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


Section 1 – Foreword
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Cautions and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Assistance Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Component Code Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Line Set Ticket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Vehicle Storage Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Exterior Noise Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Tampering With Noise Control System Prohibited. . . . . . . . . . . . . . .3
Emission Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Verification of Inspection — Noise Emissions. . . . . . . . . . . . . . .4
Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
U.S. Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Canadian Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Safety Recalls and Authorized Field Changes. . . . . . . . . . . . . .5
International Customer Security Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Section 2 – Vehicle Inspection Guide
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Tilting/Lowering Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Tilting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Cab/Fuel Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Engine Start with Parking Brake(s) Applied. . . . . . . . . . . . . . . . . . . . .12
Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Front Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Front Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Under Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3812586R1
Table of Contents
Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Rear Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Rear Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Rear Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Section 3 – Vehicle Controls
Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Warning Lights and Chimes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Climate Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Heater Only System (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Heater and Air Conditioning System (Optional). . . . . . . . . . . .28
Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Headlamp Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Turn Signal Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Hazard Flasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Interior Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Bulb Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Driver Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Windshield Wiper/Washer Controls. . . . . . . . . . . . . . . . . . . . . . . . .33
Tilt/Telescope Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Power Windows (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Speed Control (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Regeneration Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Lock and Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Power Door Locks (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Remote Entry System (if equipped). . . . . . . . . . . . . . . . . . . . . . . . .39
Unlocking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
i
Table of Contents
Locking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Sounding a Panic Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Replacing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Replacing Lost Remote Entry Transmitters. . . . . . . . . . . . . . . .40
Section 4 – Vehicle Operation
Vehicle Entry and Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Seating and Occupant Restraints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Seat Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Combination Lap and Shoulder Belts. . . . . . . . . . . . . . . . . . . . . . .44
Vehicle Sensitive Retractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Front Safety Belt Height Adjustment. . . . . . . . . . . . . . . . . . . . . . . .45
Lap Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Safety Belt Warning Light And Indicator Chime. . . . . . . . . . . .46
Care of Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Positions Of The Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Restarting After Running Out Of Fuel. . . . . . . . . . . . . . . . . . . . . . .48
Optional Engine Protection System — 3 Way (08WPP). . .48
General Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Backing up/Electric Back-up Alarm. . . . . . . . . . . . . . . . . . . . . . . . . .50
Parking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Exhaust Filter Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Parked Regeneration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Regeneration Inhibit Switch (Optional). . . . . . . . . . . . . . . . . . . . . .53
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
If Brakes Do Not Grip Well. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
ii
Hydraulic Brake Booster System (HydroBoost). . . . . . . . . . . .55
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Antilock Brake System (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Automatic Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Brake-Shift Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Understanding Shift Positions of the 5–speed
Automatic Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
If Vehicle Gets Stuck In Mud Or Snow. . . . . . . . . . . . . . . . . . . . . .61
Power Take Off Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Gross Axle Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Axle Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Vehicle Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Jump Starting Your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Preparing Your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Connecting the Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Jump Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Removing the Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Towing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Towing Vehicle With Front Wheels Suspended. . . . . . . . . . . .65
Towing Vehicle With Rear Wheels Suspended. . . . . . . . . . . .66
Tow Hooks (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Section 5 – Vehicle Maintenance, Service
Intervals and Specifications
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Supporting Your Vehicle for Service. . . . . . . . . . . . . . . . . . . . . . . . .69
Chassis Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Cab Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Care Of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Washing and Waxing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
3812586R1

Bright Metal Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Upholstery Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Plastic Bumper and Side Skirt Protection. . . . . . . . . . . . . . . . . .71
Air Conditioning System Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Front Axle - General Service Information. . . . . . . . . . . . . . . . . . . . . . . .71
Rear Axle - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Rear Axle Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Brake System - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Hydraulic Brakes - General Inspection And Adjustment. . .74
Hydraulic Brakes - Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Hydraulic brakes - Fluid Precautions. . . . . . . . . . . . . . . . . . . . . . . .74
Brake Fluid Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Hydraulic Brakes - Brake Lines, Hoses And Fittings. . . . . .75
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Tilting/Lowering Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Tilting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Checking Engine Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Checking Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Adding Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Extended Life Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Coolant Concentration Freeze point. . . . . . . . . . . . . . . . . . . . . . . .79
Recycled Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Engine Coolant Capacities and Part Numbers. . . . . . . . . . . . .79
Fan Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Windshield Washer Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Steering - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Tightening Steering Column Joint Bolts. . . . . . . . . . . . . . . . . . . .82
Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
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Table of Contents
Power Steering Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Transmission Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Checking Automatic Transmission Fluid. . . . . . . . . . . . . . . . . . . .83
Automatic Transmission Fluid Filter. . . . . . . . . . . . . . . . . . . . . . . . .85
Engine and Subsystem Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Air Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Air Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Ultra Low Sulfur Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . .87
Unacceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Hazards Of Diesel Fuel/Gasoline Blends. . . . . . . . . . . . . . . . . . .88
Fuel and Lubricant Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Fueling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Reserve Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Running Out of Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Fuel Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Chassis-Mounted Charge Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Air Intake Piping Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Electrical System Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Noise Emissions — Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Instructions For Proper Maintenance. . . . . . . . . . . . . . . . . . . . . . .92
Air Intake System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Body:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Cooling System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Engine and Driveline System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Exhaust System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Suspension Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Frame and Tow Hooks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
iii
Table of Contents
Propeller Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Wheel Installation, Tightening And Alignment. . . . . . . . . . . . . .95
Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Wheel Mounting Nuts Torque Sequence. . . . . . . . . . . . . . . . . . .97
Aluminum Disc Wheels with Flange Nuts (Hub Piloted). . .97
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Checking Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Under Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Matching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Dual Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Mixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rotation Is Always Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rotation May Not Be Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . .101
Wheel And Tire Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Tires — Irregular Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Use Of Tire Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Lubrication and Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . .103
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Tire/Wheel Rim Selection And Inflation Pressures. . . . . . . . . . . .109
iv
Headlamp Aim Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Lubricant and Sealer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Disc Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Spring U-Bolt Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Power Distribution Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Relay Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Section 6 – Entertainment Systems
AM/FM Stereo (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
AM/FM Stereo/Cassette (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . .123
AM/FM Stereo/CD (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Radio Frequencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Section 7 – Customer Assistance
Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
International® Warranty Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Section 8 – Index
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
3812586R1

