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CF 500, CF 600

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 Printed in the United States of America


CF 500, CF 600

Printed in the United States of America 3812586R1


Table of Contents

Section 1 – Foreword Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16


Rear Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Rear Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Cautions and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Rear Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Assistance Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Component Code Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Line Set Ticket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Section 3 – Vehicle Controls
Vehicle Storage Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Exterior Noise Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Tampering With Noise Control System Prohibited. . . . . . . . . . . . . . .3 Warning Lights and Chimes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Emission Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Verification of Inspection — Noise Emissions. . . . . . . . . . . . . . .4 Climate Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Heater Only System (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
U.S. Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Heater and Air Conditioning System (Optional). . . . . . . . . . . .28
Canadian Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Safety Recalls and Authorized Field Changes. . . . . . . . . . . . . .5 Headlamp Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
International Customer Security Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Turn Signal Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Hazard Flasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Section 2 – Vehicle Inspection Guide Interior Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Bulb Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Driver Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Tilting/Lowering Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Windshield Wiper/Washer Controls. . . . . . . . . . . . . . . . . . . . . . . . .33
Tilting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Tilt/Telescope Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Power Windows (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Speed Control (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Cab/Fuel Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Regeneration Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Engine Start with Parking Brake(s) Applied. . . . . . . . . . . . . . . . . . . . .12 Lock and Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Power Door Locks (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Front Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Remote Entry System (if equipped). . . . . . . . . . . . . . . . . . . . . . . . .39
Front Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Unlocking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Under Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

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
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Bright Metal Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Power Steering Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83


Upholstery Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Transmission Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Plastic Bumper and Side Skirt Protection. . . . . . . . . . . . . . . . . .71 Checking Automatic Transmission Fluid. . . . . . . . . . . . . . . . . . . .83
Air Conditioning System Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Automatic Transmission Fluid Filter. . . . . . . . . . . . . . . . . . . . . . . . .85
Front Axle - General Service Information. . . . . . . . . . . . . . . . . . . . . . . .71 Engine and Subsystem Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Rear Axle - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Air Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Rear Axle Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Air Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Brake System - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Hydraulic Brakes - General Inspection And Adjustment. . .74 Ultra Low Sulfur Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . .87
Hydraulic Brakes - Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Unacceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Hydraulic brakes - Fluid Precautions. . . . . . . . . . . . . . . . . . . . . . . .74 Hazards Of Diesel Fuel/Gasoline Blends. . . . . . . . . . . . . . . . . . .88
Brake Fluid Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Fuel and Lubricant Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Hydraulic Brakes - Brake Lines, Hoses And Fittings. . . . . .75 Fueling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Reserve Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Tilting/Lowering Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Running Out of Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Tilting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Fuel Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Chassis-Mounted Charge Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Checking Engine Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Air Intake Piping Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Checking Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Adding Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Electrical System Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Extended Life Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Coolant Concentration Freeze point. . . . . . . . . . . . . . . . . . . . . . . .79 Noise Emissions — Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Recycled Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Instructions For Proper Maintenance. . . . . . . . . . . . . . . . . . . . . . .92
Engine Coolant Capacities and Part Numbers. . . . . . . . . . . . .79 Air Intake System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Fan Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Body:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Windshield Washer Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Cooling System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Engine and Driveline System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Steering - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Exhaust System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Tightening Steering Column Joint Bolts. . . . . . . . . . . . . . . . . . . .82 Suspension Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Frame and Tow Hooks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

3812586R1 iii
Table of Contents

Propeller Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Headlamp Aim Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109


Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Wheel Installation, Tightening And Alignment. . . . . . . . . . . . . .95 Lubricant and Sealer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Wheel Mounting Nuts Torque Sequence. . . . . . . . . . . . . . . . . . .97 Disc Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Aluminum Disc Wheels with Flange Nuts (Hub Piloted). . .97 U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Spring U-Bolt Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Checking Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Power Distribution Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Under Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Relay Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Section 6 – Entertainment Systems
Matching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Dual Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 AM/FM Stereo (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Mixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 AM/FM Stereo/Cassette (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . .123
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 AM/FM Stereo/CD (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Rotation Is Always Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Radio Frequencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Rotation May Not Be Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . .101
Wheel And Tire Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Section 7 – Customer Assistance
Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Tires — Irregular Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Use Of Tire Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 International® Warranty Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Lubrication and Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . .103
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 Section 8 – Index
Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Tire/Wheel Rim Selection And Inflation Pressures. . . . . . . . . . . .109 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

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

Superintendent of Documents than for purposes of maintenance, repair, or replacement, of any


U.S. Government Printing Office device or element of design incorporated into any new vehicle
Washington, D.C. 20402 for the purpose of noise control prior to its sale or delivery to
the ultimate purchaser or while it is in use, or (2) The use of
International Truck and Engine Corporation warrants to the
the vehicle after such device or element of design has been
first person who purchases this vehicle for purposes other than
removed or rendered inoperative by any person. Among those
resale and to each subsequent purchaser that this vehicle, as
acts presumed to constitute tampering are the acts listed as
manufactured by International Truck and Engine Corporation,
follows: A. Air Intake System: Removal of air cleaner, intake
was designed, built and equipped to conform at the time it left
silencer or piping. B. Acoustical Shielding (Body): Removal of
International Truck and Engine Corporation’s control with all
wheel well splash shields, cab shields or acoustical (underhood)
applicable U.S. Environmental Protection Agency Noise Control
insulation. C. Cooling System: 1. Removal or rendering
Regulations.
inoperative the fan clutch. 2. Removal of fan shrouds. D.
This warranty covers this vehicle as designed, built and Engine and Driveline System: 1. Removal or rendering engine
equipped by International Truck and Engine Corporation, and speed governor inoperative so as to allow engine speed to
is not limited to any particular part, component or system of exceed manufacturer specifications. 2. Removal of engine
the vehicle manufactured by International Truck and Engine block shield, oil sump shield or transmission enclosures. E.
Corporation. Defects in design, assembly or in any part, Exhaust System: Removal or rendering inoperative exhaust
component or system of the vehicle as manufactured by system components including aftertreatment system or tailpipe.
International Truck and Engine Corporation, which at the time it
Use the following “Verification Of Inspection” forms to log Noise
left International Truck and Engine Corporation’s control, cause
Emission inspections of, at a minimum, the above systems.
noise emissions to exceed Federal standards, are covered by
this warranty for the life of the vehicle.
Emission Control Systems
Tampering With Noise Control System Prohibited
NOTE: Federal and California Emission system warranties are
Federal law prohibits the following acts or the causing thereof: found in your Engine Operation and Maintenance Manual.
(1) The removal or rendering inoperative by any person other

3812586R1 3
Foreword

VERIFICATION OF INSPECTION — NOISE EMISSIONS

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

• Steering wheel locks Layer 4: Tracking System


• Steering column collars The final layer is a tracking system that emits a signal to the
police or a monitoring service when the vehicle is reported
• Theft deterrent decals
stolen. If your vehicle has a tracking system and is stolen, it
• Wheel locks can oftentimes be recovered faster and with less damage. Put
your vehicle on the radar screen by installing a tracking system,
• Window etching
such as International’s AWARE™ Vehicle Intelligence System.
• Mechanical or electronic steering locks that restrict the
steering shaft u-joint are easy to use and provide a very
high level of affordable theft protection.

Layer 3: Vehicle Immobilizer


• Fuse cut-offs
• Kill switches
• Starter, ignition and fuel disablers
• Fuel cut-off switch

3812586R1 7
Foreword

8 3812586R1
Vehicle Inspection Guide

SECTION 2 — VEHICLE INSPECTION GUIDE

Description • Make sure the parking brake is fully set.


• Turn the engine off (unless it is required to be running for
WARNING inspection)
• Make sure all doors are closed tightly.
This vehicle has many parts dimensioned in the
metric system as well as the English system.
NOTE: Never lower handle B when cab is tilted (see the Figure
Some fasteners are metric and are very close
below).
in dimension to English fasteners in the inch
system. Mismatched or incorrect fasteners can
TILTING
loosen and reduce clamping load, which could
result in vehicle damage, personal injury or Remove all loose objects from cab, close doors, and chock
death. wheels.
To be sure your vehicle is ready to operate, conduct a pre-trip
inspection at the beginning of each work period. Follow the steps
below and check them off to assure a proper vehicle inspection
procedure. The pages in this section may be reproduced locally
and used on a regular basis.

Tilting/Lowering Cab

WARNING

CRUSH HAZARD. Failure to follow recommended


tilting or lowering procedures could result in Refer to the Figure above when following these directions.
property damage, personal injury or death.
1. Raise lever A then raise handle B until it comes to a stop.
Before tilting the cab:
2. Pull lever C toward you. Tilt the cab while holding grip E.
• Make sure the vehicle is parked on a level surface.
3. After tilting, ensure pin on rod F is seated in groove.

3812586R1 9
Vehicle Inspection Guide

NOTE: Never lower handle B when cab is tilted. Engine Compartment

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.

Engine Start with Parking Brake(s) Applied

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.

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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.

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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.

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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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Vehicle Controls

SECTION 3 — VEHICLE CONTROLS


Instrument Cluster

Warning Lights and Chimes

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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Vehicle Controls

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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Vehicle Controls

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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Vehicle Controls

Climate Controls CAUTION


To clear system of humid air, operate blowers for
Heater Only System (Standard)
30 seconds at high speed, with the AIR FLOW
knob on the normal heating (floor vent) position
WARNING before selecting the DEF position. This will
prevent fogging the glass, which can occur if
Never drive the vehicle unless the windshield and humid air is blown onto a cool windshield.
all other windows are clear. A fogged, ice/snow
covered, or dirty windshield or window limits
vision, which could cause an accident, resulting
in property damage, personal injury or death. To
improve defroster efficiency, remove ice and/or
snow by hand from the windshield and windows
with a non-metallic scraper.

