60K Service

Complete 60,000 mile service including all fluid changes, filters, and inspection of major components for the 5.9L Cummins diesel engine and 4WD drivetrain.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Mopar 5083285AA or equivalent
• Fuel filter/water separator assembly × 1 — Mopar 5083285AB or equivalent
• Air filter element × 1 — Use OEM specification
• Cabin air filter (if equipped) × 1 — Use OEM specification
• Automatic transmission filter kit × 1 — Mopar 5013470AA or equivalent
• Transmission pan gasket × 1 — Use OEM specification
• Front differential cover gasket × 1 — Use OEM specification or RTV sealant
• Rear differential cover gasket × 1 — Use OEM specification or RTV sealant
• Transfer case drain plug gasket × 1 — Use OEM specification
• Drive belt(s) × 1 — Inspect and replace if worn

Fluids

• 15W-40 diesel engine oil — 12 qt
• Mopar ATF+4 (transmission) — 14 qt
• 75W-90 synthetic gear oil (front differential) — 3.5 qt
• 75W-90 synthetic gear oil (rear differential) — 5.5 qt
• Mopar ATF+4 (transfer case) — 4.5 qt
• Ethylene glycol 50/50 coolant — 28 qt
• Chassis grease (NLGI Grade 2) — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine and drivetrain to cool completely if recently operated
3. Gather all required fluids, filters, and gaskets before beginning work
4. Raise vehicle safely using floor jack and support with jack stands at frame rails
5. Remove skid plates if equipped to access drain plugs and filters
6. Place wheel chocks behind rear wheels for additional safety

Procedure

1. 1

   Engine oil and filter change
   Position drain pan under oil pan. Remove drain plug from bottom of oil pan and allow oil to drain completely (approximately 15-20 minutes for full drainage). Remove oil filter using filter wrench - filter is located on driver side of engine block. Clean oil filter mounting surface. Apply thin film of clean oil to new filter gasket. Install new filter hand-tight plus 3/4 turn. Reinstall drain plug and fill engine with approximately 11-12 quarts of 15W-40 diesel engine oil (verify capacity for your engine variant) through oil fill cap on valve cover.
2. 2

   Fuel filter/water separator replacement
   Locate fuel filter housing on driver side of engine. Place drain pan underneath. Open water drain valve at bottom of filter housing and drain any water and fuel. Use fuel filter wrench to remove filter canister by turning counterclockwise. Remove and discard old filter element. Clean inside of housing canister. Install new filter element and transfer the water-in-fuel sensor to the new element (reuse unless damaged), using the appropriate socket for the sensor. Fill new filter housing with clean diesel fuel before installation to prevent air from entering system. Thread canister onto housing hand-tight. Prime fuel system using lift pump primer on filter housing (approximately 50-100 pumps until firm resistance felt).
   ⚠Do not start engine until fuel system is properly primed. Air in fuel system can cause difficult starting and potential injection pump damage.
3. 3

   Air filter replacement
   Open hood and locate air filter housing (typically on the driver side front of engine bay - verify location for your model year). Release clamps securing air filter housing cover. Remove cover and extract old air filter element. Inspect housing for debris and clean if necessary using shop rag. Install new air filter element ensuring proper seating in housing. Reinstall cover and secure all clamps.
4. 4

   Automatic transmission service
   Position large drain pan under transmission pan. Loosen all transmission pan bolts but do not remove. Carefully pry one corner of pan down to allow fluid to drain slowly. Once fluid flow slows, remove all pan bolts and lower pan completely. Remove old filter by pulling straight down from valve body. Clean pan thoroughly, removing all gasket material and magnet debris. Install new filter by pushing firmly into valve body until seated. Install new gasket on pan. Reinstall pan and tighten bolts in criss-cross pattern to proper specification. Fill transmission through dipstick tube with approximately 4-6 quarts of the specified ATF (ATF+4 for later models; verify correct spec such as Mopar 7176/ATF+3 for earlier years) initially. Start engine, shift through all gears, then check level with engine running in Park on level ground. Add additional fluid to bring level to proper mark (a pan-drop service typically requires only 4-6 quarts; full dry fill capacity is much higher).
   ℹ️Transmission fluid level must be checked with engine running at operating temperature. Initial fill is only partial to prevent overfilling.
5. 5

   Front differential service
   Position drain pan under front differential. Remove fill plug first (upper plug on cover or side of housing) to ensure it is not seized before draining. Remove drain plug from bottom of differential cover and allow fluid to drain completely. If differential has cover bolts rather than drain plug, loosen cover bolts gradually to allow fluid to drain. Remove cover completely if applicable. Clean cover and housing mating surfaces, removing all old gasket material. Install new gasket or apply thin bead of RTV sealant to cover. Reinstall cover or drain plug. Using fluid pump, fill differential through fill hole with 75W-90 synthetic gear oil until fluid reaches bottom of fill hole (approximately 2.5-3.0 quarts depending on axle; verify for your axle). Reinstall fill plug.
6. 6