SECTION 1 — FOREWORD
Preface
Your vehicle has been engineered and manufactured so that it
can provide economical and trouble-free service. However, it is
the owner’s responsibility to see that the vehicle receives proper
care and maintenance.
Making modifications to various parts, components and
systems of your vehicle, such as brake and steering systems,
can adversely affect the quality and reliability of your vehicle.
Such modifications must be avoided.
Cautions and Warnings
Throughout this manual you will find Cautions and Warnings:
CAUTION
Cautions will advise you of the proper care to be
taken to avoid damage to your vehicle or property.
WARNING
Warnings advise you of hazards, the
consequences, and what to do to avoid
them, not only to avoid damage to your vehicle
or property, but to help avoid situations and
occurrences which could result in personal
injury or death.
3812586R1
Foreword
Study this manual carefully. Do not operate your vehicle until you
are completely familiar with the contents of this manual. Always
retain this manual in your vehicle for reference. If you sell the
vehicle, make sure the manual goes with it.
Assistance Guide
When parts are required, always provide the unit code number,
vehicle model and Vehicle Identification Number (VIN). Request
the salesperson to assist you in obtaining this information upon
delivery.
For information not given in this manual, or if you require services
of trained service personnel, we urge you to contact a nearby
International® dealer, or phone 1-800-44-TRUCK (87825) for
assistance.
International® believes that every customer is entitled to the best
service, both from the product itself and from the firm who sells
and services that product.
If, for any reason, you do not feel you are receiving these
services in connection with the operation of your vehicle or
the sales transaction, you should return to your selling dealer
so that these matters can be corrected to your satisfaction. If
the matter is not resolved at that time, it is suggested that the
following steps be taken:
1
Foreword
Contact a Member of Management at the Dealer.
Discuss the details of the difficulty. In most instances any
problem can be resolved to your satisfaction by the owner or
manager in charge.
Contact Closest International® Sales Region Office or the
Customer Relations Manager.
Addresses of Region Sales Offices and the Customer Relations
Manager are found on the first page of this manual. Should you
desire to contact any of these offices, it is important to include
the following information in your communication.
• Name under which new vehicle was purchased, address and
telephone number of purchaser
• Vehicle model, year, vehicle identification number,
component code and serial numbers
• Vehicle delivery date and present mileage
• Location where purchased
• Details of the problem.
Component Code Numbers
Code numbers are the basis for identifying the components used
on International trucks. They are used by sales personnel to
order the truck, by manufacturing to build that truck and by parts
personnel to service the truck. Many items in this manual are
identified by codes.
Code numbers are a combination of numbers and/or
alphabetical letters. These codes are listed on the Vehicle
2 3812586R1
Line Set Ticket which is sometimes known as the vehicle
specification card or code sheet.
Line Set Ticket
Each vehicle is provided with a Line Set Ticket (code sheet)
which lists identification code numbers of component units used
to build the vehicle.
One copy of the line set ticket is included in the literature
provided with the vehicle. When replacement parts are
required, take this copy with you to positively identify vehicle
components to be sure of getting the correct parts.
Be Sure To Return Line Set Ticket To Vehicle After Obtaining
Parts.
Vehicle Storage Instructions
When a vehicle is not used for an extended period of time,
certain precautions must be taken to prevent deterioration of
some components. Contact your dealer for advice on vehicle
storage, as well as proper procedures to follow when you return
the vehicle to service.
Exterior Noise Emissions
Many operators and owners of the type of vehicles described
herein are subject to Federal Motor Carrier Safety Regulations
and Noise Emission Requirements. All owners and operators
are urged to obtain a copy and comply with these regulations.
Copies of these regulations can be purchased from:

Superintendent of Documents
U.S. Government Printing Office
Washington, D.C. 20402
International Truck and Engine Corporation warrants to the
first person who purchases this vehicle for purposes other than
resale and to each subsequent purchaser that this vehicle, as
manufactured by International Truck and Engine Corporation,
was designed, built and equipped to conform at the time it left
International Truck and Engine Corporation’s control with all
applicable U.S. Environmental Protection Agency Noise Control
Regulations.
This warranty covers this vehicle as designed, built and
equipped by International Truck and Engine Corporation, and
is not limited to any particular part, component or system of
the vehicle manufactured by International Truck and Engine
Corporation. Defects in design, assembly or in any part,
component or system of the vehicle as manufactured by
International Truck and Engine Corporation, which at the time it
left International Truck and Engine Corporation’s control, cause
noise emissions to exceed Federal standards, are covered by
this warranty for the life of the vehicle.
Tampering With Noise Control System Prohibited
Federal law prohibits the following acts or the causing thereof:
(1) The removal or rendering inoperative by any person other
3812586R1
Foreword
than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle
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
the vehicle after such device or element of design has been
removed or rendered inoperative by any person. Among those
acts presumed to constitute tampering are the acts listed as
follows: A. Air Intake System: Removal of air cleaner, intake
silencer or piping. B. Acoustical Shielding (Body): Removal of
wheel well splash shields, cab shields or acoustical (underhood)
insulation. C. Cooling System: 1. Removal or rendering
inoperative the fan clutch. 2. Removal of fan shrouds. D.
Engine and Driveline System: 1. Removal or rendering engine
speed governor inoperative so as to allow engine speed to
exceed manufacturer specifications. 2. Removal of engine
block shield, oil sump shield or transmission enclosures. E.
Exhaust System: Removal or rendering inoperative exhaust
system components including aftertreatment system or tailpipe.
Use the following “Verification Of Inspection” forms to log Noise
Emission inspections of, at a minimum, the above systems.
Emission Control Systems
NOTE: Federal and California Emission system warranties are
found in your Engine Operation and Maintenance Manual.
3
Foreword
VERIFICATION OF INSPECTION — NOISE EMISSIONS
Reporting Safety Defects
U.S. REGISTERED VEHICLES
If you believe that your vehicle has a defect which could cause
a crash or could cause injury or death, you should immediately
4 3812586R1
inform the National Highway Traffic Safety Administration
(NHTSA) in addition to notifying International Truck and Engine
Corporation. To notify International, see regional numbers,
listed in the front of the manual.
If NHTSA receives similar complaints, it may open an
investigation, and if it finds that a safety defect exists in a