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Vehicle Controls

1. Temperature selection: Controls the temperature of the airflow in the vehicle.


2. Fan speed adjustment: Controls the volume of air circulated in the vehicle.
3. Used to manually enable or disable recirculated air operation. When activated (control
moved all the way to the left), may help reduce undesired outside odors from reaching
the interior of the vehicle. To reduce humidity inside the vehicle, turn recirc off (control
moved all the way to the right).
4. 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 floor vents.

Distributes air through the windshield defroster vents and floor vents.

Distributes air through the windshield defroster 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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Vehicle Controls

Heater and Air Conditioning System (Optional) CAUTION


To clear system of humid air, operate blowers for
WARNING 30 seconds at high speed, with the AIR FLOW
knob on the normal heating (floor vent) position
Never drive the vehicle unless the windshield and before selecting the DEF position. This will
all other windows are clear. A fogged, ice/snow prevent fogging the glass, which can occur if
covered, or dirty windshield or window limits humid air is blown onto a cool windshield.
vision, which could cause an accident, resulting
in property damage, personal injury or death. To
improve defroster efficiency, remove ice and/or
snow by hand from the windshield and windows
with a non-metallic scraper.

1. Temperature selection: Controls the temperature of the airflow in the vehicle.


2. A/C: Used cool the vehicle.
3. Fan speed adjustment: Controls the volume of air circulated in the vehicle.

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Vehicle Controls

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 floor vents.

Distributes air through the windshield defroster vents and floor vents.

Distributes air through the windshield defroster 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

OFF: Turns the lamps off.


Turns on the parking lamps, instrument panel
lamps, license plate lamps and tail lamps.
Turns the headlamps on.

High beams/Flash-to-pass
To turn on the high beams, push the lever
away from you. Pull the lever towards you
to deactivate.

For flash-to-pass operation, pull the lever


toward you slightly to activate and release 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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Vehicle Controls

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.

Panel Dimmer Control

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.

Turn Signal Control

• Push down to activate the left turn signal.

• Push up to activate the right turn signal.

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Vehicle Controls

Hazard Flasher Interior Lamps

The hazard flasher 1. OFF: Light always


control is located on the off.
instrument panel, to the
2. DOOR: Light turns
right of the steering wheel.
on when either
The hazard flashers will
door is open.
operate when the ignition
is off. 3. ON: Light always
on.
Push in the flasher control and all front and rear direction signals
will flash. Press the flasher control again to turn them off. Use
Bulb Inspection
it when your vehicle is disabled and is creating a safety hazard
for other motorists. It is a good safety practice
to check operation of headlamps, parking lamps, turn signals,
NOTE: With extended use, the flasher may run down your clearance and marker lamps, instrument panel and control
battery. lamps each day. See Bulb Replacement in the Vehicle
Maintenance, Service Intervals and Specifications section.

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Vehicle Controls

Driver Controls

Windshield Wiper/Washer Controls

• MIST: For a single wipe (without washer), push the control up once.

• OFF: Wipers off.

• INT: Interval wiper operation.

• 1: Low-speed wiper operation.

• 2: High-speed wiper operation.

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

Do not adjust the steering column while vehicle is


moving. It could suddenly or unexpectedly move
causing the driver to lose control of vehicle which
could result in property damage, personal injury
or death.

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Vehicle Controls

Power Windows (if equipped)

• 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.

Window Lock (if equipped)

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.

Adjust the auxiliary convex mirrors. Convex mirrors are a ball-stud


design for precise adjustment to maximize viewing area.

The mirrors can be manually folded forward or backward for negotiating


narrow spaces. The mirrors can also be manually folded forward to fit
within the front cab width of the vehicle.

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Vehicle Controls

Speed Control (if equipped) To turn speed control off

Press the top portion of the control or


WARNING turn off the ignition.

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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Vehicle Controls

To set a lower set speed To disengage speed control

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

Press RESUME +. For RESUME


To set a higher set speed
+ to operate, the vehicle speed
Press and hold RESUME +. If the must be above 35 mph (56 km/h) or
vehicle is moving, this will increase engine speed must be above 1,000
vehicle speed; if the vehicle is RPM.
stationary, this will increase engine
RPM. Release the control when the
desired vehicle speed/engine RPM
is reached.

Press and release RESUME + to


operate the tap-up function. Each
press will increase the set speed in
increments of 1 mph (1.6 km/h) or
engine RPM in idle mode.

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Vehicle Controls

Regeneration Control Panel Lock and Security

Keys

The key operates all locks on your vehicle. In case of loss,


replacement keys are available from your dealer.
You should always carry a second key with you, in a safe place,
in case you require it in an emergency.

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

PARKD REGEN: To help reduce the risk of personal injury in the


event of an accident, keep doors locked when
Used to activate the Parked
vehicle is in motion.
Regeneration process.
Both doors lock and unlock automatically when the driver’s door
is locked or unlocked with a key.

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:

Used to inhibit both active


and parked regeneration.

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Vehicle Controls

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.

Unlocking the Doors


This device complies with part 15 of the FCC rules and with
RS-210 of Industry Canada. Operation is subject to the • Press UNLOCK to unlock the driver’s door.
following two conditions: (1) This device may not cause harmful
interference, and (2) This device must accept any interference • Press UNLOCK again within three seconds to unlock both
received, including interference that may cause undesired doors.
operation.
NOTE: The vehicle doors may be unlocked by using the remote
Changes or modifications not expressly approved by the entry transmitter, however, in the event of a low battery charge,
party responsible for compliance could void the user’s the door can be manually unlocked and opened by inserting
authority to operate the equipment. the key into the driver’s door lock cylinder and turning counter
The typical operating range for your remote entry transmitter clockwise.
is approximately 33 feet (10 meters). A decrease in operating
range could be caused by: Locking the Doors
• weather conditions, • Press LOCK to lock both doors.
• nearby radio towers, • Pressing LOCK a second time will sound the horn to confirm
• structures around the vehicle, or the doors are locked.

• other vehicles parked next to your vehicle.

3812586R1 39
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.

NOTE: Replacement of the battery will not cause the remote


transmitter to become deprogrammed from your vehicle.
The remote transmitter should operate normally after battery
replacement.

Replacing Lost Remote Entry Transmitters

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

SECTION 4 — VEHICLE OPERATION


Vehicle Entry and Exit WARNING

Do not use the door handle as a handhold during


WARNING
entry and exit. Failure to follow this warning
Do not step or climb upon any vehicle surface could cause you to slip or fall and could result in
unless it is slip resistant and a handhold is personal injury or death.
provided. Failure to follow this warning could
cause you to slip or fall and could result in Seating and Occupant Restraints
personal injury or death.
WARNING
WARNING
Always use occupant restraint system when
A three-point stance should be used (three out vehicle is moving. Any location in the vehicle not
of four extremities should be in contact with equipped with a seat belt should not be occupied
the vehicles climbing system at all times). Face when the vehicle is being operated. In the event
inward towards the cab when entering and of a vehicle accident or sudden, unexpected
exiting. Always keep steps and handholds in movement, failure to properly use an occupant
continuous good repair. Make sure all attaching restraint system could result in personal injury
bolts and hardware are tight, thus eliminating or death.
any movement of steps and handholds. Keep
steps, grab handles and shoes free of grease,
mud, dirt, fuel, ice and snow. Use extra care
during inclement weather. Failure to follow this
warning could cause you to slip or fall and could
result in personal injury or death.

3812586R1 41
Vehicle Operation

Seat Adjustment 40/20/40 Split Bench Seat

The driver seat can be


WARNING
adjusted forward or backward
by lifting the lever (1) located
Do not adjust driver’s seat while vehicle
under the seat.
is moving. The seat could suddenly or
unexpectedly move causing the driver to lose Pull the lever (2) to flip the
control of the vehicle, which could result in driver seat forward. When
property damage, personal injury or death. pushing the seat back to its
upright position, make sure it
latches securely.
WARNING

Reckless operation of this vehicle over rough


roads or surfaces can cause loss of vehicle Pull the center seat down while
control and result in property damage, personal pulling the loop to flip the seat
injury, or death. Use caution and reduce speed. down. When pushing the seat
Properly adjusted seats and seating systems back to its upright position,
may not compensate completely for severe road make sure it latches securely.
conditions.
Ensure that head clearance will be maintained
during all road conditions, as the seat may move
up and decrease the available space.

42 3812586R1
Vehicle Operation

Pull the right-hand passenger Seat Belts


seatback down while pulling
the latch handle to flip the WARNING
seatback down flat. When
pushing the seatback to its Failure to properly inspect and maintain seat
upright position, make sure it belts could result in personal injury or death.
latches securely.

WARNING

Any seat belt in use during an accident must


be replaced. When replacement of any part of
Before returning any seatbacks to the upright position, always the seat belt is required, the entire belt must be
make sure no objects are trapped underneath or behind the replaced, both retractor and buckle sides. Belt
seatback. Trapped objects could keep the seatback from failure could result in personal injury or death.
latching properly. After returning a seatback to the upright
position, always pull on the seatback to ensure that it is fully
latched.