   Rear differential service
   Position drain pan under rear differential. Remove fill plug first (located on front of differential housing) to verify accessibility. Remove drain plug from bottom of differential cover and drain fluid completely. If equipped with cover bolts, loosen bolts gradually and remove cover. Clean all gasket surfaces thoroughly. Apply new gasket or RTV sealant to cover. Reinstall cover or drain plug. Using fluid pump, fill through fill hole with 75W-90 synthetic gear oil until fluid reaches bottom of fill hole (approximately 3.0-4.0 quarts depending on Dana 70/80 axle; fill to bottom of fill hole and verify for your axle). If equipped with limited slip differential, ensure gear oil contains proper limited slip additive. Reinstall fill plug.
7. 7

   Transfer case service
   Locate transfer case mounted behind transmission. Position drain pan underneath. Remove fill plug from side of transfer case first. Remove drain plug from bottom of case and allow fluid to drain completely. Inspect drain plug magnet for metal shavings (slight fuzz is normal, chunks indicate wear). Clean drain plug. Install new drain plug gasket and reinstall plug. Using fluid pump, fill transfer case through fill hole with the specified transfer case fluid (typically Mopar ATF+4/NV273 fluid - verify for your case) until fluid reaches bottom of fill hole (approximately 1.5-2.0 quarts). Reinstall fill plug.
8. 8

   Cooling system service
   Ensure engine is completely cool. Place large drain pan under radiator. Remove radiator cap slowly to release any residual pressure. Open radiator drain petcock at bottom of radiator or remove lower radiator hose to drain coolant. Once drained, close petcock or reinstall hose. If performing flush, refill with water, run engine briefly, drain again, and repeat. Fill cooling system through radiator cap with the correct 50/50 coolant for your model year (conventional green for early years, HOAT for 2002+) or mix concentrate with distilled water. Verify system capacity for your model year. Fill radiator completely, then fill overflow reservoir to proper level. Start engine and allow to reach operating temperature with radiator cap off. Add additional coolant as needed while engine warms and air purges from system. Once at operating temperature and thermostat opens, top off radiator and install cap. Check for leaks.
   ⚠️Never remove radiator cap when engine is hot. Pressurized coolant can cause severe burns.
   ℹ️Verify correct coolant type for your model year. Do not mix green conventional and HOAT coolant types.
9. 9

   Chassis lubrication
   Using grease gun, lubricate all chassis grease fittings that are present (note many components may be factory-sealed and non-greasable): check front suspension ball joints, tie rod ends, drag link, track bar, and driveshaft U-joints for zerk fittings, greasing only those equipped. Verify actual fitting locations and counts for your specific vehicle. Pump grease until fresh grease appears at joint seals or until resistance increases significantly. Wipe excess grease from fittings. Inspect all dust boots for tears or damage during lubrication.
   ℹ️Some grease fittings may be difficult to access and require angled grease gun attachment. Sealed components do not have fittings and cannot be greased.
10. 10

    Drive belt inspection and adjustment
    Inspect serpentine belt or V-belts for cracks, glazing, fraying, or missing ribs. Check belt tension by pressing firmly on longest span - deflection should be approximately 1/2 inch. If equipped with automatic tensioner, inspect tensioner for proper operation and wear indicators. If equipped with manual adjustment, loosen adjustment bolts and move alternator or other component to achieve proper tension, then retighten. Replace belt if showing signs of wear or damage. Check all pulleys for wobble or noise indicating bearing wear.
11. 11

    Brake system inspection
    Inspect brake fluid level in master cylinder reservoir and top off with the specified brake fluid (DOT 3 or DOT 4 per reservoir cap marking) if needed. Inspect brake fluid condition - if dark or contaminated, recommend full brake fluid flush. Remove wheels and inspect brake pads for remaining thickness (replace if less than 3mm). Inspect rotors for scoring, heat cracks, or excessive wear. Check brake lines and hoses for cracks, bulging, or corrosion. Inspect caliper slide pins and boots for proper lubrication and damage. Reinstall wheels.
    ⚠Do not allow brake fluid to contact painted surfaces. Clean immediately if spilled.
12. 12

    Additional inspections
    Inspect all steering and suspension components for wear, damage, or looseness including ball joints, tie rod ends, control arm bushings, and track bar. Check for fluid leaks at engine, transmission, differentials, transfer case, and axle seals. Inspect exhaust system for leaks, damage, or loose hangers. Check battery terminals for corrosion and clean if necessary. Inspect all lights for proper operation. Check tire pressure and adjust to specification on door placard. Inspect tires for abnormal wear patterns indicating alignment issues.

Reassembly

1. Reinstall any skid plates or protective covers removed during service
2. Lower vehicle from jack stands safely
3. Reset maintenance reminder light if equipped by cycling key on-off three times or using factory procedure
4. Double-check all drain plugs and fill plugs are properly tightened
5. Verify all fluid levels one final time with vehicle on level ground

Verification

• Start engine and verify no warning lights are illuminated on instrument cluster
• Check for any fluid leaks under vehicle after 5 minutes of running
• Verify engine oil pressure is normal (gauge should show pressure immediately after starting)
• Test drive vehicle for 5-10 miles and recheck all fluid levels
• Check transmission fluid level with engine at operating temperature in Park
• Verify smooth shifting through all transmission gears
• Listen for any unusual noises from engine, transmission, or drivetrain
• Inspect ground under vehicle after test drive for any new leaks
• Record service date and mileage in maintenance log

More procedures for this vehicle