group of vehicles, it may order a recall and remedy campaign.
However, NHTSA cannot become involved in individual
problems between you, your dealer, or International Truck and
Engine Corporation.
To contact NHTSA, you may either call the Auto Safety Hotline
toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation,
Washington, D.C. 20590. You can also obtain other information
about motor vehicle safety from the Hotline.
CANADIAN REGISTERED VEHICLES
If you believe that your vehicle has a defect which could cause
a crash or could cause injury or death, you should immediately
contact International Truck and Engine Corporation Canada and
then Transport Canada.
To contact International Truck and Engine Corporation Canada,
you may either call the Regional Service Manager (Canadian
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
Foreword
To contact Transport Canada, Defect Investigation and Recalls,
you may call 800-333-0510. You can also write to: Transport
Canada, ASFAD, Place deVille Tower C, 330 Sparks Street,
Ottawa, Ontario K1A 0N5.
SAFETY RECALLS AND AUTHORIZED FIELD CHANGES
Safety Recalls and Authorized Field Changes are two
campaigns that are used to notify owners of modifications
that may involve their vehicle. If you receive such notification,
PLEASE FOLLOW ALL INSTRUCTIONS PROVIDED IN THE
CUSTOMER LETTER. If your vehicle is part of a Safety Recall
campaign, the recall service procedure must be completed
to assure safe operation of your vehicle. As a vehicle owner,
you must provide International Truck and Engine Corporation
dealers with address corrections and changes to ensure that
you receive all notifications. Please verify that your local dealer
has your correct address. Dealers will also have a record of any
outstanding campaigns that affect your vehicle.
5
Foreword
International Customer Security Guide
International has prepared this guide to help you protect
your vehicle investment from theft. We realize the financial
commitment you have made is significant, and that you depend
on that vehicle to generate profits and a livelihood. Vehicle theft
can be more than an economic crime. Protecting your vehicle
from theft or hijacking can be crucial to the safety and security
of the country and economy. While no system or device is 100%
effective, our intention is to provide some tips that you or your
drivers can use to reduce the risk of theft.
If you suspect vehicle theft activity, take a minute to tell the
National Insurance Crime Bureau (NICB) at 1–800–TEL-NICB.
You can make the free call anonymously and you might be
eligible for a reward. To learn more about vehicle theft and how
you can protect yourself, visit the NICB’s website, www.nicb.org
Add Layers of Protection
International recommends four layers of protection for your
vehicle — the more layers of protection on your vehicle, the
more difficult it is to steal.
Layer 1: Common Sense
• Lock your doors.
• Remove your keys from the ignition.
• Close your windows completely.
• Park in well-lit areas.
6 3812586R1
• Drop a business card with your name on it between the glass
and doorframe. This can aid in identifying the truck when it’s
recovered.
• Keep a copy of the lineset ticket in a location other than your
truck for reporting purposes and a copy of the VIN in your
wallet.
• Photograph the interior and exterior of your truck from
various angles and keep these photographs in a safe
non-truck location, or send them to your insurance agent.
• Report a theft as soon as it’s discovered to the local police
and to your insurance company.
• Post a driver has no cash sign on your door to discourage a
robbery.
• Permanently mount your C.B. radio or remove it when you
will be away from your truck.
• Do not discuss where your vehicle is located when you are
not on the road.
• Do not share information about your specific destination, or
the load you are hauling.
• Be conscious of other vehicles that may be following you
over long distances — call the police.
• Be very suspicious of motorists that are signaling the driver
to stop or pull over. Call the police, report the incident, and
let the police respond.
Layer 2: Visible or Audible Device
• Audible alarm system
 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):
Leaks:
Windshield Washer Fluid Level:
Master Cylinder Brake Fluid:
Check to see that tank(s) is secure and that caps are secure. Make sure there is no damage to
the tank(s).
Check for any fuel leaks from tank(s).
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.
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.