3812586R1 43
Vehicle Operation

Combination Lap and Shoulder Belts


WARNING
1. Insert the belt tongue into
The seat belt in a commercial truck application
the proper buckle (the buckle
should be considered to have a finite life and
closest to the direction the
must be replaced as needed throughout the life
tongue is coming from) until
of the vehicle. Belt must be inspected for needed
you hear a snap and feel it
care and maintenance every 20,000 miles or
latch. Make sure the tongue
more often if exposed to severe environmental
is securely fastened in the
or vocational conditions. All belts should be
buckle.
replaced at least every 5 years. Failure to
maintain the seat belts can weaken the system
resulting in belt failure, personal injury or death.
Seat belts should be worn at all times the vehicle is in motion to 2. To unfasten, push the
avoid personal injury. Before fastening a front seat belt, always release button and remove the
adjust the driver’s seat to the position in which you will drive. Lap tongue from the buckle.
and shoulder (three-point) seat belts with retractor are standard
for driver and door-side passenger. An adjustable belt that does
not retract is provided for the center passenger with full and
two-man bench seats.

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

Vehicle Sensitive Retractor


WARNING
The vehicle sensitive retractor allows free shoulder belt length
Position the safety belt height adjusters so that
adjustment to your movements and locks in response to vehicle
the belt rests across the middle of your shoulder.
movement. For example, if the driver brakes suddenly or
Failure to adjust the safety belt properly could
turns a corner sharply, or the vehicle receives an impact of
reduce the effectiveness of the seat belt and
approximately 5 mph (8 km/h) or more, the combination safety
result in personal injury or death.
belts will lock to help reduce forward movement of the driver
and passengers.
Lap Belts
Front Safety Belt Height Adjustment
The front center lap belt does not adjust automatically.
Vehicles have safety belt height
Insert the tongue into the correct
adjustments for the driver. Adjust
buckle (the buckle closest to the
the height of the shoulder belt so the
direction the tongue is coming from).
belt rests across the middle of your
To lengthen the belt, turn the tongue
shoulder.
at a right angle to the belt and pull
To lower the shoulder belt height, across your lap until it reaches the
push the button and slide the height buckle. To tighten the belt, pull the
adjuster down. To raise the height loose end of the belt through the
of the shoulder belt, slide the height tongue until it fits snugly across the
adjuster up. Pull down on the height hips.
adjuster to make sure it is locked in Shorten and fasten the belt when not
place. in use.

3812586R1 45
Vehicle Operation

Safety Belt Warning Light And Indicator Chime Starting


The safety belt warning light illuminates in the instrument cluster
and a chime sounds to remind the occupants to fasten their WARNING
safety belts.
Never start the engine unless you’re sure the
Care of Seat Belts transmission selector is in neutral and the brake
is applied, otherwise accidental movement of the
Inspect the seat belt systems periodically to make sure they work vehicle can occur which could result in property
properly and are not damaged. Inspect the seat belts to make damage, personal injury, or death.
sure there are no nicks, tears or cuts. Replace if necessary.
All seat belt assemblies, including retractors, buckles, front seat POSITIONS OF THE IGNITION
belt buckle assemblies, buckle support assemblies (slide bar-if
equipped), shoulder belt height adjusters (if equipped), shoulder 1. LOCK, shuts off the engine
belt guide on seatback (if equipped), and attaching hardware, and all accessories, locks the
should be inspected after a collision. steering wheel, gearshift lever
and allows key removal.

WARNING 2. ACC, allows the electrical


accessories such as the radio
Do not bleach or re-dye seat belt webbing. to operate while the engine is
Bleaching or re-dying may cause a weakening not running. This position also
of the webbing, resulting in personal injury or unlocks the steering wheel.
death.
3. ON, all electrical circuits operational. Warning lights
illuminated. Key position when driving.
4. START, cranks the engine. Release the key as soon as the
engine starts.

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.

In the event engine shutdown occurs, make


certain that vehicle is safely off the roadway,
the 4–way emergency flashers are on, and the
warning devices are properly placed. Failure to
remove vehicle from roadway could result in an
accident, personal injury or death.

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

Exhaust Filter Regeneration


WARNING
This vehicle is equipped with a Diesel Particulate Filter (DPF)
Failure to perform a Parked Regeneration when
in the exhaust system to meet 2007 emissions requirements.
exhaust filter indicator is ON will cause the engine
This DPF traps particulate matter from the engine exhaust and
to lose power and eventually shutdown.
is subject to “plugging” after a certain amount of time due to
accumulation of soot particles. At some point, this plugging When performing Parked Regeneration, make
effect may reach a level where action must be taken. If the certain vehicle is safely off roadway and exhaust
plugging effect becomes severe, engine performance will be pipe is away from people, or any flammable
automatically derated (power reduced) and the engine may materials or structures.
shutdown completely. Electronic sensors in the engine exhaust
Failure to follow these instructions may result in
system and on the DPF itself determine the level of plugging in
a loss of engine power, vehicle speed, increased
the DPF and are used to provide an indication to the operator,
exhaust temperatures, and may cause an
through the instrument cluster, that the DPF needs to be
accident or fire resulting in property damage
cleaned.
personal injury, or death.
The DPF may be cleaned by having an International dealer
remove and clean it or through a process called regeneration.
There will be four levels of indication that the vehicle’s exhaust
The regeneration process involves extended driving at highway
filter is accumulating soot and needs to be cleaned, each with
speeds (to increase engine exhaust temperatures). If the
an increasing urgency for action.
DPF indicator in the instrument cluster does not turn off, a
manual Parked Regeneration procedure must be performed. If
NOTE: A Level 1 indication may disappear or a Level 2 may
regeneration is not performed soon enough, the DPF may get
revert to a Level 1 if the vehicle is driven at highway speeds for
to a condition where removal and cleaning by an International
an extended period. This process of Auto Regeneration of the
dealer must be done. (Parked regeneration in this case must
exhaust filter is activated when the engine load is increased as
not be performed.)
a result of highway driving at highway speeds. If the exhaust
See the following information for a detailed explanation of DPF filter indicator does not reduce in level or disappear, a Parked
indicators and the corresponding procedures that must be Regeneration must be performed.
followed.

3812586R1 51
Vehicle Operation

Level Indication Vehicle Condition/Operation Action Required


Drive on highway at highway speeds OR start Parked Regeneration to
Exhaust filter regeneration prevent loss of power.
1
required.
Solid

Pull vehicle safely off roadway and start Parked Regeneration to prevent
2 Exhaust filter is full.
loss of engine power.
Flashing

WARNING

Flashing Pull vehicle safely off roadway and start Parked


Exhaust filter is full. Engine Regeneration to prevent engine stopping.
3
performance is LIMITED.

Solid

A serious engine problem has WARNING


occurred. Exhaust filter may be
4 Pull vehicle safely off roadway, turn on flashers, place
overfull. Engine may SHUTDOWN
Solid soon. warning devices, and STOP ENGINE. DO NOT USE Parked
Regeneration. Call for service.
HEST (High Exhaust System Temperature) Indicator.

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

Brakes worn-out and should be inspected by a qualified service


technician.
WARNING
DOWNHILL OPERATION
Always check and maintain brakes in proper
Always descend hills with extreme care, relying primarily on the
condition and adjustment. Out of adjustment
engine braking effect to control vehicle speed. Heed warning
brakes could cause reduced braking ability and
signs posted for any grade. Stop and check brakes for condition
result in property damage, personal injury, or
and adjustment at available pull off areas before starting a
death.
descent.

WARNING Observe the following precautions:


Never coast downhill. Service brakes alone should not be used
Hydraulic brake systems are power assisted to control speed on major downgrades. Brakes will fade from
by the engine. Braking capabilities will be overuse.
greatly reduced without engine assist. Do
not move vehicle without the engine running Downhill speed is controlled by removing one’s foot from the
as reduced braking capability could result in accelerator pedal (engine running with closed throttle) and
property damage, personal injury or death. putting the transmission/rear axle in reduced gear. If the
transmission/rear axle is in a gear that results in more than
Your service brakes are self-adjusting. Refer to the Vehicle the appropriate speed, a proper downshift should be made to
Maintenance, Service Intervals and Specifications for scheduled avoid overuse of the brakes. If the proper gear selection was
maintenance. not made and the brakes were overused, then stop the vehicle
Occasional brake noise is normal and often does not indicate and wait for the brakes to cool. After the brakes have cooled,
a performance concern with the brake system. In normal continue down grade in a lower gear range.
operation, brake systems may emit occasional or intermittent The common rule to follow in using the engine and
squeal or groan noises when the brakes are applied. Such transmission/rear axle to control vehicle speed is to select a
noises are usually heard during the first few brake applications lower gear going down the hill than would be required to ascend
in the morning; however, they may be heard at any time while the hill. There are some exceptions, such as going down a
braking and can be aggravated by environmental conditions short hill with good visibility and no hazards.
such as cold, heat, moisture, road dust, salt or mud. If a
“metal-to-metal,” “continuous grinding” or “continuous squeal” The service brakes should be used to supplement available
sound is present while braking, the brake linings may be vehicle retardation methods. When descending long grades

