortion which
would allow unfiltered air to enter the engine.
5. Install the new filter. Install the cover onto the housing,
then turn it clockwise and close the clamp.
After replacing the filter, reset the gauge by pressing the reset
button on top of the gauge.
Fuel
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International Truck and Engine Corporation does not According to the Federal Motor Carrier Safety Regulations,
recommend the blending of gasoline, and/or alcohol with diesel no driver or any employee of a motor carrier shall:
fuel due to the hazards of fire/explosion and the detrimental
1. Fuel a motor vehicle with the engine running, except
effects on engine performance.
when it is necessary to run the engine to fuel the vehicle.
2. Smoke or expose any open flame in the vicinity of a
WARNING vehicle being fueled.
Never add gasoline, gasohol and/or alcohol to 3. Fuel a motor vehicle unless the nozzle of the fuel hose
diesel fuel. This mixture creates an extreme is continuously in contact with the intake pipe of the fuel
fire and explosion hazard, which could result in tank.
property damage, personal injury, or death.
4. Permit, insofar as practicable, any other person to
As little as two percent volume gasoline mixed with diesel fuel engage in such activities as would be likely to result in
will create a flammable/explosive mixture in the fuel tank vapor fire or explosion.
space, which will pose an extreme fire/explosion hazard during
refueling or engine operation. Reserve Fuel
Fuel and Lubricant Additives No extra supply of fuel for the propulsion of the vehicle or for the
operation of accessories shall be carried on any motor vehicle
International Trucks are designed and built to operate except in a properly mounted fuel tank or tanks.
satisfactorily on fuels and lubricants of good quality marketed
by the petroleum industry. International Truck and Engine Running Out of Fuel
Corporation does not recommend the use of any supplementary
fuel or lubricant additives. Malfunctions attributed to the use of Avoid running out of fuel as this can allow air to enter the fuel
such additives or failure to follow recommended fuel or lubricant system, which will make restarting the vehicle difficult.
recommendations may not be covered by any applicable
If you have run out of fuel, refer to the Engine Operation and
warranty. Refer to the Engine Operation and Maintenance
Maintenance Manual for specific restarting instructions.
Manual for specific fuel requirements.
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Electrical To access the PDC, the protective cover must be taken off the
vehicle by removing the two screws (shown in the figure below),
Fuses and Relays then gently pulling the cover off.
If electrical components in the vehicle are not working, the NOTE: Remove and install the cover carefully so that no wires
appropriate fuse/relay should be checked before replacing any or cables become disconnected or damaged.
electrical components.
Fuses and relays are in two locations, the Power Distribution NOTE: Always re-install the protective cover to avoid water or
Center and the Relay Box. The Power Distribution Center (PDC) fluids from damaging the PDC or other electrical components.
is located behind the cab on the right-hand frame rail, behind a
protective cover.
Once the cover has been removed, simply lift the tab on the PDC
cover to access the fuses and relays.
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WARNING
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• Air Cleaner — should be inspected and its location should • Transmission enclosure — inspect for cracks, holes, and
not be altered. Do not alter inlet and outlet piping. tears. Clean any deposits such as oil, dirt, and stones.
• Engine valve covers and block covers are made to damp out
Body:
engine mechanical noise and, if needed, should be replaced
• Wheel Well — splash shields, cab shields and under-hood with recommended parts. Check for mechanical isolations.
insulation should be inspected for deterioration, dislocation,
and orientation. Exhaust System:
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Installation Procedures
WARNING
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Wheel Mounting Nuts Torque Sequence 4. Draw up nuts alternately following the (criss-cross)
pattern illustrated. Do not fully tighten nuts at this time.
This will allow uniform seating of nuts and assure even
face to face contact of wheel and hub.
5. Continue tightening the nuts to torque specifications
in the TORQUE CHART using the same alternating
sequence shown.
6. After operating the vehicle approximately 50 miles (80
km) check the stud nuts for tightness. Some natural
seating of parts may be encountered and the torque on
nuts will drop. Retighten all nuts to specified torque.
Prior to each trip visually inspect the wheel stud nuts for
tightness. Check for missing or loose wheels stud nuts. Look
for rust streaks originating at the wheel stud nut which can be
an indication of a loose wheel stud nut.
Tightening procedure for disc wheels with flange nuts (hub
piloted): Aluminum Disc Wheels with Flange Nuts (Hub Piloted)
1. Slide inner rear tire and wheel or front tire and wheel in Prior to reinstalling rear aluminum hub-piloted wheels, clean
position over studs and push back as far as possible. each wheel locator pad on the hub of dirt, rust and foreign
Do not damage the stud threads. material. Apply a light coat of chassis grease, anti-seize
2. Position the outer rear tire and wheel in place over the compound, or disc brake corrosion control grease only to the
studs and push back as far as possible. Again, do not wheel locator pad. This reduces the likelihood of the wheel
damage the stud threads. getting stuck on the wheel hub due to corrosion.
3. Run the nuts on the studs until nuts contact the wheel
or wheels. Rotate wheel assembly a half turn to permit
parts to seat and snug the nuts again by hand.