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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:
Lights, Reflectors:
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.
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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 Vehicle Controls

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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 Vehicle Controls

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
• To reduce fog build up on the windshield during humid
weather, place the air flow selector in the defrost position.
• To reduce humidity build up inside the vehicle: do not drive
with the recirculated air selector in the recirc position.
• Under normal weather conditions, do not leave the
recirculated air selector in recirc when the vehicle is
parked. This allows the vehicle to “breathe” using the
outside air inlet vents.
• Remove any snow, ice or leaves from the air intake area at
the base of the windshield.
To aid in side window defogging/demisting in cold weather:
1. Select panel vent
2. Set the temperature control to full heat
3. Set the fan speed to its highest setting
4. Direct the outer instrument panel vents towards the side
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)
WARNING
Do not use the cruise control system when
unpredictable driving conditions are present.
Such conditions include heavy traffic, roads
that are winding, icy, snow covered, slippery,
or with a loose surface. These conditions may
cause wheel slippage and loss of vehicle control,
resulting in property damage, personal injury or
death.
To turn speed control on
Press CRUISE RPM. If the vehicle
is moving, speed control will be
enabled; if the vehicle is stationary,
engine RPM can be controlled.
Do not shift the gearshift lever into N (Neutral) with the
speed control on.
36
To turn speed control off
Press the top portion of the control or
turn off the ignition.
Once speed control is switched off,
the previously programmed engine
RPM will be erased.
To set a speed (with speed control
on)
Press SET - If the vehicle is moving,
this will set the vehicle speed. If the
vehicle is stationary, this will set the
vehicle idle RPM.
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
than the set speed while driving on a downhill, you may want to
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.
3812586R1
 Vehicle Controls

To set a lower set speed To disengage speed control

Press and hold SET - If the vehicle
is moving, this will decrease vehicle
speed; if the vehicle is stationary, this
will decrease engine RPM. Release
the control when the desired vehicle
speed/engine RPM is reached.
Press and release SET - to operate
the tap-down function. Each press
will decrease the set speed by 1 mph
(1.6 km/h) or engine RPM in idle
mode.
Depress the brake pedal.
Disengaging the speed control
will not erase the previously
programmed set speed or engine
RPM.
Pressing the top portion of the
control will erase the previously
programmed engine RPM.
To return to a previously set
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.

3812586R1 37
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.

38 3812586R1

Remote Entry System (if equipped)
This device complies with part 15 of the FCC rules and with
RS-210 of Industry Canada. Operation is subject to the
following two conditions: (1) This device may not cause harmful
interference, and (2) This device must accept any interference
received, including interference that may cause undesired
operation.
Changes or modifications not expressly approved by the
party responsible for compliance could void the user’s
authority to operate the equipment.
The typical operating range for your remote entry transmitter
is approximately 33 feet (10 meters). A decrease in operating
range could be caused by:
• weather conditions,
• nearby radio towers,
• structures around the vehicle, or
• other vehicles parked next to your vehicle.
3812586R1
Vehicle Controls
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
• Press UNLOCK to unlock the driver’s door.
• Press UNLOCK again within three seconds to unlock both
doors.
NOTE: The vehicle doors may be unlocked by using the remote
entry transmitter, however, in the event of a low battery charge,
the door can be manually unlocked and opened by inserting
the key into the driver’s door lock cylinder and turning counter
clockwise.
Locking the Doors
• Press LOCK to lock both doors.
• Pressing LOCK a second time will sound the horn to confirm
the doors are locked.
39
Vehicle Controls
Sounding a Panic Alarm
Press “!” to activate the alarm. Press “!” again, or turn the ignition
to the 3 (ON) position to deactivate.
NOTE: The panic alarm will only operate when the ignition is in
the 1 (LOCK) position.
Replacing the Battery
The remote entry transmitter uses one button type three-volt
lithium battery CR2025 or equivalent.
To replace the battery:
1. Twist a thin coin between the two halves of the remote entry
transmitter near the key ring. DO NOT TAKE THE RUBBER
40
COVER AND CIRCUIT BOARD OFF THE FRONT HOUSING
OF THE REMOTE ENTRY TRANSMITTER.
2. Do not wipe off any grease on the battery terminals on the
back surface of the circuit board.
3. Remove the old battery. NOTE: Please refer to local
regulations when disposing of transmitter batteries.
4. Insert the new battery. Refer to the diagram inside the remote
entry transmitter for the correct orientation of the battery. Press
the battery down to ensure that the battery is fully seated in the
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
If the remote entry transmitters are lost, replacements can be
ordered and programmed for the vehicle by an authorized dealer.
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
WARNING
Do not adjust driver’s seat while vehicle
is moving. The seat could suddenly or
unexpectedly move causing the driver to lose
control of the vehicle, which could result in
property damage, personal injury or death.
WARNING
Reckless operation of this vehicle over rough
roads or surfaces can cause loss of vehicle
control and result in property damage, personal
injury, or death. Use caution and reduce speed.
Properly adjusted seats and seating systems
may not compensate completely for severe road
conditions.
Ensure that head clearance will be maintained
during all road conditions, as the seat may move
up and decrease the available space.
42
40/20/40 Split Bench Seat
The driver seat can be
adjusted forward or backward
by lifting the lever (1) located
under the seat.
Pull the lever (2) to flip the
driver seat forward. When
pushing the seat back to its
upright position, make sure it
latches securely.
Pull the center seat down while
pulling the loop to flip the seat
down. When pushing the seat
back to its upright position,
make sure it latches securely.
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
in the vehicle cargo area or on the outside of
the vehicle. Ride only in designated seating
positions or sleeper berth with seat belts or bunk
restraints fastened and properly adjusted.
The front safety restraints in the vehicle are combination lap and
shoulder belts. The passenger outboard safety belt has vehicle
sensitive emergency locking retractors.