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

Antilock brake systems are designed to enhance


overall vehicle safety when a vehicle is driven
within its normal safety limits. ABS cannot
compensate for a vehicle that is being driven
beyond the physical limits of control. Drivers
operating an ABS equipped vehicle should
employ safe driving skills and assume no
additional driving risks. Failure to do so could
result in property damage, personal injury, or
death.
Apply the parking brake whenever the vehicle is parked. To set
the parking brake, pull the handle (1) up until it stops. WARNING
To release the parking brake, pull the handle up slightly, push the Do not rely on the ABS system to interrupt
button (2) on the end of the handle, then push the handle down to vehicle retarder, engine or exhaust brake on
its original position. Driving with the parking brake on will cause slippery road surfaces. Turn these devices off
the brakes to wear out quickly and reduce fuel economy. during hazardous driving conditions. Failure to
follow this warning may cause wheel slippage
The parking brake warning light in the instrument cluster and/or loss of vehicle control, which could result
illuminates, and remains illuminated (when the ignition is in property damage, personal injury, or death.
turned on), until the parking brake is released.
This system helps you maintain steering control during
The parking brake is not recommended to stop a moving emergency stops by keeping the brakes from locking. Noise
vehicle. However, if the normal brakes fail, the parking from the ABS pump motor and brake pedal pulsation may be
brake can be used to stop your vehicle in an emergency. Since

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

• Remove the shifter shroud and lift up on the override lever


connected to the solenoid. Note that the center pin on the
rear of the solenoid will extend when the lever is lifted.
1. Apply the parking brake, turn ignition key to LOCK, then • While the override lever is lifted, apply the brake pedal and
remove the key. shift to N (Neutral).
2. Remove the three fasteners as shown in the illustration;
there is one at the bottom of the gearshift console and WARNING
one on both sides of the console.
To prevent unexpected vehicle movement, hold
Note: You may need to roll back the floor cover to access
the brake pedal down while you move the
the bottom fastener and/or remove the middle seat cushion to
gearshift from position to position. Failure to
access the passenger side top fastener.
follow this warning could result in property
damage, personal injury, or death.
• Start or move the vehicle

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

Do not use the Tow/Haul mode on slippery road


surfaces or while lightly loaded. Doing so may
cause wheel slippage and/or loss of control,
which could result in property damage, personal
injury or death.
The TOW HAUL indicator light will illuminate in the instrument
cluster.

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

Power Take Off Control AXLE CONVERSIONS

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.

CAUTION VEHICLE LOADING


Installing a PTO without the proper electrical Every vehicle is supplied with information on the Vehicle Rating
connections to the transmission may result in Decal listing the maximum loading for the vehicle (GVWR), and
transmission failure. its axle systems (GAWR) at the tire to ground interface.

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

The following procedures must be performed


Gross Axle Weight exactly as outlined, otherwise a fire or a battery
explosion could result in property damage,
WARNING personal injury or death.

Do not exceed the truck’s gross axle weight,


gross vehicle weight, and gross combination
weight ratings. Exceeding these ratings by
overloading can cause component failure
resulting in property damage, personal injury, or
death.

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.

Preparing Your Vehicle


1. Connect the positive (+) jumper cable to the positive (+)
When the battery is disconnected or a new battery is installed, terminal of the discharged battery.
the transmission must relearn its shift strategy. As a result, the
transmission may have firm and/or soft shifts. This operation is Note: In the illustrations, lightning bolts are used to designate
considered normal and will not affect function or durability of the the assisting (boosting) battery.
transmission. Over time, the adaptive learning process will fully
update transmission operation.
1. Use only a 12–volt supply to start your vehicle. Do not
attach the jumper cables to the glow plug relay as this could
severely damage the glow plugs, injector drive module (IDM)
and engine control module (ECM).
2. Do not disconnect the battery of the disabled vehicle as this 2. Connect the other end of the positive (+) cable to the positive
could damage the vehicle’s electrical system. (+) terminal of the assisting battery.

3812586R1 63
Vehicle Operation

Removing the Jumper Cables

3. Connect the negative (-) cable to the negative (-) terminal of


the assisting battery.
Remove the jumper cables in the reverse order that they
were connected.
1. Remove the jumper cable from the ground metal surface.
Note: In the illustrations, lightning bolts are used to designate
the assisting (boosting) battery.
4. Make the final connection of the negative (-) cable to an
exposed metal part of the stalled vehicle’s engine, away from
the battery and the fuel injection system. Do not use fuel lines,
engine rocker covers or the intake manifold as grounding points.
5. Ensure that the cables are clear of fan blades, belts, moving
parts of both engines, or any fuel delivery system parts.
2. Remove the jumper cable on the negative (-) connection of
Jump Starting the booster vehicle’s battery.
1. Start the engine of the booster vehicle and run the engine at
moderately increased speed.
2. Start the engine of the disabled vehicle.
3. Once the disabled vehicle has been started, run both engines
for an additional three minutes before disconnecting the jumper
cables.

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

SECTION 5 — VEHICLE MAINTENANCE, SERVICE INTERVALS AND


SPECIFICATIONS
Preface As with any vehicle, care should be taken to avoid being injured
when performing maintenance or repairs or making any checks.
Improper or incomplete service could result in the vehicle not
WARNING
working properly which, in turn, may result in personal injury
If the owner/operator of the vehicle is a or damage to the vehicle or its equipment. If you have any
skilled technician and intends to perform the question about performing some service, have the service done
vehicle maintenance and servicing, he/she by a skilled technician.
is strongly urged to purchase and follow
the appropriate International service manual. Maintenance Guidelines
Ordering information is included at the back
of this manual. Failure to properly perform WARNING
maintenance and servicing procedures could
result in property damage, personal injury or Failure to perform proper maintenance and
death. service could result in property damage, personal
injury or death.
Your vehicle has been engineered and manufactured to provide
economical and trouble-free service. However, it is the owner’s
responsibility to see that the vehicle receives proper care and WARNING
maintenance.
Making any modifications to any part, component
Quality International® service parts are available through your
or system of the vehicle, can adversely affect the
International dealer. If International® service parts are not used,
quality and reliability of your vehicle and must be
the owner must make sure that the parts used are equivalent to
avoided. Modifications to systems could result in
International® service parts.
property damage, personal injury or death.

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

Supporting Your Vehicle for Service Chassis Lubrication

New vehicles are lubricated at the factory. After the vehicle


WARNING is placed in operation, regular lubrication and maintenance
intervals, based on the type of service and road conditions,
Always use floor stands to support the vehicle should be established. The loads carried, speed, road and
before working under it. Using only a jack could weather conditions all contribute to the frequency of lubrication
allow the vehicle to fall resulting in property intervals. Thorough lubrication and maintenance at the specified
damage, personal injury or death. intervals will insure Outstanding Life Cycle Value and will reduce
When performing service repairs on a vehicle, first: overall operating expense.
1. Park vehicle on level concrete floor. In some types of operation, and where operating conditions are
extremely severe (such as in deep water, mud or unusually dusty
2. Set parking brake and/or block wheels to prevent vehicle conditions), the vehicle may require re-lubrication after every
from moving. twenty-four (24) hours of operation.
3. Select jack with a rated capacity sufficient to lift the Only lubricants of superior quality, such as Fleetrite lubricants,
vehicle. should be used. The use of inferior products will reduce the
4. Raise vehicle with jack applied to axle. (DO NOT use service life of the vehicle or result in failure of its components.
bumper as a lifting point.) International Truck and Engine Corporation recommends the
use of Fleetrite lubricants and International Engine original
5. Support vehicle with floor stands under axle(s). equipment parts.
If axle or suspension components are to be serviced, support The lubrication intervals specified should be performed at
vehicle with floor stands under frame side members, preferably whatever interval occurs first, whether it is miles (kilometers),
between the axles. hours, or months.
These intervals are provided in the Lubrication And Maintenance
Interval Chart in the Maintenance Intervals section.

3812586R1 69
Vehicle Maintenance, Service Intervals and Specifications

Cab Lubrication

It is important to lubricate the cab tilt/latch mechanism and other


cab components such as door hinges/latches/strikers, door
lock cylinders and seat adjuster slides at the recommended
intervals. These intervals are provided in the Lubrication and
Maintenance Intervals section. The cab latch/tilt mechanism
should be lubricated as shown below (only the driver side latch
is shown).

Care Of Vehicle

WASHING AND WAXING

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

BRIGHT METAL CARE PLASTIC BUMPER AND SIDE SKIRT PROTECTION

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.

Hydraulic Brakes - Brake Lines, Hoses And Fittings

Inspect these components every 7,500 miles (12,000 km).


• Check lines for kinks, dents, corrosion or rupture.
• Check hoses for abrasions, kinks, soft spots or rupture,
collapse, cracks, twists or loose frame supports. When
replacing a hose, be sure there is adequate clearance to
the hose to avoid an abrasion to the new hose.
• Examine all connections for leaks.
• Repair or replace brake line tubes, hoses or fittings as
required.

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

To avoid property damage, personal injury or


death when servicing the vehicle, park on a flat
level surface, set the parking brake, turn off the
engine, and chock the wheels.

Tilting/Lowering Cab

Refer to the Figure above when following these directions.


WARNING
1. Raise lever A then raise handle B until it comes to a stop.
CRUSH HAZARD. Failure to follow recommended
2. Pull lever C toward you. Tilt the cab while holding grip E.
tilting or lowering procedures could result in
property damage, personal injury or death. 3. After tilting, ensure pin on rod F is seated in groove.
Before tilting the cab:
NOTE: Never lower handle B when cab is tilted.
• Make sure the vehicle is parked on a level surface.
LOWERING
• Make sure the parking brake is fully set.
• Turn the engine off (unless it is required to be running for Refer to the Figure above when following these directions.
inspection) 1. Push the cab up using grip E. Pull handle G rearward while
• Make sure all doors are closed tightly. holding grip E.

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.

