100K Service

Complete 100,000 mile service including oil change, filter replacements, fluid inspections, drivetrain service, and comprehensive system checks for the 5.9L Cummins diesel.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Mopar 5083285AA or equivalent
• Fuel filter/water separator assembly × 1 — Mopar 68197867AA or equivalent
• Engine air filter × 1 — Use OEM specification
• Cabin air filter (if equipped) × 1 — Use OEM specification
• Transmission filter kit (automatic) × 1 — Use OEM specification
• Transmission pan gasket (automatic) × 1 — Use OEM specification
• Front differential fill plug gasket × 1 — Use OEM specification
• Rear differential fill plug gasket × 1 — Use OEM specification
• Rear differential drain plug gasket × 1 — Use OEM specification
• Transfer case fill/drain plug gasket × 2 — Use OEM specification

Fluids

• 15W-40 diesel engine oil or 5W-40 synthetic — 12 qt
• ATF+4 automatic transmission fluid — 6 qt
• 75W-90 synthetic gear oil (front differential) — 3.5 qt
• 75W-90 synthetic gear oil (rear differential) — 5.5 qt
• ATF+4 (transfer case) — 2.5 qt

Preparation

1. Park vehicle on level surface and allow engine to cool completely (minimum 2 hours)
2. Chock rear wheels securely
3. Disconnect negative battery cable to reset service intervals if applicable
4. Raise front of vehicle with floor jack and support with jack stands under frame rails
5. Raise rear of vehicle and support with jack stands under axle housing or frame
6. Remove skid plates if equipped to access oil pan, fuel filter, and transmission pan
7. Organize drain pans, new filters, fluids, and tools in work area

Procedure

1. 1

   Engine oil and filter service
   Locate the oil drain plug on the driver side of the oil pan. Place drain pan underneath and remove drain plug, allowing oil to drain completely (10-15 minutes). While draining, locate the oil filter on the driver side of the engine block. Use filter wrench to remove old filter (expect residual oil spillage). Clean filter mounting surface thoroughly. Apply thin coat of clean oil to new filter gasket. Verify oil filter part number against current Mopar/Fleetguard catalog for 2007 5.9L Cummins (commonly Fleetguard LF16035 or Mopar equivalent). Install new filter hand-tight plus 3/4 turn. Reinstall drain plug once oil stops dripping. Refill engine with approximately 12 quarts of 15W-40 or 5W-40 diesel oil through fill cap, then verify final level with dipstick.
2. 2

   Fuel filter/water separator replacement
   Locate fuel filter housing on driver side of engine (verify exact location against service manual). Place drain pan underneath. Open water drain valve at bottom of filter housing and drain any water and sediment. Close drain valve. Using appropriate wrench, loosen filter canister and remove old filter assembly. Clean sealing surfaces on filter head. Install new fuel filter/water separator, ensuring O-ring is properly seated. Verify fuel filter/water separator part number against current Mopar catalog for 2007 5.9L Cummins application. Hand-tighten filter until snug, then tighten an additional 1/2 turn. Prime fuel system per service manual procedure (2007 common-rail typically uses key-cycle electric lift pump priming; the hand primer of earlier engines may not be present).
3. 3

   Engine air filter replacement
   Open hood and locate air filter housing on passenger side of engine compartment. Release clamps or fasteners securing air box cover. Remove cover and inspect housing for debris. Remove old air filter element. Clean inside of air box with damp cloth, removing any dirt or debris. Inspect air intake tube and connections for cracks or loose clamps. Install new air filter element ensuring proper seating in housing. Reinstall cover and secure all clamps/fasteners.
4. 4

   Cabin air filter replacement (if equipped)
   Locate cabin air filter access behind glove box or under dash on passenger side. Remove glove box if necessary by squeezing sides to release stops. Remove cabin air filter cover. Slide out old cabin air filter, noting airflow direction arrow. Vacuum out filter housing. Install new cabin air filter with airflow arrow pointing in correct direction (typically toward rear of vehicle). Reinstall cover and glove box.
5. 5

   Automatic transmission service
   Locate transmission pan underneath vehicle (centered under transmission). Position large drain pan underneath. Remove all pan bolts except two at one corner, loosening gradually to allow fluid to drain slowly. Once drained, remove remaining bolts and lower pan carefully. Remove old filter by pulling straight down from valve body. Clean pan thoroughly, removing all gasket material and magnet debris. Inspect magnet for excessive metallic particles (small amount normal). Install new filter, pushing firmly into place. Install new pan gasket on pan. Reinstall pan and torque bolts in criss-cross pattern to manufacturer specification (approximately 13 ft-lbs - consult service manual). Refill transmission with approximately 4-5 quarts ATF+4 through dipstick tube (pan-drop refill), then verify final level per procedure. Start engine, cycle through gears, check level with engine running in park, and add fluid to reach proper mark on hot range.
6. 6