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Tires
WARNING
Inflation To avoid personal injury or death, always follow
these instructions when mounting radial tires on
WARNING wheels:
Due to tire manufacturers re-marking tires to • Only personnel that have had proper training and
conform to the SI (metric) system, tires marked experience should mount or remove tires from rims or
with old and new loads or inflation pressures wheels.
could be placed on the same vehicle. For field • Use only heavy-duty rims or approved rims for radial
maintenance, only inflate and load tires to the tires. It may be necessary to contact your wheel and
maximum of the least-rated tire on the axle. rim distributor to determine if your rims are approved
Failure to adhere to this warning could possibly for radial tires.
result in tire malfunction, damage to your vehicle,
personal injury, or death. • If a tube is to be used, make sure special radial tire
tubes are used because of the increased flexing of the
sidewalls on radial tires.
WARNING
• Never use anti-freeze, silicones, or petroleum based
Always maintain your tires in good condition. lubricants when mounting radial tires. Only an
Frequently check and maintain correct inflation approved lubricant should be used as an aid for
pressures as specified by tire manufacturers. mounting tires.
Inspect periodically for abnormal wear patterns • Always inflate tires in a safety cage.
and repair/replace cut or broken tire casing.
Always use experienced, trained personnel with
proper equipment and correct procedures to
mount or remove tires and wheels. Failure to
adhere to these warnings could result in wheel
or tire malfunction, damage to your vehicle,
personal injury, or death.
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Mixing If rib tire is used on front axle and lug or off-road type on
rear axle positions:
NOTE: Never mix bias and radial tires on this vehicle.
• Front (Steering) Axle — Replace tires at front wheels when
It is recommended for best overall performance that only radial tread is worn to 4/32 inch (3mm) or less.
tires be used on this vehicle.
• Rear Axles — Tires must be removed when the tread
Never mix different tire sizes or constructions on the same axle. is worn to 2/32 inch (2mm) or less. Tires identified with
the word “re-groovable” molded on the sidewall can be
Rotation re-grooved. A minimum of 3/32 of under-tread must be left
at the bottom of the grooves.
Rotation Is Always Advisable:
Wheel And Tire Balancing
1. If front (steering) axle tires become irregularly worn,
move to rear position. Out-of-round or out-of-balance wheels or tires can cause
vehicle vibration, bounce and shimmy. Replace damaged or
2. In a dual assembly, reverse the position of the tires if
out-of-round wheels. Out-of-round tires and wheel assemblies
one tire wears much faster than its mate.
can be corrected by re-clocking the tire relative to the wheel.
3. On the drive axle, if heel and toe wear or alternate lug The tire and wheel assembly should then be dynamically
wear occurs, rotating the tires from one end of the axle balanced.
to the other end of the axle may help even out this wear.
Wear
Rotation May Not Be Advisable:
Radial tires can exhibit three types of normal wear patterns: 1)
• Front (Steering) Axle — Tires must be removed when tread Even, 2) Erosion, 3) Chamfer.
is worn to 4/32 inch (3mm) or less. Retread or rotate worn
Even Wear is a sign that the tire is being properly used and
tires to drive position. Retreaded tires are not recommended
maintained.
to be used on steering axles.
• Rear Axles — Tires must be removed when tread is worn
to 2/32 inch (2mm).
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Erosion Wear has also been called rolling wear, channel or river • Another rotation possibility for fleets with rib tires in all wheel
wear. Erosion wear is found more often at free rolling tires. This positions is to break in the new steer tires in the drive axle
is an indication that the tire is being used in a slow wearing positions, then move them to steer axles. This will wear
operation. What happens is that the belt plies are held very rigid away tread rubber relatively quickly in the early life of a tire
and the tread is not allowed to distort as it passes through the when it is most likely to develop an unusual wear pattern.
contact area. Wear will only occur at the edge of the tread. No
• Drive axle tires may be placed on the other end of the same
corrective action required. If erosion gets to be 1/16 inch (2mm)
axle so that direction of rotation is reversed. This is often
or more, the tire may be rotated to a drive axle.
helpful if a heel and toe or alternate lug wear pattern has
Chamfer or Shoulder Wear, with tires inflated properly, is a developed.
normal tendency of most radial tire designs. If both inside and
Irregular wear can be minimized by:
outside shoulders are wearing evenly around the tire, no further
action is required. Over-inflation is not effective in correcting this • Using the right inflation pressure for the load being carried.
effect.
• Maintaining proper front wheel alignment — especially
toe-in — to specifications.
Tires — Irregular Wear
• Maintaining proper tire and wheel balance.
If irregular wear is present, check the axle alignment, tire
pressure, wheel balancing, shock and suspension component • Maintaining shock absorbers and suspension components.
condition, and wheel bearing end play.
Use Of Tire Chains
This condition not only shortens tire life, but will adversely affect
the handling of your vehicle, which is dangerous. Refer to chain manufacturer’s recommendation for correct tire
chain usage, installation and removal.