Engine Oil and Filter Recommendations


Diesel engines require specially formulated oil to resist
contamination. Proper quality oils also provide maximum
efficiency of the crankcase ventilation system which reduces
air pollution. Refer to the Engine Operation and Maintenance
Manual for proper oil specifications.
To help achieve proper engine performance and durability, it is
important that you:
4. Locate and carefully remove the engine oil dipstick. The • Use only engine lubricating oils and oil filters of the proper
dipstick is located between the air filter housing and the back quality.
of the cab; you do not need to tilt the cab to access it.
• Change the engine oil and filter no later than the
recommended service interval. Refer to the Engine
Operation and Maintenance Manual for the appropriate
intervals for changing the engine oil and filter.

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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.

ADDING ENGINE COOLANT

When adding coolant, make sure it is a 50/50 mixture of engine


coolant and distilled water. Add the mixture to the coolant
reservoir, when the engine is cool, until the appropriate fill
level is obtained.

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.
The reservoir has two see-through level indicators on it. The top Push down, loosen cap slowly to its first notch
indicator is the FULL mark and the bottom indicator is the ADD position; then pause a moment to allow pressure
mark. If engine coolant is visible through either indicator, it will to release through the overflow tube. After the
appear red in color. The engine coolant should be kept at a level pressure has been released, the pressure cap
that is visible through the bottom indicator. may be removed.

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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.

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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

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, The fluid reservoir is located on the far right side of the instrument
personal injury or death. panel, accessible by opening the passenger’s door. Add fluid to
fill the reservoir if the level is low. In very cold weather, do not fill
The vehicle air conditioning system is equipped with an the reservoir completely.
auxiliary fan to enhance efficiency. This fan is controlled by air
conditioning system sensors and must not be tampered with. State or local regulations on volatile organic compounds may
restrict the use of methanol, a common windshield washer
antifreeze additive. Washer fluids containing non-methanol
antifreeze agents should be used only if they provide cold
weather protection without damaging the vehicle’s paint finish,
wiper blades or washer system.

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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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Vehicle Maintenance, Service Intervals and Specifications

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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Vehicle Maintenance, Service Intervals and Specifications

Power Steering Fluid Transmission Fluid

CHECKING AUTOMATIC TRANSMISSION FLUID

Refer to Lubrication and Maintenance Intervals Chart for


scheduled intervals for fluid checks and changes. Check fluid
level and shift linkage for proper operation.
Automatic transmission fluid expands when warmed. To obtain
an accurate fluid check, drive the vehicle until it is at normal
operating temperature (approximately 20 miles [30 km]). If
your vehicle has been operated for an extended period at high
speeds, in city traffic during hot weather or pulling a trailer, the
vehicle should be turned off for about 30 minutes to allow fluid
Check the power steering fluid level by looking at the to cool before checking.
see-through plastic reservoir. Make sure that the fluid is
within the FULL and ADD range as marked on the reservoir. If
the fluid level is below the ADD line, add fluid in small amounts,
continuously checking the level until it reaches the proper level.
Refer to the Lubrication and Maintenance Intervals Chart for
the recommended service intervals. If adding fluid is necessary,
use only approved power steering fluid.
A low fluid level may indicate a leak in the power steering
system. Inspect the power steering system and repair the leak.
If necessary, see your dealer or a qualified service technician.
To avoid damage to the power steering system, do not operate
the vehicle with a low power steering fluid level. 1. Drive the vehicle 20 miles (30 km) or until it reaches
normal operating temperature.
2. Park the vehicle on a level surface and engage the
parking brake.

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Vehicle Maintenance, Service Intervals and Specifications

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.

Low Fluid Level


The transmission fluid should be in this range if at ambient
temperature (50°F-95°F [10°C-35°C]).

High Fluid Level

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).

Correct Fluid Level


Fluid levels above the safe range may result in transmission
The transmission fluid should be checked at normal operating
failure. An overfill condition of transmission fluid may cause shift
temperature 150°F-170°F (66°C-77°C) on a level surface.
and/or engagement concerns and/or possible damage.
The normal operating temperature can be reached after
approximately 20 miles (30 km) of driving. High fluid levels can be caused by an overheating condition.

84 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

Adjusting Automatic Transmission Fluid Levels


Before adding any fluid, make sure the correct type is used.
The type of fluid used is indicated on a tag located on the
transmission fill tube and also in the Lubricant specifications
section in this chapter. If an overfill occurs, excess fluid should be removed by a
NOTE: Use only Mercon® SP transmission fluid. Use of qualified technician.
a non-approved automatic transmission fluid may cause An overfill condition of transmission fluid may cause shift
internal transmission component damage. and/or engagement concerns and/or possible damage.
Do not use supplemental transmission fluid additives, treatments
or cleaning agents. The use of these materials may affect
transmission operation and result in damage to internal
transmission components.

AUTOMATIC TRANSMISSION FLUID FILTER

The automatic transmission is equipped with a serviceable


internal fluid filter mounted inside the transmission’s oil pan.
This filter can be accessed by removing the oil pan, which is
located on the bottom of the transmission. Refer to Lubrication
and Maintenance Interval Chart for service intervals.
If necessary, add fluid in ½ pint (250 ml) increments through the
filler tube until the level is correct. To replace the transmission filter, refer to the service manual.

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Vehicle Maintenance, Service Intervals and Specifications

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

86 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

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

Ultra Low Sulfur Fuel Requirements

NOTE: This vehicle requires the use of Ultra Low Sulfur


Diesel (ULSD) fuel (sulfur content less than 15 ppm) per U.S.
Government regulations.

Unacceptable Fuel Blends


The air filter should be replaced any time the air filter restriction
gauge reads 25 inches (635 mm) or as indicated by the Biodiesel blends having more than 5% pure biodiesel are not
Maintenance Intervals chart. within ASTM D975 diesel specifications.

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Vehicle Maintenance, Service Intervals and Specifications

Hazards Of Diesel Fuel/Gasoline Blends Fueling Precautions

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.

88 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

Fuel Filter/Water Separator Chassis-Mounted Charge Air Cooler


Your vehicle is equipped with two fuel filters; one is mounted The charge air cooler should be inspected daily. With the
on top of the engine, the second one is mounted inside the engine off, visually inspect the charge air cooler core assembly
Horizontal Fuel Conditioner Module (HFCM) on the inside of the for debris and clogging of external fins. Prior to engine operation,
left frame rail by the transmission. The fuel filter/water separator remove any debris blocking the core.
removes any contaminated particles and/or water from the fuel
• Turbocharger-to-charge air cooler
before the fuel enters the engine.
• Charge air cooler-to-intake manifold pipe
The fuel filter/water separator should be drained whenever the
water in fuel warning light comes on or at the intervals specified • Mounting bracket
in the Engine Operation and Maintenance Manual. Refer to
• Chassis-mounted charge air cooler core
the Engine Operation and Maintenance Manual for specific
instructions.
AIR INTAKE PIPING INSPECTION
NOTE: If the water in fuel warning light comes on frequently, • Check for accumulation of salt deposits (where applicable).
water should be drained from the fuel tank(s) every 3 months. If present, disassemble and clean the complete air intake
piping system. If the intake piping is pitted, use RTV silicone
Fuel Filter Replacement to seal joints against leakage.
Both filters should be replaced at the same time. Refer to • Check for loose hoses and clamps.
the Engine Operation and Maintenance Manual for specific
• Check for ruptured or collapsed hoses.
instructions.
• Check air filter housing for cracks.

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Vehicle Maintenance, Service Intervals and Specifications

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.

90 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

The instrument panel lower trim panel must be removed to


access the relays. Remove the plastic rivet from the driver side
of the trim panel.

Individual fuse and relay information is included in the Fuses and


Relays section at the end of this chapter.
The relay box is located under the center of the instrument panel.

Remove the two screws on the passenger side bottom of the


panel, then the plastic rivets on the top end. Push the panel up
slightly to disengage the locking tabs, then pull the panel toward
you and off.

3812586R1 91
Vehicle Maintenance, Service Intervals and Specifications

Accessory Feed Connections

WARNING

Electrical circuits are designed with a particular


wire gauge to meet the fuse and circuit breaker
current rating. Do not increase size of fuse or
circuit breaker or change type of breaker supplied
with your truck. To do so could cause wiring to
overheat and possibly burn, resulting in a fire
which could cause property damage, personal
injury or death.
Vehicle electrical systems are complex and often include
electronic components such as engine and transmission
controls, instrument panels, ABS, etc. While most systems
operate on battery voltage (12 volts), some systems can be as
high as 90 volts or as low as five volts. Refer to the Electrical
Re-install the panel in the reverse order of the removal Circuit Diagram Manuals, available from International®,
procedure. to assure that any additional body lights and accessories
are connected to circuits that are both appropriate and not
Electrical System Inspections overloaded. No modification should be made to any vehicle
control system without first contacting your dealer.
Periodically inspect electrical connectors on the engine, Power
Distribution Center (PDC), battery and frame for corrosion and Noise Emissions — Exterior
tightness. Inspect exposed cables and harnesses for fraying or
signs of abrasion. Exposed terminals such as the fuel sender, Instructions For Proper Maintenance
cranking motor, alternator and feed-through studs should be
cleaned and re-coated with a lubricant sealing grease such as In order to comply with federal exterior noise regulations, your
Fleetrite® 472141–C1, or equivalent. This should include feed vehicle may be equipped with noise emission items. Depending
through connections, power and ground cable connections for upon the vehicle configuration, it may incorporate all or some of
batteries, engine and cab as well as the jump starting stud. the following.