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

STARTING THE ENGINE
WARNING
Operation of a diesel engine near flammable
vapors in the air may cause the engine speed
to increase uncontrollably and over speed. If
this situation occurs, mechanical damage, fire,
explosion, personal injury or death could result.
Turning off the ignition key will not slow or
stop the engine due to uncontrollable fueling
of the engine through flammable vapors being
drawn into the engine air inlet. Operation of
components such as starter, alternator, electric
motors, etc. and static electricity could also
ignite flammable vapors.
Do not operate the truck in the possible presence
of flammable vapors unless both a complete
hazard analysis is performed and necessary
additional safety processes and/or equipment
such as vapor testing, air intake shutoff devices,
ventilation, etc. are utilized. The operator is
responsible for using those processes and/or
equipment to ensure that the diesel engine
and all other components on the truck can be
operated safely under the specific conditions
and hazards that may be encountered.
3812586R1
Vehicle Operation
1. Ensure headlamps and all accessories are turned off, the
parking brake is applied and the transmission is in the P
(Park) position.
2. Turn the key to ON, but do not start the engine. In cooler
weather, the glow plugs may activate the WAIT TO START
light in the instrument cluster.
If the WAIT TO START light illuminates, do not crank
the engine until the light goes off.
3. When the WAIT TO START light turns off, turn the
key to START; when the engine starts, release the
key.
If the engine does not start within 20 seconds of cranking,
release the key and allow two or three minutes for the starter to
cool before trying again. Excessive cranking may damage the
starter and/or engine.
After the engine starts:
• Idle the engine for at least five minutes before operating with
a full load.
• Try to limit engine idle to 10 minutes. Excessive idling
reduces fuel economy.
• When starting a cold engine, increase the engine speed
(RPM) slowly to make sure adequate lubrication is available
to the bearings.
47
Vehicle Operation
COLD WEATHER OPERATION
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.
In order to correctly operate the engine in cold and hot
temperatures, it is important to read and follow the instructions
in the Engine Operation and Maintenance Manual.
RESTARTING AFTER RUNNING OUT OF FUEL
Avoid running out of fuel as this can allow air to enter the fuel
system, which will make restarting difficult. Refer to the Engine
Operation and Maintenance Manual for specific restarting
instructions.
OPTIONAL ENGINE PROTECTION SYSTEM — 3 WAY
(08WPP)
WARNING
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
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
the warning limits, the appropriate fault codes are set and
the Red Engine Warning Light is turned ON. If the engine oil
pressure, engine coolant temperature or engine coolant level
conditions exceed the preset critical limit, the engine is shut
down. After an automatic shutdown, the engine can be restarted
and will operate in a de-rated mode for an additional 30 seconds
if the conditions causing the shutdown are still present, allowing
the vehicle to be moved to a safe location.
General Operating Instructions
• Accelerate smoothly and evenly; rapid acceleration
increases fuel consumption without increasing engine
performance.
• When approaching a hill, depress the accelerator smoothly
to start the incline at full power, then shift down as needed
to maintain vehicle speed.
• When going down a hill, or long steep grades, prevent
over-speeding of the engine. The engine governor has no
control over engine speed when it is being pushed by a
loaded vehicle.
3812586R1

WARNING
In the event engine shutdown occurs, make
certain that vehicle is safely off the roadway, the
4–way emergency flashers are on, and traffic
warning devices are properly placed. Failure to
remove vehicle from roadway could cause an
accident and result in property damage, personal
injury or death.
WARNING
Exhaust gases from engines contain hazardous
compounds. Do not operate engines in enclosed
areas without abundant forced ventilation (with
garage doors and windows wide open). Maintain
exhaust system in good operating condition.
Breathing exhaust gases could result in personal
injury or death.
3812586R1
Vehicle Operation
WARNING
Operating an engine beyond the maximum
governed speed could result in engine failure
and cause vehicle damage, personal injury or
death.
WARNING
Always use the ashtray(s) provided for disposing
of cigar, cigarette, or pipe ashes and tobacco.
Failure to use an ashtray is a fire hazard and
could result in property damage, personal injury,
or death.
WARNING
All vehicles have blind spots. Make sure your
way is clear in all directions before moving your
vehicle. Failure to follow these procedures could
result in property damage, personal injury or
death.
49
Vehicle Operation
BACKING UP/ELECTRIC BACK-UP ALARM
WARNING
Before backing up, check to see that area behind
vehicle is clear of people, animals and objects.
Use a spotter whenever possible and always
keep that person in sight. Failure to do so may
result in property damage, personal injury, or
death. If so desired, backup alarms are available
through your International dealer. However, they
are never a substitute for the above procedures.
Before backing your vehicle, be sure you can do so safely. If
anything behind the cab limits your view, do not rely on mirrors
alone to ensure that your intended path is clear. If other people
are in the vicinity, have someone standing well behind your
vehicle and outside of your intended path (visible through an
exterior mirror) guide you as you back up.
Although OSHA or some governmental regulations may require
the use of an electrical or mechanical back-up alarm to warn
bystanders, such an alarm does not ensure that the intended
path is clear. When in doubt, get out of the vehicle and visually
50
check the intended path is clear; back up slowly as to allow
others time to move, if necessary.
PARKING
WARNING
When parking your vehicle, do not leave
transmission in gear; if vehicle rolls, engine
could start by heat of compression. Always
use parking brake. When parking on a grade,
chock wheels and turn front wheels to keep the
vehicle from rolling into the traveled portion of
the roadway. Failure to follow these procedures
could cause an unattended vehicle to move,
resulting in property damage, personal injury or
death.
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
vehicle rolls, the front tires will act against the curb to stop the
vehicle. The front wheels will be more effective at stopping a
rolling vehicle than the rear wheels.
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