Rotating tires from one wheel position to another is a way often
used to even out many types of irregular wear or to avoid it
altogether. Some of the more effective tire rotation programs
are:
• Steer tires that have developed some type of irregular wear
pattern can be rotated to drive axles if rib tires are being
used on all wheel positions. Applying steer tires to a drive
position will often clean them and they can be moved back to
the steer axles or run out to re-tread stage on the rear axle.
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Lubrication and Maintenance Intervals maximize vehicle availability and minimize unexpected failures.
Recommended synchronized intervals are shown for each item.
New vehicles are lubricated at the factory. After the vehicle
is placed in operation, regular lubrication and maintenance Synchronized “A” Service and “B” Service intervals are designed
intervals, based on the type of service and road conditions, to coordinate maintenance activities to provide appropriate
should be established. The loads carried, speed, road and levels of service for components while minimizing the number of
weather conditions all contribute to the frequency of lubrication times per year that the vehicle must be brought into the shop for
periods. Thorough lubrication and maintenance at the specified service. A “Special” Service Interval column is provided for those
intervals will insure Outstanding Life Cycle Value (OLCV) and items that are infrequently serviced or have an initial service
will reduce overall operating expense. requirement that may be less than the standard A interval.
These are the recommended maximum intervals. Specific fleets
In some types of operation, and where operating conditions may find that due to the severity of their environment and duty
are extremely severe (such as in deep water, mud or unusually cycle that the intervals should be shortened.
dusty conditions), the vehicle may require lubrication after every
twenty-four (24) hours of operation. Lubrication and Maintenance Interval Chart Symbols Key
Only lubricants of superior quality, such as Fleetrite lubricants, Symbol Interval Definition (Whichever comes
should be used. The use of inferior products will reduce the first)
service life of the vehicle or result in failure of its components.
A 10,000 miles (16,000 km)
International recommends the use of Fleetrite lubricants.
300 hours
See Note
6 months
Maintenance Intervals
B 20,000 miles (32,000 km)
Maintenance intervals are provided for normal service. In all 600 hours
applications the actual interval is determined by monitoring 12 months
miles (kilometers), hours of operation and the passage of time
NOTE: Be sure to check the Lubrication and Maintenance Interval
(months).
Chart and also the Maintenance Schedule in the Engine Operation
The following LUBRICATION AND MAINTENANCE INTERVAL and Maintenance Manual for items that may require initial servicing
CHART contains an extensive list of components and systems prior to the standard A interval.
that must be regularly inspected, serviced, and or replaced to
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NOTE 2: Kingpin thrust washers must be lubricated with vehicle weight on tires. Kingpins and kingpin bushings must be lubricated with weight off of the wheels
and tires.
NOTE 3: Certain services are performed at Special Intervals or in addition to A or B Service when the interval dictates.
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Refill Capacities
Fluid Capacity
Engine coolant 24 quarts (22.7L) 1
Power steering fluid Keep level between ADD and FULL marks as shown on reservoir.
Washer fluid 4.25 quarts (4.0L)
Fuel tank - Single tank, mounted on left side 35 gallons (132.0L)
Fuel tank - Single tank mounted between frame sidemembers 40 gallons (151.4L)
and behind rear axle
Fuel tanks - Dual 35 gallons (132.0L) each, 70 gallons total
1
Coolant system refill capacity may vary due to the amount of 3
Indicates approximate refill capacity (less than initial dry fill
coolant remaining in the system after draining. capacity). Refill capacity may vary depending on the amount
of fluid remaining in the system after draining. The amount of
2
Use only MERCON® SP transmission fluid. Check the
fluid and fluid level should always be set by the indication on the
container to verify the fluid being added is of the correct type.
dipstick’s normal operating range.
MERCON®, MERCON® V and MERCON® SP are not 4
Quantities listed are approximate. Fill axle until the lubricant
interchangeable. DO NOT mix MERCON®, MERCON® V
level is at the bottom of the filler hole, with the vehicle on level
and MERCON® SP. Use of dual usage fluids in an automatic
ground.
transmission application requiring MERCON® SP may
cause transmission damage. Use of a transmission fluid 5
If hubs are removed, add an additional 1.6 pints (0.75L) of axle
other than the recommended fluid may cause transmission lubricant. Add lubricant through the axle vent.
damage.
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d. Draw a horizontal line (H line) on the paper, showing g. Start the engine.
where the headlamps should strike (at the same height
h. Turn the LOW beam headlamps ON.
from ground as the headlamp bulb center, which is
marked on the headlamp lens by a 2 mm by 2 mm i. On the paper, observe the portion of the light pattern
square). that has a distinctly higher area of intensity. Check that
the top edge of this high intensity area is at the H RH/H
e. Draw a horizontal line (H LH and H RH lines) parallel to
LH reference line and below the cross-hatched area as
the H line but 20.9 mm (0.82 in) below it.
shown in the illustration below.
f. Take appropriate measures to prevent any influence of
j. If not, adjust the lights in the vertical direction.
other lights.
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CAUTION
Both the inboard and outboard vertical aim
screws must be turned the same amount in the
same direction. Do NOT turn the screws different
amounts or in different directions.