92 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

Air Intake System: Engine and Driveline System:

• 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:

• Inspect for leaks at various joint connections and tighten


clamps. Make visual inspection for cracks or holes in
Cooling System: aftertreatment system and tail pipe. Always replace with
manufacturer recommended parts. Tail pipe elbow or offset
• Check fan for damage to blades; replace, if damaged, with tail pipe orientation must not be changed from standard
manufacturer recommended parts. Inspect for fan to shroud position as originally received.
interference, and any damage to shroud such as cracks and
holes. • To avoid abnormal changes in vehicle sound level, it
is necessary for the owner to perform inspections and
• Fan ratio should not be changed and fan spacer dimensions necessary maintenance at the intervals shown in the
and position should not be altered. maintenance schedules, and record on the inspection
• Inspect for proper operation of fan clutch making sure that verification form provided.
the fan is disengaged when cooling of engine is not required.
• Check for proper operation of radiator shutters, if
provided. Shutters should be open during normal operating
temperatures.

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Vehicle Maintenance, Service Intervals and Specifications

Suspension Inspection a specific manner to assure maximum service life. Before


attempting frame repair or modification, consult the service
Periodically: manual or your dealer.
• Check condition of spring leaves for evidence of fatigue, It is important, particularly on vehicles where the tow hooks are
bending or breaks. used frequently to inspect the tow hooks for damage or a loose
• Check condition of suspension mounting brackets and mounting.
bushings.
Propeller Shaft
• Check that suspension mounting fasteners (brackets,
bushings, etc.) are tight. At the regular lubrication interval, check the universal joints,
• Check that torque rod mounting fasteners are tight. slip joints, slip joint boot for any evidence of wear or looseness.
Should propeller shaft vibrations occur, stop the vehicle
• Check to be sure the suspension alignment is maintained at immediately to avoid possible hazardous consequences or
all time. damage to other components.
• Check U-bolts after the chassis has been operating under
load for 1,000 miles (1,600 km) or six months, whichever Wheels
comes first, the U-Bolt nuts must be re-torqued. The U-Bolt
nuts thereafter must be re-torqued every 36,000 miles General
(58,000 km). The U-Bolt and nut threads and seats should
be cleaned and lubricated to assure a “like new” condition Wheel bearings should be inspected, lubricated and adjusted
when re-torquing. at regular intervals. This is especially important if operating in
deep sand, mud, or water. Refer to Lubricant specifications in
Note: See the U-Bolt Nut Torque chart. this chapter.
When installing wheel balance weights, they must be mounted
Frame and Tow Hooks
on the dome-side of the wheel only. Failure to do so may result
The vehicle chassis is manufactured with frame rails of either in loss of wheel weight and/or damage to brakes or wheels.
mild carbon steel, or HSLA steel. Each must be handled in

94 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

Wheel Installation, Tightening And Alignment


WARNING

WARNING • Do not attempt to mix stud piloted wheels or fasteners


with hub piloted wheels or fasteners. To do so may
To avoid personal injury or death, always follow cause premature wheel failure resulting in property
these instructions when mounting radial tires on damage, personal injury, or death.
wheels:
• Do no mix foreign (not made in North America)
• Only personnel that have had proper training and wheel mounting parts with domestic (made in North
experience should mount or remove tires from rims or America) parts. Many foreign wheel components look
wheels. similar to, but not exactly the same as domestic made
components. Mixing components could cause wheel
• Use only heavy-duty rims or approved rims for radial
or fastener failures and result in property damage,
tires. It may be necessary to contact your wheel and
personal injury, or death.
rim distributor to determine if your rims are approved
for radial tires. • Do not change from aluminum wheels to steel wheels
or vice-versa without changing the mounting hardware
• If a tube is to be used, make sure special radial tire
where required or, in some cases with flange nut
tubes are used because of the increased flexing of the
mounting systems, changing the hub and stud
sidewalls on radial tires.
assembly. Mixing components could cause wheel
• Never use anti-freeze, silicones, or petroleum based or fastener failures and result in property damage,
lubricants when mounting radial tires. Only an personal injury, or death.
approved lubricant should be used as an aid for
mounting tires.
• Always inflate tires in a safety cage.

3812586R1 95
Vehicle Maintenance, Service Intervals and Specifications

Installation Procedures
WARNING

When installing the tire and rim assembly on WARNING


disc - brake equipped axles, make sure the tire
valve stem clears the brake caliper. The use of Use only the same type and style wheels and
either an International® valve stem retainer or a mounting hardware to replace original parts.
tire manufacturer’s stem forming tool is the only Failure to do so may result in an assembly, which
acceptable method of obtaining clearance when looks fine, but does not fit together properly. This
necessary. Failure to obtain proper clearance could cause wheel or fastener failures and result
may result in rapid tire deflation and cause in property damage, personal injury or death.
property damage, personal injury, or death. When installing wheels, make sure the threads on studs and
Tighten and maintain wheel and rim mounting nuts to the proper nuts are clean to permit correct torquing of nuts. The mounting
torque. Loose nuts or over-tightened nuts can lead to premature surfaces of wheels, spacer rings and clamps must be free of dirt,
wear and possible failure of the wheel, rim and/or mounting rust, lubricants or damage.
hardware. Use a wire brush to clean mounting contact surfaces. Do not
use lubricant on threads.
NOTE: Do not use lubrication on dry threads, however where
excessive corrosion exists, a light coat of lubricant on first three After the wheel has been properly tightened, check it for
threads of stud bolt is permitted. Keep lubricant away from: alignment. Rotate the wheel and tire with the tire sidewall in
close proximity to a stationary object. If the distance between
• Hex nut and rim clamp contact surfaces; the tire sidewall and the stationary object varies more than
• Flange nut washer surface and flat on disc wheel. 3/16 inch (4 mm). Check the tire, wheel, and wheel mounting
surfaces for possible damage or improper installation.

96 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

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.

3812586R1 97
Vehicle Maintenance, Service Intervals and Specifications

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.

98 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

Failure to maintain correct inflation pressure may result in


WARNING
sudden tire destruction, improper vehicle handling, and may
• Do not attempt to mix stud piloted wheels or fasteners cause rapid and irregular tire wear. Therefore, inflation
with hub piloted wheels or fasteners. To do so may pressures should be checked daily and always before long
cause premature wheel failure resulting in property distance trips.
damage, personal injury, or death. Follow the tire manufacturer’s recommended cold inflation
• Do no mix foreign (not made in North America) pressure for the tire size, type, load range (ply rating) and axle
wheel mounting parts with domestic (made in North loading typical for your operation. (Each steer axle tire load will
America) parts. Many foreign wheel components look equal 1/2 steer axle loading; each drive tire load will be 1/4 the
similar to, but not exactly the same as domestic made axle loading if fitted with four tires).
components. Mixing components could cause wheel
or fastener failures and result in property damage, Checking Inflation
personal injury, or death.
Always check inflation pressure when tires are cold. Never bleed
• Do not change from aluminum wheels to steel wheels air from hot tires to relieve normal pressure build-up. Normal
or vice-versa without changing the mounting hardware increases in pressure due to service conditions will be 10 to 15
where required or, in some cases with flange nut psi, which is allowable in truck tires.
mounting systems, changing the hub and stud
It is particularly important to keep moisture from the inside
assembly. Mixing components could cause wheel
of tires, and proper selection of air compressor equipment,
or fastener failures and result in property damage,
proper air line routing, and the use of shop air dryers is strongly
personal injury, or death.
recommended to avoid moisture in the high pressure air used
for tire inflation.
WARNING
Under Inflation
Do not mount tube type tires on tubeless wheels
or tubeless tires on tube type wheels. To do so Tires should not be permitted to become under-inflated.
could result in tire or wheel failure and cause Increased flexing due to under-inflation causes heat build-up
property damage, personal injury or death. within the tire components. This leads to reduced strength,
breakdown of the rubber compounds, and possible separation of
Preserving proper inflation pressure is a very important the tire components (i.e., ply and tread separation and reduced
maintenance practice to insure safe vehicle operation and long retreadability).
life for the tires.

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Vehicle Maintenance, Service Intervals and Specifications

Under-inflation is also the primary cause of blowouts. In addition, Loads


low inflation causes an increase in rolling resistance. This results
in reduced fuel mileage, a loss in tread mileage, and uneven
WARNING
wear due to increased tread movement. To determine proper
inflation refer to the tire inflation range stated on the tire sidewall. Loading tires beyond their rated capacity
decreases tire life requiring more frequent
Inspection replacement of tires. Overloading creates an
unsafe condition that may result in sudden air
Check condition of tires for abnormal wear patterns, and proper
loss from a tire failure resulting in an accident
inflation pressures. Cut or broken tire casing must be repaired
that could cause property damage, personal
or replaced.
injury or death.
Tires should be inspected for the following conditions. If any are
present, the tire should be removed and repaired, retreaded or NOTE: Your GAW / GVW rating is correct at the time of your
scrapped as the condition indicates. vehicle production, and reflects the exact rating of the tires
specified. When replacing tires be sure that the replacement tire
• Any blister, bump or raised portion anywhere on the surface
load rating (listed in pounds and kilograms on the tire sidewall)
of the tire tread or sidewall (other than a bump made by a
is the same or higher than the tire that is removed. Failure to do
repair). These indicate the start of internal separation.
so will adversely affect maximum load carrying capacity. Tires
• Any cut that reaches to the belt or ply cords, or any cut that with the same size specification do not always have the same
is large enough to grow in size and depth. load specification.
• Any nail or puncturing object.
Matching
• If any stone or object is held by a tread groove and is starting
to drill into the tread base, remove the object. Dual Tires
Proper tire inflation, toe-in adjustment, loads, and road speeds Dual tires should be matched using tires of equivalent size. Tires
are important factors governing tire mileage, steering ease and which differ more than 1/4 inch (6mm) in diameter or 3/4 inch
maneuverability. (19mm) in circumference should not be mounted on the same
dual wheel assembly.