PARKED REGENERATION PROCEDURE
Perform the following steps to initiate Parked Regeneration
(cleaning) of the exhaust filter:
1. Park the vehicle safely off the roadway and away from
flammable materials.
2. Before initiating parked regeneration (pressing
the PARKD REGEN switch), the following conditions
must be in place:
a. Park brake must be set
b. Transmission must be in Neutral (N) or Park
(P), if available
c. Accelerator, foot brake and clutch (if present)
pedals must not be depressed.
NOTE: If any of the above conditions are altered during the
Parked Regeneration process, regeneration will be halted, and
must be restarted.
3. Press the PARKD REGEN switch to initiate the regeneration
cycle.
NOTE: The engine must be at normal operating temperature
before the parked regeneration will initiate.
3812586R1
Vehicle Operation
The engine speed will automatically ramp up to a preset RPM
and the switch indicator will illuminate solidly when the cycle
is started. If the indicator is blinking, check to be sure that all
conditions in step 2 are met. Once started, the regeneration
cycle will last approximately 20 minutes.
NOTE: In the event of an emergency situation where the vehicle
must be moved after beginning Parked Regeneration, press
PARKD REGEN switch to cancel Parked Regeneration.
4. When the regeneration cycle is complete, the switch light will
go off, the engine rpm will return to normal idle and all exhaust
filter indicators will be off. The vehicle may now be driven
normally.
REGENERATION INHIBIT SWITCH (OPTIONAL)
The Regeneration Inhibit switch is used to prevent the Active
Regeneration or Parked Regeneration process.
Regeneration Inhibit Switch
Pressing the ON position of the ON/INHIBT
REGEN switch will inhibit both Active and Parked
Regeneration. Regeneration will be inhibited
(latched) when in this position and the switch
indicator is turned on.
53
Vehicle Operation
Brakes
WARNING
Always check and maintain brakes in proper
condition and adjustment. Out of adjustment
brakes could cause reduced braking ability and
result in property damage, personal injury, or
death.
WARNING
Hydraulic brake systems are power assisted
by the engine. Braking capabilities will be
greatly reduced without engine assist. Do
not move vehicle without the engine running
as reduced braking capability could result in
property damage, personal injury or death.
Your service brakes are self-adjusting. Refer to the Vehicle
Maintenance, Service Intervals and Specifications for scheduled
maintenance.
Occasional brake noise is normal and often does not indicate
a performance concern with the brake system. In normal
operation, brake systems may emit occasional or intermittent
squeal or groan noises when the brakes are applied. Such
noises are usually heard during the first few brake applications
in the morning; however, they may be heard at any time while
braking and can be aggravated by environmental conditions
such as cold, heat, moisture, road dust, salt or mud. If a
“metal-to-metal,” “continuous grinding” or “continuous squeal”
sound is present while braking, the brake linings may be
54
worn-out and should be inspected by a qualified service
technician.
DOWNHILL OPERATION
Always descend hills with extreme care, relying primarily on the
engine braking effect to control vehicle speed. Heed warning
signs posted for any grade. Stop and check brakes for condition
and adjustment at available pull off areas before starting a
descent.
Observe the following precautions:
Never coast downhill. Service brakes alone should not be used
to control speed on major downgrades. Brakes will fade from
overuse.
Downhill speed is controlled by removing one’s foot from the
accelerator pedal (engine running with closed throttle) and
putting the transmission/rear axle in reduced gear. If the
transmission/rear axle is in a gear that results in more than
the appropriate speed, a proper downshift should be made to
avoid overuse of the brakes. If the proper gear selection was
not made and the brakes were overused, then stop the vehicle
and wait for the brakes to cool. After the brakes have cooled,
continue down grade in a lower gear range.
The common rule to follow in using the engine and
transmission/rear axle to control vehicle speed is to select a
lower gear going down the hill than would be required to ascend
the hill. There are some exceptions, such as going down a
short hill with good visibility and no hazards.
The service brakes should be used to supplement available
vehicle retardation methods. When descending long grades
3812586R1

requiring use of the brakes, short applications (three to five
seconds duration) should be made rather than long, continuous
applications. This minimizes temperature rise, brake fade and
air consumption of air brake system.
IF BRAKES DO NOT GRIP WELL
• If you have been driving through deep water, gently apply
the brakes several times while the vehicle is moving slowly.
• 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.
HYDRAULIC BRAKE BOOSTER SYSTEM (HYDROBOOST)
The HydroBoost system receives fluid pressure from the power
steering pump to provide power assist during braking.
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
steering fluid pressure loss. The accumulator will also deliver a
limited number of power assisted brake applications when the
engine is off.
The HydroBoost’s reserve accumulator provides reduced
braking power, and the number or reserve stops is limited
(depending on the severity and duration of the brake
applications).
3812586R1
Vehicle Operation
Under normal operating conditions, noise of the fluid flowing
through the booster may be heard whenever the brake is applied.
This is normal and should be no reason for concern.
If braking performance or pedal response becomes very poor,
even when the pedal is strongly applied, this may indicate
the presence of air in the hydraulic system or fluid leakage.
Safely stop the vehicle as soon as possible and seek service
immediately.
If the brake fluid warning light in the instrument cluster remains
illuminated after engine start-up, and an audible tone is heard
while the light is illuminated, this indicates a system failure in the
brake system. Stop the vehicle as soon as safely possible and
seek service immediately.
WARNING
Stopping distance may increase under the failed
condition since only one section of the brake
system is operating. Reduce speed and employ
safe driving practices. Have brake system
repaired immediately. Loss of braking capability
could cause an accident and result in property
damage, personal injury or death.
55
Vehicle Operation
PARKING BRAKE
WARNING
Driving with the parking brakes applied can lead
to excessive heat build up and fire resulting 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.
To release the parking brake, pull the handle up slightly, push the
button (2) on the end of the handle, then push the handle down to
its original position. Driving with the parking brake on will cause
the brakes to wear out quickly and reduce fuel economy.
The parking brake warning light in the instrument cluster
illuminates, and remains illuminated (when the ignition is
turned on), until the parking brake is released.
The parking brake is not recommended to stop a moving
vehicle. However, if the normal brakes fail, the parking
brake can be used to stop your vehicle in an emergency. Since
56
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.
ANTILOCK BRAKE SYSTEM (ABS)
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.
WARNING
Do not rely on the ABS system to interrupt
vehicle retarder, engine or exhaust brake on
slippery road surfaces. Turn these devices off
during hazardous driving conditions. Failure to
follow this warning may cause wheel slippage
and/or loss of vehicle control, which could result
in property damage, personal injury, or death.
This system helps you maintain steering control during
emergency stops by keeping the brakes from locking. Noise
from the ABS pump motor and brake pedal pulsation may be
3812586R1