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Vehicle Maintenance, Service Intervals and Specifications
e. Turn the screwdriver the same number of turns in the Side Marker Lights 168
same direction as was done in the inboard aiming hole, Reverse Light 1156
but make sure you finish in the clockwise screwdriver
Stop/Tail Lights 1157
direction. If you are adjusting in the counterclockwise
screwdriver direction, overshoot the adjustment by one
full turn and then turn it clockwise one full turn, so you Filter Replacement
finish the adjustment in the clockwise direction and still
line up with the vertical aiming line. Do NOT turn this Filter Part Number
outboard screw in a different direction or a different
Engine Oil Filter 1847174C91
amount than was done with the inboard aiming
screw. Transmission Oil Filter 6051071C1
Primary Fuel Filter (HFCM) 2587857C1
Secondary Fuel Filter 1847170C92
Air Filter 3587702C1
Use only genuine International® service parts.
112 3812586R1
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DISC WHEEL TORQUE CHART Check U-Bolt Nuts and re-torque every 36,000 miles (58,000 km)
after initial 1,000 mile re-torque.
DISC WHEELS
Size Nut Mounting Torque
Fuses and Relays
lbf – ft N.m If electrical components in the vehicle are not working, a fuse
may have blown. Blown fuses are identified by a broken wire
M14 Flange 140–160 190–217
within the fuse. Check the appropriate fuses before replacing
NOTE: Do not use lubrication on dry threads. Where excessive any electrical components.
corrosion exists, a light coat of lubricant on first three threads of stud
on bolt is permitted. Keep lubricant away from flange nut washer Note: Always replace a fuse with one that has the specified
surface and flat on disc wheel. amperage rating. Using a fuse with a higher amperage rating
can cause severe wire damage and could start a fire.
Torque
lbf – ft N.m
260 — 300 353 — 407
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118 3812586R1
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**Mini fuse
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120 3812586R1
Entertainment Systems
1. ON/AUDIO: Press to turn the radio on/off and 3. BAND: Press to alternate between AM, FM1 and
turn to adjust the volume. FM2.
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Entertainment Systems
To set the clock: 7. SCAN: Press to search the current band for all
listenable stations. Press again to stop the scan.
• Turn the ignition on.
• Press and hold the DSPL TM SET button until the hours
digits flash, then press either the TUNE or SEEK buttons
to set the hour. 8. Memory preset buttons (1–6): To set a
• Press the DSPL TM SET button again and the minutes digits station: Select frequency band AM/FM;
will flash. Press either the TUNE or SEEK buttons to set the tune to a station, press and hold a preset
minutes. button until sound returns.
5. AUTO: Press to automatically set the strongest 9. TUNE: Press to manually change radio frequency
stations to presets. up or down.
6. DIM: Press to adjust the brightness of the radio 10. SEEK: Press to find the next strong station up or
display. down the frequency band.
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1. VOLUME/BALANCE: Turn clockwise to FADER: Pull the VOL control out and turn
turn the radio on and raise the volume; turn to shift sound to the rear/front speakers.
counterclockwise to lower the volume and turn
the radio off. Pull the control out and turn left or
right to adjust the balance between the left and
right speakers.
2. BAND: Press to select AM, FM1, FM2 and FM3.
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Entertainment Systems
To set the clock for the first time (or after the battery
has been disconnected, then reconnected) follow
this procedure:
• Press the clock button; “Adj” will show on the display. 7. << / >>: When the program indicator lights ▲, press
Press and hold the button again for more than two seconds; << to fast forward or >> to rewind. To stop rewind or
“12” will blink indicating the time setting mode has been fast forward, press the button that is not in use.
activated. Changing cassette sides: Press << and >> at the
• To set the hour, press TUNE ↑ or ↓. same time. The program indicator (▲ / ▼) will change
directions.
• To set the minutes, press the clock button again, then press
TUNE ↑ or ↓. 8. Memory preset buttons (1–6): To manually
• When the time has been set, press the clock button again. set a station: Select frequency band
AM/FM1/FM2/FM3; tune to a station, press
If you need to reset the time, press and hold the clock button and hold a preset button until the display blinks.
for more than two seconds to activate the time setting mode, To automatically set a station: press BAND for more than
then follow Steps 2 through 4 as shown under Setting the two seconds; the six strongest stations will be automatically
clock. set in the six memory preset buttons.
Press the clock button to alternate between radio, tape and
clock modes. 9. MONO/ST: Press for monaural reception in case
a lot of interference is present in an FM stereo
4. TUNE: Press ↑ or ↓ to manually go up or down the signal or to improve the listening quality of weak
radio frequency. FM broadcasts.
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Entertainment Systems
1. PWR: Press to turn the audio system on or off. speakers. Fader: Adjust the audio between front and rear
speakers.