100 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

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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Vehicle Maintenance, Service Intervals and Specifications

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.

102 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

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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Vehicle Maintenance, Service Intervals and Specifications

Lubrication and Maintenance Interval Chart — Recommended Synchronized Intervals


System Item Intervals Special Interval3 : miles (km) / hours / months
Vehicle Inspection Items listed in Section 2 — Check All A, B
Front Axle Drag Link – Lubricate 1
A, B
Suspension Fasteners / Components – Check A, B
Tie Rod Ends – Lubricate 1
A, B
King Pins and Bushings – Lubricate 1, 2
A, B
Shock Absorbers - Inspect A, B
Wheel Bearing-Mineral Grease or Synthetic Grease –
30,000 (48,000)/–/6
Repack
Wheel Bearing-Mineral Oil or Synthetic Oil – Repack 60,000 (96,000)/–/6
Wheel Bearings - Check End-play B
Axle U-bolts – Retorque @ 1ST 1,000 miles (1,600 km) then every
36,000 mi (58,000 km) thereafter
NOTE 1: A hand-pumped grease gun should be used for optimal grease distribution within the component joint.

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.

Electrical Engine Start and Gauge/Warning Lights - Check A, B


Instrument Readings Proper - Check A, B
ABS Wiring Connections & Sensors - Reseat A, B
Alternator-Starter-Battery - Check B

104 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

Lubrication and Maintenance Interval Chart — Recommended Synchronized Intervals (cont.)


System Item Intervals Special Interval3 : miles (km) / hours / months
Steering Power Steering Fluid – Check Level A, B
Steering System – Check Tightness A, B
Steering Gear - Lubricate ATTN: Install grease slowly at low pressure.
A, B
Power grease guns may blow out seals.
Steering Intermediate Shaft U-Joints – Retorque 60,000 (96,000)/1,500/12
Power Steering Fluid – Change 100,000/-/5 years
Power Steering Filter – Replace 60 months
Drive Shaft U-Joints and Slip Joint - Lubricate Special grease is required to maintain the A
“Non-booted interval (see Lubrication and Sealer specifications
A
Slip Joint” — Drive Shaft). If not used, interval will be
7,500 miles or 3 months.
Hydraulic Master Cylinder – Check Fluid Level A, B
Brakes
Brake Pedal Holds Pressure - Check A, B
Service Brakes Operation - Check A, B
Parking Brake Operation and Adjustment - Check A, B
Discs, Calipers, Lines, etc – Check for wear / damage A, B
Parking Brake Cable – Check condition A, B

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Vehicle Maintenance, Service Intervals and Specifications

Lubrication and Maintenance Interval Chart — Recommended Synchronized Intervals (cont.)


System Item Intervals Special Interval3 : miles (km) / hours / months
Cooling Coolant – Check Level A, B
System
Radiator & CAC Fins – Check for Blockage A, B
Fan Clutch - Check A, B
Fan Blade / Shroud – Check Damage/Contact A, B
Extended Life Coolant – Add Extender Refer to Engine Operation and Maintenance Manual
Extended Life Coolant – Replace Refer to Engine Operation and Maintenance Manual
Engine Engine Oil Level - Inspect A, B
Fan Belt - Inspect A, B
Air Filter – Check Restriction A, B
Air Induction System – Check looseness/leaks A, B
Air Filter – Replace @ Restriction Indication or 60 months
Engine Oil and Filter(s) - Replace Refer to Engine Operation and Maintenance Manual
Fan Belt Auto Tensioner - Inspect Refer to Engine Operation and Maintenance Manual
Fuel Filters — Drain Separated Water Refer to Engine Operation and Maintenance Manual
Fuel Filters – Replace Refer to Engine Operation and Maintenance Manual
Fuel Tank(s) Fuel Tank(s) — Drain Water B
Fuel Sender, Hose Connections — Check for Loose
12 months
Connectors
Exhaust Pipes / Aftertreatment System - Inspect for leakage /
A, B
System looseness
Diesel Particulate Filter (DPF) – Cleaning As required by dash warning light.

106 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

Lubrication and Maintenance Interval Chart — Recommended Synchronized Intervals (cont.)


System Item Intervals Special Interval3 : miles (km) / hours / months
Transmission Trans Fluid, Automatic – Check Level A, B
Shift Selector / Linkage – Check Function A, B
Neutral Start Switch – Check Function A, B
Automatic Trans Fluid and Internal Filter – Replace 60,000(96,000)/1600/—
Rear Axle Suspension Fasteners / Components – Check A, B
Axle Flange Nuts – Retorque B
Rear Axle with Mineral Oil - Change 100,000 (160,000)/—/12
Rear Axle with Synthetic Oil – Change 250,000 (400,000)/—/5 years
Axle U-bolts – Retorque @ 1st 1,000 mi (1,600 km) then every 36,000
mi (58,000 km) thereafter
Tires / Air Pressure - Check A, B
Wheels
Wear and Condition - Check A, B
Wheel Stud Nuts - Retorque A, B
Spin Balance @ time of tire mounting
Cab Door HInges/Latches/Strikers – Lubricate, Check Link (Use
Components Multi-purpose lithium grease or light engine oil. Do Not A, B
use silicone lubricant).
Door Lock Cylinders — Lubricate A, B
Seat Adjuster Slides — Lubricate A, B
Cab Tilt and Latch Mechanism — Lubricate A, B

3812586R1 107
Vehicle Maintenance, Service Intervals and Specifications

Refill Capacities
Fluid Capacity
Engine coolant 24 quarts (22.7L) 1

Without filter change: 14 quarts (13.3L)


Engine oil
With filter change: 15 quarts (14.2L)
Transmission fluid 2 7.5 quarts (7.1L) 3 (Includes filter change)
Rear axle 16 pints (6.6L) 4, 5

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.

108 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

Tire/Wheel Rim Selection And Inflation Pressures

Approved rim Axle capacity


Tire size Load range
widths Front - lbs. (kg)/psi (kPa) Rear - lbs. (kg)/psi (kPa)
225/70R19.5 F 6.00 6000 (2722)/ 95 (655) 11000 (4990)/ 95 (655)
225/70R19.5 F 6.00 7000 (3175)/ 95 (655) 13000 (5897)/ 95 (655)

Headlamp Aim Adjustment


1. Place the vehicle with the following conditions:
a. The area around the headlamps is not deformed.
b. The unloaded vehicle is parked on a flat level surface.
c. Tire inflation pressure is at the specified value.
d. The vehicle is in a state ready for driving (with a full tank
of fuel, oil level and coolant).
e. The vehicle has been bounced several times.
2. To check the headlamp aiming:
a. Prepare a thick white paper.
b. Stand the paper perpendicular to the ground at a
position 3 m (9.84 ft) away from the headlamps.
c. Ensure that the centerline of the vehicle is perpendicular
to the paper face.

3812586R1 109
Vehicle Maintenance, Service Intervals and Specifications

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.

110 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

3. To adjust the headlamp aim:

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.

NOTE: Do not finish the aiming procedure by turning the


screws in the counterclockwise screwdriver direction. If you
are adjusting in the counterclockwise screwdriver direction,
overshoot the adjustment by one full turn and then turn the
screwdriver clockwise one full turn, so you finish the adjustment
in the clockwise direction and still line up with the vertical aiming
line. This applies to both screws.

a. Use a #2 Phillips screwdriver with at least a 150 mm (6


in) long shaft.
b. Insert the screwdriver in the inboard aiming hole until it
engages the gear at the back of the headlamp. ALWAYS
start with the inboard aiming screw as it is the primary
vertical aiming screw.

3812586R1 111
Vehicle Maintenance, Service Intervals and Specifications

c. Turn the screwdriver in the counterclockwise direction Bulb Replacement


to move the headlamp aim upward or in the clockwise
direction to move the headlamp aim downward, WHILE Function Trade Number
COUNTING THE NUMBER OF TURNS MADE.
Ashtray 74T-5
Continue turning this screw until the vertical aim is
properly adjusted, but make sure you finish in the Dome L:2X
clockwise screwdriver direction. If you are adjusting in Foglights 64151
the counterclockwise screwdriver direction, overshoot
the adjustment by one full turn and then turn it clockwise Roof Marker Lights 0194
one full turn, so you finish the adjustment in the High Beam Headlight 9007 LL
clockwise direction and still line up with the vertical
Low Beam Headlight 9007 LL
aiming line.
Park Lamp 1157NA
d. Then insert the screwdriver in the outboard aiming hole
until it engages the gear at the back of the headlamp. Front Turn Signal 1157NA

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
Vehicle Maintenance, Service Intervals and Specifications

Lubricant and Sealer Specifications

Lubricant and Sealer Specifications


Component Component Vendor / Lubrication Type Viscosity/Ambient Temperature/Notes
Non-driving Front Axle
Front axle wheel bearing Fleetrite® Lithium Complex Based Moly grease P/N NOTE: With chassis load on axle, force grease thru thrust
grease, Tie Rod Ends, 991044C2 or equivalent GC/LB NLGI #2 Multi-purpose bearings; then with axle lifted clear of floor, force grease
Drag Link, King Pin and Lithium Complex grease between king pin and bushing surfaces.
Bushing
Brakes
Brake Fluid DOT 3 Brake fluid
Engine
Engine Lubricating Oil See Engine Operation and Maintenance Manual See Engine Operation and Maintenance Manual

3812586R1 113
Vehicle Maintenance, Service Intervals and Specifications

Lubricant and Sealer Specifications (cont.)