observed during ABS braking and the brake pedal may suddenly
travel a little further as soon as ABS braking is done and normal
brake operation resumes. These are normal characteristics of
the ABS and should be no reason for concern.
Using ABS
When hard braking is required, apply continuous force on the
brake pedal; do not pump the brake pedal since this will reduce
the effectiveness of the ABS and will increase your vehicle’s
stopping distance. The ABS will be activated immediately,
allowing you to retain full steering control during hard braking
and on slippery surfaces. However, the ABS does not decrease
stopping distance.
ABS Warning Lamp
The ABS lamp in the instrument
cluster momentarily illuminates when
the ignition is turned on. If the light
does not illuminate during start up,
remains on or flashes, the ABS may
be disabled and may need to be
serviced.
Even when the ABS is disabled, normal braking is still effective.
(If your BRAKE warning lamp illuminates with the parking brake
released, have your brake system serviced immediately.)
3812586R1
Vehicle Operation
WARNING
If the ABS warning light comes on, your stopping
distances may increase under certain braking
conditions. Have the ABS system repaired
immediately. Take every precaution to avoid
wheel lockup, which could result in loss of
vehicle control causing property damage,
personal injury or death.
Automatic Transmission
WARNING
To avoid sudden, unexpected vehicle movement
and property damage, personal injury or death,
always use the parking brake. Do not leave
transmission in gear instead of using parking
brake.
BRAKE-SHIFT INTERLOCK
This vehicle is equipped with a brake-shift interlock feature that
prevents the gearshift lever from being moved from P (Park)
when the ignition is in the ON position unless brake pedal is
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:
57
Vehicle Operation
1. Apply the parking brake, turn ignition key to LOCK, then
remove the key.
2. Remove the three fasteners as shown in the illustration;
there is one at the bottom of the gearshift console and
one on both sides of the console.
Note: You may need to roll back the floor cover to access
the bottom fastener and/or remove the middle seat cushion to
access the passenger side top fastener.
58
• 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.
• While the override lever is lifted, apply the brake pedal and
shift to N (Neutral).
WARNING
To prevent unexpected vehicle movement, hold
the brake pedal down while you move the
gearshift from position to position. Failure to
follow this warning could result in property
damage, personal injury, or death.
• Start or move the vehicle
3812586R1

If it is necessary to use the above procedure to move the
gearshift lever, it is possible that a fuse has blown or the
vehicle’s brakelamps are not operating properly.
WARNING
To prevent unexpected vehicle movement, hold
the brake pedal down while you move the
gearshift from position to position. Failure to
follow this warning could result in property
damage, personal injury, or death.
UNDERSTANDING SHIFT POSITIONS OF THE 5–SPEED
AUTOMATIC TRANSMISSION
3812586R1
Vehicle Operation
This vehicle is equipped with an adaptive Transmission Shift
Strategy. Adaptive Shift Strategy offers the optimal transmission
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
like having to reset your radio stations when your vehicle battery
has been disconnected. The Adaptive Transmission Strategy
allows the transmission to relearn these operating parameters.
This learning process could take several transmission upshifts
and downshifts; during this learning process, slightly firmer shifts
may occur. After this learning process, normal shift feel and shift
scheduling will resume.
P (Park)
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)
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
If your vehicle is equipped with a power take off (PTO), refer to
the PTO equipment manufacturer’s instructions.
CAUTION
Installing a PTO without the proper electrical
connections to the transmission may result in
transmission failure.
NOTE: PTO applications draw auxiliary horsepower from the
powertrain, often while the vehicle is stationary. In this condition,
there may be limited cooling air flow through the radiator and
around the vehicle that normally occurs when a vehicle is
moving. Depending on the level and duration of PTO use,
vehicle conditions, surrounding environmental conditions and
other factors, this can contribute to elevated transmission fluid
temperatures and result in accelerated fluid deterioration, fuel
vapor over-pressurization and other concerns.
Gross Axle Weight
WARNING
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
AXLE CONVERSIONS
It is not recommended, or approved, for axle conversions to be
performed.
VEHICLE LOADING
Every vehicle is supplied with information on the Vehicle Rating
Decal listing the maximum loading for the vehicle (GVWR), and
its axle systems (GAWR) at the tire to ground interface.
Under no circumstances should your vehicle be loaded in
excess of the GVWR or GAWR. It is the operator’s responsibility
to ensure that neither the axle capacities, spring capacities, tire
capacities nor the vehicle rated GVWR is exceeded.
Jump Starting Your Vehicle
WARNING
The following procedures must be performed
exactly as outlined, otherwise a fire or a battery
explosion could result in property damage,
personal injury or death.
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