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Entertainment Systems
4. ALM: Press and hold ALM to set the alarm. The 8. TUNE٨ / ٧:
display will flash indicating alarm time setting mode
In radio mode: Press to manually go up or
is activated. Press ٧ to set the hour and ٨ to set
down the radio frequency.
the minute. (Press and hold ٧ or ٨ to change the
numbers rapidly.) Once the alarm time has been set, release In CD mode: Press once to go to the beginning
ALM. If the alarm time has not been stored in the radio, “AM of the current track; press twice to go to the
12:00” will be displayed. previous next track.
The alarm is turned on or off each time ALM is pressed.
9. SEEK٨ / ٧:
When the alarm is on, the alarm will sound for 90 seconds at
the set alarm time. To turn the alarm off while it is sounding, In radio mode: Press and hold for more than
press ALM. ½ second to have the radio automatically search
for the next strongest radio station.
You can also select alarm volume by selecting ALARM VOL
1 or ALARM VOL 2 when pressing ALM. The volume for In CD mode: Press and hold for more than
ALARM VOL 2 is higher than ALARM VOL 1, which is the ½ second to activate fast forward or reverse.
default setting. Release to resume normal CD play.
5. ▲: Press to eject a CD. “EJ” will display while the 10. SCAN: Press SCAN and each station will be
disc is being ejected. scanned sequentially and the display will blink for
5 seconds. Press SCAN again to stop scanning
6. CD door: Insert a CD into the CD door. “LOAD” will
and the last station will continue to broadcast.
be displayed until the CD is fully loaded.
ILLUMINATION switching: Press SCAN for more
than 2 seconds to switch radio illumination between green
7. MUTE: Press to mute the playing media; press and amber.
again to cancel. Press and hold for more than two
seconds to enhance bass and treble tones when
listening at low or medium volume. Press and
hold for more than two seconds to deactivate this
feature when listening at higher volumes.
11. Radio preset stations 1–6: Press BAND to select the
frequency band. Automatic preset: Stores the strongest
stations as stored by the SCAN function. Manual preset:
126 3812586R1
Entertainment Systems
Press TUNE/SEEK to manually find a station to be stored 14. If the radio does not respond when any of the buttons are
and pressing and holding one of the preset station buttons pressed, press the reset using a small pointed object such
until the display blinks once. as a pencil point or similar object. Pressing the reset will
erase all preset radio stations, clock and alarm settings.
In CD mode: press preset 4 to hear the first 10 seconds of
If resetting the radio does not restore normal operation,
each CD track. Press preset 4 to select a track. Press preset
have your vehicle inspected by your dealer or a qualified
5 to repeat the current CD track. Press again to turn the
technician.
repeat function off. Press preset 6 to randomly play tracks
on the CD. Press again to play the CD tracks in order.
Radio Frequencies
12. MODE: Switches between radio and CD.
AM and FM frequencies are established by the Federal
Communications Commission (FCC) and the Canadian
Radio and Telecommunications Commission (CRTC). Those
frequencies are:
AM - 530, 540–1700, 1710 kHz
13. BAND: Switches between AM, FM, FM2 and WB
(Weather Band). APM: Press BAND for more than FM- 87.7, 87.9–107.7, 107.9 MHz
two seconds to activate Auto Preset Memory; this
will automatically store the six strongest stations Radio Reception Factors
into memory preset 1 through 6. There are three factors that can affect radio reception:
Note: During APM activity • Distance/strength: The further you travel from an FM station,
• When APM is active, only FM2 is available for FM stations. the weaker the signal and the weaker the reception.
• APM does not work in Weather Band mode. • Terrain: Hills, mountains, tall buildings, power lines, electric
fences, traffic lights and thunderstorms can interfere with
• When selecting APM, any existing preset stations will be your reception.
erased in favor of the automatically selected stations.
3812586R1 127
Entertainment Systems
• Station overload: When you pass a broadcast tower, a • Inspect discs before playing. Clean only with an approved
stronger signal may overtake a weaker one and play while CD cleaner and wipe from the center out.
the weak station frequency is displayed.
Don’t:
Cassette/Player Care • Expose discs to direct sunlight or heat sources for extended
periods of time.
Do:
• Clean using a circular motion.
• Use only cassettes that are 90 minutes long or less.
CD units are designed to play commercially pressed 4.75
• Tighten very loose tapes by inserting a finger or pencil into
inch (12 cm) audio compact discs only. Due to technical
the hole and turning the hub.
incompatibility, certain recordable and re-recordable
• Remove loose labels before inserting tapes. compact discs may not function correctly when used in
the CD players. Irregular shaped CDs, CDs with a scratch
• Allow tapes which have been subjected to extreme heat,
protection film attached, and CDs with homemade paper
humidity or cold to reach a moderate temperature before
(adhesive) labels should not be inserted into the CD player.
playing.
The label may peel and cause the CD to become jammed.
• Clean the cassette player head with a cassette cleaning It is recommended that homemade CDs be identified with
cartridge after 10–12 hours of play to maintain good permanent felt tip marker rather than adhesive labels. Ball
sound/operation. point pens may damage CDs. Please contact your dealer
for further information.
Don’t:
• Expose tapes to direct sunlight, extreme humidity, heat or Audio System Warranty and Service
cold.