   Front differential service
   Locate front differential fill plug (upper) and drain plug (lower) on differential housing. Clean area around both plugs. Remove fill plug first to ensure it can be removed before draining. Place drain pan underneath and remove drain plug, allowing gear oil to drain completely. Inspect drained fluid for metal particles or contamination. Once drained, reinstall drain plug with new gasket. Using fluid pump, fill differential with 75W-90 synthetic gear oil (approximately 2.5-3 quarts - verify against service manual) through fill hole until fluid reaches bottom of fill hole. Install fill plug with new gasket and torque to specification.
7. 7

   Rear differential service
   Locate rear differential cover or drain plug on bottom of differential and fill plug on front face of differential housing. Clean area around plugs thoroughly. Remove fill plug first to verify accessibility. Place drain pan underneath and remove drain plug (or differential cover bolts if no drain plug). Allow gear oil to drain completely. If removing cover, clean both cover and housing mating surfaces thoroughly, removing all old gasket material. Inspect drained fluid for excessive metal particles. Reinstall drain plug or cover with new gasket. Fill differential with 75W-140 synthetic gear oil (approximately 3.5-4 quarts - verify grade and capacity against service manual) through fill hole using fluid pump until oil level reaches bottom of fill hole. Install fill plug with new gasket.
8. 8

   Transfer case service
   Locate transfer case mounted to rear of transmission. Identify fill plug (on side) and drain plug (on bottom) of transfer case. Clean area around both plugs. Remove fill plug first. Place drain pan underneath and remove drain plug, allowing ATF+4 to drain completely. Inspect fluid for metal particles or contamination. Reinstall drain plug with new gasket. Using fluid pump, fill transfer case with ATF+4 (approximately 2 quarts - verify against service manual) through fill hole until fluid reaches bottom of fill hole. Install fill plug with new gasket.
9. 9

   Coolant system inspection
   With engine cool, remove radiator cap slowly to release any residual pressure. Inspect coolant level in overflow reservoir and radiator. Check coolant condition and color (should be Mopar HOAT coolant, typically orange/red). Use coolant tester to verify freeze protection to at least -34°F. Inspect all coolant hoses for cracks, soft spots, or deterioration. Check hose clamps for tightness. Inspect radiator fins for damage or blockage. Check water pump for leaks around weep hole. Top off coolant with 50/50 HOAT coolant mixture if needed. Reinstall radiator cap. Note: Full coolant flush and replacement recommended if coolant is discolored or contaminated.
10. 10

    Belt and hose inspection
    Inspect serpentine belt for cracks, glazing, fraying, or missing ribs. This engine uses an automatic belt tensioner - inspect the tensioner operation and belt wear indicator rather than measuring manual deflection. Inspect all accessible hoses including radiator hoses, heater hoses, and fuel lines for cracks, soft spots, or deterioration. Check all hose clamps and connections for security. Inspect power steering hoses for leaks or damage. Replace any deteriorated belts or hoses as needed.
11. 11

    Brake system inspection
    Check brake fluid level in master cylinder reservoir. Fluid should be at MAX line and clear amber color (if dark or contaminated, flush recommended). Inspect brake lines and hoses for leaks, damage, or corrosion. Remove wheels and inspect brake pads/shoes for remaining thickness (should have at least 3mm remaining). Check rotors/drums for scoring, cracks, or excessive wear. Inspect calipers for leaks or seized pins. Reinstall wheels and torque lug nuts to specification (approximately 145 ft-lbs - verify SRW vs DRW against service manual).
12. 12

    Chassis lubrication and final inspections
    Using grease gun, lubricate all chassis grease fittings including: ball joints (upper and lower), tie rod ends, drag link ends, track bar ends, U-joints on driveshafts, and slip yoke. Pump grease until fresh grease appears at seals (2-3 pumps typically). Inspect steering components for excessive play or wear. Check suspension components including control arms, sway bar links, and shock absorbers for damage or leaks. Inspect driveshafts for looseness or damaged CV boots. Check exhaust system for leaks, damage, or loose hangers. Inspect tires for wear, proper inflation (refer to door jamb sticker), and uneven wear patterns. Check all fluid levels one final time.

Reassembly

1. Reinstall any skid plates or protective covers removed during service
2. Lower vehicle from jack stands and remove stands from under vehicle
3. Reconnect negative battery cable if disconnected
4. Double-check that all drain plugs, fill plugs, and filters are properly tightened
5. Clean up any spilled fluids from chassis and surrounding area

Verification

• Start engine and verify no oil leaks from filter or drain plug. Allow to reach operating temperature
• Check all fluid levels with engine at operating temperature and verify proper levels
• Test drive vehicle and verify smooth shifting, proper differential operation, and no unusual noises
• After test drive, recheck all fluid levels and inspect underneath for any leaks
• Verify no warning lights on instrument cluster
• Reset oil change indicator if equipped using instrument cluster buttons or scan tool
• Document service performed including mileage, date, and all fluids/filters replaced for maintenance records

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