60K Service

Complete 60,000 mile service including oil change, fuel filter replacement, transmission service, differential services, transfer case service, air filter replacement, and full inspection of critical systems.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Mopar 68197867AA or equivalent
• Fuel filter assembly with water separator × 1 — Mopar 68197867AB or equivalent
• Engine air filter × 1 — Use OEM specification
• Cabin air filter (if equipped) × 1 — Use OEM specification
• Transmission pan gasket or RTV sealant × 1 — Use OEM specification
• Front differential fill plug gasket × 1 — Use OEM specification
• Rear differential fill plug gasket × 1 — Use OEM specification
• Transfer case gasket/seal × 1 — Use OEM specification

Fluids

• 15W-40 diesel oil or 5W-40 synthetic — 12 qt
• ATF+4 — 10 qt
• 75W-90 synthetic gear oil (front diff) — 3.5 qt
• 75W-90 synthetic gear oil (rear diff) — 5.5 qt
• ATF+4 (transfer case) — 2.5 qt

Preparation

1. Park vehicle on level ground and allow engine to cool completely for at least 2 hours
2. Gather all fluids, filters, and tools before beginning
3. Place wheel chocks behind rear wheels
4. Raise front of vehicle using floor jack and secure with heavy-duty jack stands on frame rails
5. Raise rear of vehicle and secure with jack stands to allow access to differentials
6. Verify vehicle is stable and cannot roll or fall
7. Place drain pans under vehicle in preparation for oil change

Procedure

1. 1

   Engine oil and filter service
   Locate oil drain plug on bottom of oil pan. Remove drain plug and allow oil to drain completely (approximately 11 quarts). While oil drains, remove oil filter located on driver side of engine block using oil filter wrench. Clean filter mounting surface. Apply thin film of clean oil to new filter gasket. Install new oil filter hand-tight plus 3/4 turn. Once oil has completely drained, reinstall drain plug. Fill engine with 11 quarts of 15W-40 diesel oil or 5W-40 synthetic through fill cap on valve cover.
2. 2

   Fuel filter replacement
   Locate fuel filter assembly mounted on the engine (canister-style water separator on the driver side of the engine). Place drain pan underneath. Open drain valve on bottom of water separator bowl and drain completely (approximately 1-2 cups). Disconnect electrical connector from water-in-fuel sensor. Use fuel filter wrench to remove entire filter assembly by turning counterclockwise. Clean mounting surface on filter head. Fill new fuel filter assembly with clean diesel fuel to pre-prime system. Apply clean diesel fuel to gasket on new filter. Install new filter assembly and tighten securely by hand. Reconnect water-in-fuel sensor connector. After starting engine (in verification phase), check for leaks.
3. 3

   Air filter replacement
   Open hood and locate air filter housing on passenger side of engine bay. Release clamps on air filter housing. Remove housing cover and lift out old air filter element. Clean inside of housing with damp cloth, removing any debris. Inspect housing for cracks or damage. Install new air filter element ensuring proper seating in housing. Reinstall housing cover and secure clamps. If equipped with cabin air filter, locate filter access panel behind glove box, remove panel, slide out old filter, and install new cabin filter with airflow arrow pointing in correct direction.
4. 4

   Transmission service (partial drain and fill)
   Locate transmission pan underneath vehicle. For the 48RE automatic: Position large drain pan underneath transmission. Remove transmission pan bolts gradually, starting from one corner, allowing fluid to drain (approximately 5-6 quarts will drain). (Skip if equipped with G56 manual transmission.) Once drained, remove pan completely. Clean pan thoroughly and inspect for metal debris or clutch material. Clean magnet in pan. If using gasket, install new gasket on pan. If using RTV, clean surfaces completely and apply thin bead of RTV. Reinstall transmission pan with all bolts. If equipped with the 48RE automatic, fill transmission through dipstick tube with 5-6 quarts of ATF+4 to replace what was drained. If equipped with the G56 manual transmission, this ATF+4 pan procedure does not apply — service per manual transmission fluid specification instead. Check level with engine running in park after reaching operating temperature.
5. 5

   Front differential service
   Locate front differential on front axle assembly. Clean area around fill plug (upper) and drain plug (lower) with wire brush. Remove fill plug first to ensure it's not seized before draining. Position drain pan under differential. Remove drain plug and allow gear oil to drain completely (approximately 3.0 quarts). Inspect drained fluid for metal particles or unusual color. Once drained, clean and reinstall drain plug with new gasket if applicable. Using fluid pump, fill differential through fill hole with 75W-90 synthetic gear oil until fluid reaches bottom of fill hole opening. Reinstall fill plug with new gasket.
6. 6