Refer to the Warranty Guide for audio system warranty
• Leave tapes in the cassette player for a long time when not information. If service is necessary, see your dealer or qualified
being played. technician.
128 3812586R1
Customer Assistance
3812586R1 129
Customer Assistance
Finally, through Performance PM, customers can obtain a * International provides Optional Service Contracts, Custom
comprehensive preventative maintenance program designed to Service Contracts, and Performance PM designed to assure
ensure consistency in pricing and the level of service received. the lowest possible cost of ownership
* Optional Service Contracts have been pre-packed by
ADVANTAGES of International Warranties
International to fit most common applications
* Extends warranty protection to specified length and
* Custom Service Contracts are designed to meet your
component coverage to suit individual needs
individual needs
* Honored at over 1,000 International Dealer locations in
North America HOW TO OBTAIN International Warranties
* Stabilized and predictable maintenance costs * Standard Warranty: Your new International vehicle is
automatically registered in the International Warranty
* Increased owner confidence and peace of mind
system at the time of delivery. No further action on your part
* Improved resale value on your vehicle – International is required.
Warranties are transferable for a nominal fee
* Optional Service Contracts, Custom Service Contracts,
* Most coverage is 100% parts and labor with NO or Performance PM: These programs are sold exclusively
DEDUCTIBLES through your International Dealer. To be eligible, your
vehicle must have been delivered less than six months ago
* International offers a customized warranty program to suit
and still be covered under the Standard Warranty. If you
your needs – your specification – your vocation
would like the predictable cost of ownership and peace
* International, North America’s leader in truck manufacturing, of mind provided by the International Warranty Program,
is also North America’s leader in warranty value please contact your International Dealer today!
130 3812586R1
Index
SECTION 8 — INDEX
A B
ABS Warning Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Backing up/Electric Back-up Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Add Layers of Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Body:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Adding Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Brake Fluid Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Adjusting Automatic Transmission Fluid Levels. . . . . . . . . . . . . . . .85 Brake System - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
ADVANTAGES of International Warranties. . . . . . . . . . . . . . . . . . . .130 Brake Fluid Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Air Conditioning System Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Hydraulic Brakes - Brake Lines, Hoses And Fittings. . . . . . . .75
Air Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Hydraulic Brakes - Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Air Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 Hydraulic brakes - Fluid Precautions. . . . . . . . . . . . . . . . . . . . . . . . . .74
Air Intake Piping Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 Hydraulic Brakes - General Inspection And Adjustment. . . .74
Air Intake System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Aluminum Disc Wheels with Flange Nuts (Hub Piloted). . . . . . .97 Brake-Shift Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
AM/FM Stereo (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
AM/FM Stereo/Cassette (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . .123 Antilock Brake System (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
AM/FM Stereo/CD (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 ABS Warning Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Antilock Brake System (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Using ABS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
ABS Warning Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Using ABS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Hydraulic Brake Booster System (HydroBoost). . . . . . . . . . . . . .55
Assistance Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 If Brakes Do Not Grip Well. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Audio System Warranty and Service. . . . . . . . . . . . . . . . . . . . . . . . . . .128 Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Automatic Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Bright Metal Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Brake-Shift Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Bulb Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
If Vehicle Gets Stuck In Mud Or Snow. . . . . . . . . . . . . . . . . . . . . . . .61 Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Understanding Shift Positions of the 5–speed Automatic
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 C
Automatic Transmission Fluid Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Cab Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Axle Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Cab/Fuel Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Canadian Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Care of Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
3812586R1 131
Index
C (CONT.) D
Care Of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Daytime Running Lamps (DRL) (If Equipped). . . . . . . . . . . . . . . . . .30
Bright Metal Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Disc Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Plastic Bumper and Side Skirt Protection. . . . . . . . . . . . . . . . . . . . .71 Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Upholstery Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Driver Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Washing and Waxing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Cassette/Player Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Power Windows (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Cautions and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Regeneration Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
CD/CD Player Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Speed Control (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Chassis Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Tilt/Telescope Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Chassis-Mounted Charge Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . .89 Windshield Wiper/Washer Controls. . . . . . . . . . . . . . . . . . . . . . . . . . .33
Air Intake Piping Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 Dual Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Checking Automatic Transmission Fluid. . . . . . . . . . . . . . . . . . . . . . . . .83
Adjusting Automatic Transmission Fluid Levels. . . . . . . . . . . . . .85 E
Correct Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
High Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Electrical System Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Low Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Checking Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Checking Engine Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Electrical System Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Engine Oil and Filter Recommendations. . . . . . . . . . . . . . . . . . . . . .77 Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Checking Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Emission Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Climate Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Verification of Inspection — Noise Emissions. . . . . . . . . . . . . . . . .4
Heater and Air Conditioning System (Optional). . . . . . . . . . . . . .28 Engine and Driveline System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Heater Only System (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Engine and Subsystem Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Air Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Combination Lap and Shoulder Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Air Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Component Code Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Connecting the Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Coolant Concentration Freeze point. . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Cooling System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Adding Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Correct Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Checking Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Coolant Concentration Freeze point. . . . . . . . . . . . . . . . . . . . . . . . . . .79
132 3812586R1
Index
E (CONT.) F (CONT.)