Component Component Vendor / Lubrication Type Viscosity/Ambient Temperature/Notes
Electrical
Terminals-Electrical International Part Number 2593148C1
Terminal Protection
Connectors - Dielectric NYOGEL 760 G
Grease
Steering
Power Steering fluid Fleetrite Power Steering Fluid P/N CH990625C2
change
Strg. Gear Ross TAS- Fleetrite ® Lithium Complex Based Moly grease P/N
Output Seal - Lubricate 991044C2 or equivalent GC/LB NLGI #2 Multi-purpose
Lithium Complex grease
Strg. Intermediate Shaft Fleetrite® Lithium Complex Based Moly grease P/N
U-Joints/ Slip Joint - 991044C2 or equivalent GC/LB NLGI #2 Multi-purpose
Lubricate Lithium Complex grease
Drive Shaft
U-Joint - Lubricate Shell Retinax LC, NLGI Grade 2, P/N 2643012R1

114 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

Lubricant and Sealer Specifications (cont.)


Component Component Vendor / Lubrication Type Viscosity/Ambient Temperature/Notes
Cooling System
Coolant REFER TO ENGINE OPERATION AND MAINTENANCE MANUAL
Extended Life Coolant Shell Rotella Extended Life Coolant (ELC)
Transmission
Transmission Fluid Mercon® SP only, part number 2645005R1
Rear Axle
Dana-Spicer Rear Axle Multipurpose EP gear lube of API GL-5 quality meeting 75W : -40°F to - 15°F (-40°C to -26°C)
MIL-PRF-2105E specs including synthetic lubricants.
75W -80: -40°F to 80°F (-40°C to 27°C)

75W -90: -40°F to 100°F (-40°C to 38°C)

75W -140: -40°F and above (-40°C and above)

80W -90: -15°F to 100°F (-26°C to 38°C)

80W -140: -15°F and above (-26°C and above)

85W -140: 10°F and above (-12°C and above)


Cab Tilt and Latch Mechanism
Latches, Locking Levers White Lithium aerosol grease, NAL4816 or equivalent
and Latch Pivots

3812586R1 115
Vehicle Maintenance, Service Intervals and Specifications

Torque Specifications SPRING U-BOLT CHECKS

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.

U-BOLT NUT TORQUE CHART

Torque
lbf – ft N.m
260 — 300 353 — 407

116 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

POWER DISTRIBUTION CENTER

3812586R1 117
Vehicle Maintenance, Service Intervals and Specifications

Fuse/ Relay Fuse Amp Fuse/ Relay Fuse Amp


Fuse Description Fuse Description
Location Rating Location Rating
1 — Not used 24 20A** Cigar lighter
2 30A* Starter 25 20A** Hazard flasher
3 20A* Park lamps 26 15A** Remote Keyless Entry (RKE)
4 50A* ECM 27 10A** Radio
5 30A* Headlamps 28 10A** Dome lamp
6 40A* Blower motor 29 60A* ABS pump
7 25A* Wipers 30 30A* A/C fan
8 30A* Electric brakes 31 20A* Diagnostic connectors
9 20A* Door locks 32 40A* Power windows
10 20A* Stoplamps 33 25A* Body builder prep
11 20A* Fuel pump 34 20A* A/C clutch
12 20A* RUN/ACC feed 35 20A* Cluster
13 20A* RUN/START feed 36 — Not used
14 15A** Horn 37 10A** Turn signals
15 10A** Cluster 38 — Not used
16 15A** Back-up lamps 39 10A** Cornering lamps
40 — Not used
17 15A** Fog lamps
41 — Not used
18 15A** Transmission
42 10A** Radio
19 20A* Fuel heater
43 — Not used
20 60A* Anti-lock Brake System (ABS)
44 — Not used
module
21 20A* Trailer Box 45 — Not used

22 — Not used 46 20A** ECM key power

23 40A* Trailer battery charge 47 Micro relay Body builder prep

118 3812586R1
Vehicle Maintenance, Service Intervals and Specifications

Fuse/ Relay Fuse Amp RELAY BOX


Fuse Description
Location Rating
48 Micro relay Fuel pump
49 Micro relay Back-up lamps
50 — Not used
51 Micro relay Fuel heater
52 Micro relay Transmission
53 Micro relay A/C clutch
54 Micro relay Fog lamps
55 Full ISO relay ECM
56 Full ISO relay Wiper
57 Full ISO relay Starter
58 — Not used
59 Micro relay Park lamps
60 — Transmission relay diode
61 — Not used
* Cartridge fuse

**Mini fuse

3812586R1 119
Vehicle Maintenance, Service Intervals and Specifications

120 3812586R1
Entertainment Systems

SECTION 6 — ENTERTAINMENT SYSTEMS


AM/FM Stereo (if equipped)

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.

4. DSPL TM SET: Press to display the time or to set


the clock.
2. PWR: Press to turn the radio on and off.

3812586R1 121
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.

• After five seconds, the display will show the time.

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.

122 3812586R1
Entertainment Systems

AM/FM Stereo/Cassette (if equipped)

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.

3812586R1 123
Entertainment Systems

3. Setting the clock: 6. ▲ : Press to eject the cassette.

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.

5. SEEK: Press and hold (for more than ½ second) ↑ or


10. BASS/TREBLE: Turn to adjust the amount of
↓; the radio will automatically stop at the next radio
bass output. Pull the control out fully (to lock it)
station.
and turn to adjust the amount of treble output.
After adjusting the treble, push the control back
in.

124 3812586R1
Entertainment Systems

AM/FM Stereo/CD (if equipped)

1. PWR: Press to turn the audio system on or off. speakers. Fader: Adjust the audio between front and rear
speakers.

3. CLK: Press to see the time or to set the clock.


To set the clock: Press and hold CLK to set the
time. The display will flash indicating time setting
2. VOL BASS/TREB/BAL/FADER: Pressing the mode is activated. Press ٧ to set the hour and ٨ to
control (SEL) will switch between Bass, Treble, set the minute. (Press and hold ٧ or ٨ to change the numbers
Balance and Fade. Volume: Turning the rapidly.) Once the time has been set, release CLK. If the time
control left or right will adjust the volume level. has not been stored in the radio, “SET” will be displayed.
Bass: Increase or decrease bass by turning
the control left or right. Treble: Increase or
decrease treble by turning the control left or
right. Balance: Adjust the audio between left and right

3812586R1 125
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.

CD/CD Player Care


Do:
• Handle discs by their edges only. Never touch the playing
surface.

128 3812586R1
Customer Assistance

SECTION 7 — CUSTOMER ASSISTANCE


Service Information (Toll-Free Fax Order phone number — 1-800-882-0484) or by
visiting www.internationaldelivers.com
The continued premium performance of this International truck
can best be assured through proper vehicle servicing. This can NOTE: When ordering any service information, be sure to
be accomplished in several ways. provide your truck’s model designation, build date, engine
International Truck Dealers ... Your local International series, and the Vehicle Identification Number (VIN).
truck dealer provides an excellent resource — through his To obtain Caterpillar® or Cummins® engine service publications,
knowledgeable, experienced, and well equipped service staff — contact your local International truck dealer or the nearest
to handle all your maintenance, repair and replacement work; Caterpillar or Cummins authorized service facility.
International Master Service Manual ... Those persons who
are properly trained technicians with the facilities, equipment, International® Warranty Program
tools, safety instructions and know-how to properly and safely
service a bus, medium duty and/or heavy duty chassis can Standard Warranty • Optional Service Contracts • Custom
purchase the appropriate individual printed Service Manual Service Contracts • Performance PM
sections applicable to specific vehicle component groups for The International Warranty Program provides International
this International vehicle; customers with a better choice when it comes to Standard
International Engine Diagnostic and Service Manuals ... Warranty and Service Contract Coverage. The Standard
Engine diagnostic and engine service manuals for all current Warranty is the first tier of the International Warranty Program.
International engines are also available to these trained persons It provides the foundation for all extended coverages.
for purchase. Vehicle Coverage, Towing, Engine and Engine Electronics,
These service resources are also available in CD-ROM Major Component, and Pre-Packaged System Component
format with quarterly updates. The Diamond ISIS® CD-ROM protection can be obtained under the International Warranty
set contains all recent available chassis and component Program through Optional Service Contracts.
service information, including TSI Letters, Circuit Diagrams, Custom Service Contracts, the most flexible aspect of
Troubleshooting Guides and other technical information for the International Warranty Program, can provide extended
virtually all International models and engines. protection that is specifically tailored to meet each customer’s
Information can also be obtained by calling Moore Wallace specific requirements.
North America, International Order Desk at (630) 313–7507

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
Index

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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L (CONT.) L (CONT.)
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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P R (CONT.)
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

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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

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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

Diesel engine exhaust and some of its constituents are known


to the State of California to cause cancer, birth defects and
other reproductive harm.