   Rear differential service
   Locate rear differential on rear axle assembly. Clean area around fill plug (on side of housing) and drain plug (bottom of housing). Remove fill plug first to ensure it's not seized. Position drain pan under differential. Remove drain plug (if equipped) and allow gear oil to drain completely (AAM 11.5" rear axle holds approximately 4.0 quarts; verify axle type and capacity). Inspect drained fluid for metal particles indicating wear. Clean drain plug and reinstall with new gasket if applicable. Using fluid pump, fill differential through fill hole with 75W-140 synthetic gear oil (add limited-slip additive if equipped with LSD) until fluid begins to seep from fill hole. Allow to settle and top off until full. Reinstall fill plug with new gasket.
7. 7

   Transfer case service
   Locate transfer case mounted to rear of transmission. Clean area around fill plug (on side) and drain plug (bottom). Remove fill plug first to verify accessibility. Position drain pan underneath transfer case. Remove drain plug and allow ATF+4 to drain completely (approximately 2.0 quarts). Inspect drained fluid for debris or contamination. Clean and reinstall drain plug with new gasket or seal. Using fluid pump, fill transfer case through fill hole with approximately 2.0 quarts of ATF+4 until fluid reaches bottom of fill hole. Reinstall fill plug with new gasket.
8. 8

   Grease all fittings
   Using grease gun loaded with multipurpose chassis grease, locate and grease all fittings including: front suspension ball joints if equipped with grease fittings (up to 4 total; many factory ball joints are sealed and non-greasable), tie rod ends (4 total), steering linkage fittings (multiple locations), driveshaft U-joints if equipped with grease fittings (typically up to 4; many factory U-joints are sealed and non-greasable), and any other grease fittings found during inspection. Pump grease into each fitting until fresh grease appears at seal or fitting begins to resist. Wipe excess grease from fittings. Inspect boots and seals for damage during greasing.
9. 9

   Inspect belts, hoses, and fluid levels
   Visually inspect serpentine belt for cracks, glazing, or fraying. Check belt tension. Inspect all coolant hoses for cracks, soft spots, or leaks. Check heater hoses and clamps. Inspect all air intake boots for cracks or loose clamps. Check power steering reservoir level and top off with ATF+4 if needed. Check brake fluid level and top off with DOT 3 if needed (do not overfill). Check coolant level in overflow tank and top off with 50/50 Mopar HOAT (Zerex G-05) coolant if needed. Check windshield washer fluid and fill to full mark.
10. 10

    Tire rotation and inspection
    With vehicle already raised on jack stands, inspect all tires for wear, damage, and proper tread depth (minimum 4/32"). Check for uneven wear patterns. Rotate tires according to 4WD rotation pattern: move front tires straight to rear on same side, move rear tires to opposite front positions (left rear to right front, right rear to left front). After rotation, torque all wheel lug nuts to proper specification in star pattern. Check tire pressures when cold and adjust to door placard specifications.
11. 11

    Brake system inspection
    With wheels removed for rotation, inspect brake pads for remaining thickness (minimum 3mm). Check brake rotors for scoring, cracking, or excessive wear. Inspect brake calipers for leaks or seized slide pins. Check brake hoses for cracks, bulging, or leaks. Inspect brake lines for corrosion or damage. Check parking brake cables for fraying or binding. Measure rotor thickness and compare to specifications if wear is suspected.
12. 12

    Underbody and exhaust inspection
    With vehicle on jack stands, perform thorough inspection of underbody. Check frame for rust, damage, or cracks. Inspect exhaust system from manifold to tailpipe for leaks, rust-through, or loose hangers. Check for exhaust leaks at turbocharger connections. Inspect fuel tank for damage or leaks. Check brake lines and fuel lines along frame for corrosion or chafing. Inspect skid plates and protective covers for damage. Check steering components for play or damage.

Reassembly

1. Lower vehicle carefully from jack stands, one axle at a time
2. Double-check that all drain plugs, fill plugs, and filters are properly installed and tightened
3. Remove all tools and equipment from under vehicle before lowering
4. Start engine and allow to idle, checking for leaks at oil filter, fuel filter, and all drain plugs
5. Check transmission fluid level with engine at operating temperature in park
6. Test drive vehicle 5-10 miles and recheck all fluid levels after cool-down
7. Reset maintenance reminder if equipped

Verification

• Start engine and verify oil pressure gauge shows normal pressure within 5 seconds
• Check for leaks around oil filter, oil drain plug, fuel filter, and all differential/transfer case plugs
• Verify no warning lights on dash related to water-in-fuel or low fluid levels
• Check transmission fluid level at operating temperature - should read in HOT range on dipstick
• Test drive vehicle and verify smooth shifting, no unusual noises from differentials or transfer case
• Verify all tires are properly torqued and no vibrations present
• Recheck all fluid levels after test drive and vehicle has sat for 5 minutes
• Verify proper operation of all greased components with no binding or unusual noise
• Document all findings and fluid conditions for maintenance records

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