Engine Coolant (cont.) Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Engine Coolant Capacities and Part Numbers. . . . . . . . . . . . . . .79 Fuel and Lubricant Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Extended Life Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Fan Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Fuel Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Recycled Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Fueling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Engine Coolant Capacities and Part Numbers. . . . . . . . . . . . . . . . . .79 Reserve Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Running Out of Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Checking Engine Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Hazards Of Diesel Fuel/Gasoline Blends. . . . . . . . . . . . . . . . . . . . .88
Engine Oil and Filter Recommendations. . . . . . . . . . . . . . . . . . .77 Ultra Low Sulfur Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . . . .87
Engine Oil and Filter Recommendations. . . . . . . . . . . . . . . . . . . . . . . .77 Unacceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Engine Start with Parking Brake(s) Applied. . . . . . . . . . . . . . . . . . . . .12 Fuel and Lubricant Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Exhaust Filter Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Fuel Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Parked Regeneration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Regeneration Inhibit Switch (Optional). . . . . . . . . . . . . . . . . . . . . . . .53 Fuel Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Exhaust System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Fueling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Extended Life Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Reserve Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Exterior Noise Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Running Out of Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90, 116
F Power Distribution Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Fan Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Relay Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Fog Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 G
Frame and Tow Hooks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Front Axle - General Service Information. . . . . . . . . . . . . . . . . . . . . . . .71 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Toe-In Setting - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . .72 General Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Front Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Backing up/Electric Back-up Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Parking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Front Safety Belt Height Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Gross Axle Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Axle Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Front Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Vehicle Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
3812586R1 133
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H I (CONT.)
Hazard Flasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Instructions For Proper Maintenance (cont.)
Hazards Of Diesel Fuel/Gasoline Blends. . . . . . . . . . . . . . . . . . . . . . . .88 Engine and Driveline System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Headlamp Aim Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 Exhaust System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Headlamp Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Daytime Running Lamps (DRL) (If Equipped). . . . . . . . . . . . . . . .30 Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Fog Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Warning Lights and Chimes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Panel Dimmer Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Interior Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Heater and Air Conditioning System (Optional). . . . . . . . . . . . . . . . .28 International Customer Security Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operating Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Add Layers of Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Heater Only System (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Layer 1: Common Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operating tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Layer 2: Visible or Audible Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
High Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Layer 3: Vehicle Immobilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
HOW TO OBTAIN International Warranties. . . . . . . . . . . . . . . . . . .130 Layer 4: Tracking System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Hydraulic Brake Booster System (HydroBoost). . . . . . . . . . . . . . . . .55 International® Warranty Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Hydraulic Brakes - Brake Lines, Hoses And Fittings. . . . . . . . . . .75 ADVANTAGES of International Warranties. . . . . . . . . . . . . . . . .130
Hydraulic Brakes - Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 HOW TO OBTAIN International Warranties. . . . . . . . . . . . . . . . .130
Hydraulic brakes - Fluid Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Hydraulic Brakes - General Inspection And Adjustment. . . . . . .74 J
Jump Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
I Jump Starting Your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
If Brakes Do Not Grip Well. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Connecting the Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
If Vehicle Gets Stuck In Mud Or Snow. . . . . . . . . . . . . . . . . . . . . . . . . . .61 Jump Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Preparing Your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Checking Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Removing the Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Under Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 K
Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Instructions For Proper Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Air Intake System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 L
Body:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Lap Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Cooling System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Layer 1: Common Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
134 3812586R1
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Layer 2: Visible or Audible Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Lubrication and Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . .103
Layer 3: Vehicle Immobilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Layer 4: Tracking System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 M
Bulb Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Hazard Flasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Headlamp Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Lubrication and Maintenance Interval Chart — Recommended
Interior Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Synchronized Intervals Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Turn Signal Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Lubrication and Maintenance Interval Chart Symbols Key
Line Set Ticket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Matching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Lock and Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Dual Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Power Door Locks (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Mixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Remote Entry System (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . .39
Locking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 N
Replacing Lost Remote Entry Transmitters. . . . . . . . . . . . . . . .40 Noise Emissions — Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Replacing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Instructions For Proper Maintenance. . . . . . . . . . . . . . . . . . . . . . . . .92
Sounding a Panic Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Air Intake System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Unlocking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Body:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Locking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Cooling System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Low Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Engine and Driveline System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10, 76 Exhaust System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Lubricant and Sealer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Lubricant and Sealer Specifications Table. . . . . . . . . . . . . . . . . .113 O
Lubricant and Sealer Specifications Table. . . . . . . . . . . . . . . . . . . . .113
Operating tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Lubrication and Maintenance Interval Chart — Recommended
Operating Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Synchronized Intervals Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Optional Engine Protection System — 3 Way (08WPP). . . . . . .48
Lubrication and Maintenance Interval Chart Symbols Key
Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
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Panel Dimmer Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Rear Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Parked Regeneration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Parking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Rear Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56, 75 Rear Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Plastic Bumper and Side Skirt Protection. . . . . . . . . . . . . . . . . . . . . . .71 Recycled Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Positions Of The Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Power Distribution Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 Regeneration Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Power Door Locks (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Regeneration Inhibit Switch (Optional). . . . . . . . . . . . . . . . . . . . . . . . . .53
Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Relay Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Power Steering Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 Remote Entry System (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Power Take Off Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Locking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Power Windows (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Replacing Lost Remote Entry Transmitters. . . . . . . . . . . . . . . . . . .40
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1, 67 Replacing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Cab Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Sounding a Panic Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Chassis Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Unlocking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Removing the Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Supporting Your Vehicle for Service. . . . . . . . . . . . . . . . . . . . . . . . . . .69 Replacing Lost Remote Entry Transmitters. . . . . . . . . . . . . . . . . . . . .40
Preparing Your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Replacing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Propeller Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Canadian Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
R Safety Recalls and Authorized Field Changes. . . . . . . . . . . . . . . . .5
Radio Frequencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 U.S. Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Audio System Warranty and Service. . . . . . . . . . . . . . . . . . . . . . . .128 Reserve Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Cassette/Player Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Restarting After Running Out Of Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . .48
CD/CD Player Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Radio Reception Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 Rotation Is Always Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Radio Reception Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 Rotation May Not Be Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rear Axle - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Rotation Is Always Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rear Axle Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Rotation May Not Be Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rear Axle Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Running Out of Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
136 3812586R1
Index
S S (CONT.)
Safety Belt Warning Light And Indicator Chime. . . . . . . . . . . . . . . .46 Steering - General Inspection (cont.)
Safety Recalls and Authorized Field Changes. . . . . . . . . . . . . . . . . . .5 Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Seat Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Tightening Steering Column Joint Bolts. . . . . . . . . . . . . . . . . . . . . . .82
Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Supporting Your Vehicle for Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Care of Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Suspension Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Combination Lap and Shoulder Belts. . . . . . . . . . . . . . . . . . . . . . . . .44
Front Safety Belt Height Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . .45 T
Lap Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Tampering With Noise Control System Prohibited. . . . . . . . . . . . . . .3
Safety Belt Warning Light And Indicator Chime. . . . . . . . . . . . . .46 Tightening Steering Column Joint Bolts. . . . . . . . . . . . . . . . . . . . . . . . .82
Vehicle Sensitive Retractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Tilt/Telescope Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Seating and Occupant Restraints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Tilting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9, 76
Seat Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Tilting/Lowering Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9, 76
Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10, 76
Care of Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Tilting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9, 76
Combination Lap and Shoulder Belts. . . . . . . . . . . . . . . . . . . . . . .44 Tire/Wheel Rim Selection And Inflation Pressures. . . . . . . . . . . .109
Front Safety Belt Height Adjustment. . . . . . . . . . . . . . . . . . . . . . . .45 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Lap Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Safety Belt Warning Light And Indicator Chime. . . . . . . . . . .46 Checking Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Vehicle Sensitive Retractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Under Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Sounding a Panic Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Speed Control (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Matching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Spring U-Bolt Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Dual Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Mixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Optional Engine Protection System — 3 Way (08WPP). . . .48 Rotation Is Always Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Positions Of The Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Rotation May Not Be Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . .101
Restarting After Running Out Of Fuel. . . . . . . . . . . . . . . . . . . . . . . . .48 Use Of Tire Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Tires — Irregular Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Steering - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Wheel And Tire Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
3812586R1 137
Index
T (CONT.) U (CONT.)
Tires — Irregular Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Understanding Shift Positions of the 5–speed Automatic
Toe-In Setting - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Unlocking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Disc Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Upholstery Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Spring U-Bolt Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Use Of Tire Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Using ABS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Tow Hooks (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Towing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 V
Tow Hooks (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Vehicle Entry and Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Towing Vehicle With Front Wheels Suspended. . . . . . . . . . . . . .65 Vehicle Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Towing Vehicle With Rear Wheels Suspended. . . . . . . . . . . . . . .66 Vehicle Sensitive Retractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Towing Vehicle With Front Wheels Suspended. . . . . . . . . . . . . . . . .65 Vehicle Storage Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Towing Vehicle With Rear Wheels Suspended. . . . . . . . . . . . . . . . .66 Verification of Inspection — Noise Emissions. . . . . . . . . . . . . . . . . . . .4
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Transmission Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 W
Automatic Transmission Fluid Filter. . . . . . . . . . . . . . . . . . . . . . . . . . .85 Warning Lights and Chimes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Checking Automatic Transmission Fluid. . . . . . . . . . . . . . . . . . . . . .83 Washing and Waxing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Adjusting Automatic Transmission Fluid Levels. . . . . . . . . . .85 Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Correct Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Tires — Irregular Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
High Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Wheel And Tire Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Low Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Wheel Installation, Tightening And Alignment. . . . . . . . . . . . . . . . . .95
Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Wheel Mounting Nuts Torque Sequence. . . . . . . . . . . . . . . . . . . . . . . .97
Turn Signal Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Aluminum Disc Wheels with Flange Nuts (Hub Piloted). . . .97
U General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
U.S. Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Wheel Installation, Tightening And Alignment. . . . . . . . . . . . . . . .95
Ultra Low Sulfur Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Wheel Mounting Nuts Torque Sequence. . . . . . . . . . . . . . . . . . . . . .97
Unacceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Windshield Washer Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Under Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Windshield Wiper/Washer Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Under Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
138 3812586R1
CALIFORNIA
Proposition 65 Warning