3. Remove the jumper cable from the positive (+) terminal of the
booster vehicle’s battery.
4. Remove the jumper cable from the positive (+) terminal of the
disabled vehicle’s battery.
After the disabled vehicle has been started and the jumper
cables removed, allow it to idle for several minutes so the
engine computer can relearn its idle conditions.
Towing Instructions
WARNING
This vehicle may be equipped with (optional) dual
tow hooks. Always use both tow hooks to prevent
possible overloading and breaking of individual
hooks. Failure to follow this warning could result
in property damage, personal injury, or death.
Before moving the towed vehicle, check for adequate road
clearance of vehicle components. International recommends
unloading the towed vehicle prior to towing to reduce any
abnormal loads to the vehicle components resulting from the
towing procedures. Before towing, be sure to fully release the
parking brake.
3812586R1
Vehicle Operation
WARNING
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
vehicle’s parking brakes.
Towing Vehicle With Front Wheels Suspended
CAUTION
To avoid transmission damage, vehicles should
not be towed even short distances without
suspending rear wheels or removing the axle
shafts or propeller shaft.
The wheel hub ends must be covered to
prevent loss of axle lubricant and entrance
of contaminants. Use extreme care in securing
the chains or U-bolts to avoid possible damage
of brake lines, hoses or other components.
When it is necessary to tow a vehicle with the front wheels
suspended, extra precautions must be taken to avoid
transmission or differential damage. Proceed as follows.
Remove axle shafts from axle assembly to prevent the wheels
from driving the differential and the transmission. The wheel
hub ends must be covered to prevent loss of axle lubricant and
entrance of contaminants.
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
WARNING
If the owner/operator of the vehicle is a
skilled technician and intends to perform the
vehicle maintenance and servicing, he/she
is strongly urged to purchase and follow
the appropriate International service manual.
Ordering information is included at the back
of this manual. Failure to properly perform
maintenance and servicing procedures 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
maintenance.
Quality International® service parts are available through your
International dealer. If International® service parts are not used,
the owner must make sure that the parts used are equivalent to
International® service parts.
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
working properly which, in turn, may result in personal injury
or damage to the vehicle or its equipment. If you have any
question about performing some service, have the service done
by a skilled technician.
Maintenance Guidelines
WARNING
Failure to perform proper maintenance and
service could result in property damage, personal
injury or death.
WARNING
Making any modifications to any part, component
or system of the vehicle, can adversely affect the
quality and reliability of your vehicle and must be
avoided. Modifications to systems could result in
property damage, personal injury or death.

3812586R1 67
Vehicle Maintenance, Service Intervals and Specifications
WARNING
Use only genuine International service parts.
The use of inferior parts can adversely affect
the quality and reliability of your vehicle, which
could result in property damage, personal injury
or death.
WARNING
To avoid property damage, personal injury
or death, take care when performing any
maintenance or making any check or repair.
Some of the materials in this vehicle may also
be hazardous if used, serviced, or handled
improperly. If you have any questions pertaining
to the service, have the work done by a skilled
technician.
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.
68
CAUTION
Always disconnect the ground battery terminal
first, then the positive cable prior to electric
welding. Attach the welder ground cable as close
as possible to the part being welded. If welding
close to an electronic component, temporarily
remove that component.
When servicing your vehicle always:
1. Turn off the ignition switch unless the procedure calls for a
running engine.
2. Set the parking brake and chock the wheels.
3. Use support stands, not a jack, whenever you must be under
a raised vehicle.
4. Do not smoke.
5. Wear safety glasses for eye protection.
6. Operate engine only in a well ventilated area.
7. Do not work on brakes or clutch unless proper precautions
are taken to avoid inhaling friction material dust.
8. Do not wear loose clothing, hanging jewelry, watches or
rings. Tie up long hair and avoid rotating machinery.
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.
3812586R1
 Vehicle Maintenance, Service Intervals and Specifications
Supporting Your Vehicle for Service
WARNING
Always use floor stands to support the vehicle
before working under it. Using only a jack could
allow the vehicle to fall resulting in property
damage, personal injury or death.
When performing service repairs on a vehicle, first:
1. Park vehicle on level concrete floor.
2. Set parking brake and/or block wheels to prevent vehicle
from moving.
3. Select jack with a rated capacity sufficient to lift the
vehicle.
4. Raise vehicle with jack applied to axle. (DO NOT use
bumper as a lifting point.)
5. Support vehicle with floor stands under axle(s).
If axle or suspension components are to be serviced, support
vehicle with floor stands under frame side members, preferably
between the axles.
3812586R1
Chassis Lubrication
New vehicles are lubricated at the factory. After the vehicle
is placed in operation, regular lubrication and maintenance
intervals, based on the type of service and road conditions,
should be established. The loads carried, speed, road and
weather conditions all contribute to the frequency of lubrication
intervals. Thorough lubrication and maintenance at the specified
intervals will insure Outstanding Life Cycle Value and will reduce
overall operating expense.
In some types of operation, and where operating conditions are
extremely severe (such as in deep water, mud or unusually dusty
conditions), the vehicle may require re-lubrication after every
twenty-four (24) hours of operation.
Only lubricants of superior quality, such as Fleetrite lubricants,
should be used. The use of inferior products will reduce the
service life of the vehicle or result in failure of its components.
International Truck and Engine Corporation recommends the
use of Fleetrite lubricants and International Engine original
equipment parts.
The lubrication intervals specified should be performed at
whatever interval occurs first, whether it is miles (kilometers),
hours, or months.
These intervals are provided in the Lubrication And Maintenance
Interval Chart in the Maintenance Intervals section.
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
To preserve the bright look of your vehicle’s trim (grilles,
bumpers, etc). Use only mild detergents and lukewarm water
for cleaning. Damage to these parts can occur if cleaning
solutions having excessive acidity or alkalinity (pH) are used.
Also, the higher the solution temperature ranges, the more
caustic the cleaner’s chemical compounds become. However,
if high-pressure washing equipment and washing compounds
are used, satisfactory results can be achieved if the solution
has a pH value between 4 and 8, and the temperature does not
exceed 160 degrees F (71 degrees C). Solutions that are more
acid or more alkaline will attack the anodic coating.
If you are having difficulty with your washing compound, contact
your local supplier for the acidity/alkalinity (pH) specification.
A non-abrasive chrome cleaner may be used sparingly to clean
the bright metal. Do not use steel wool. Use of automobile
wax or polish on bright metal usually will restore the original
brightness.
UPHOLSTERY CARE
Use a whisk broom and vacuum cleaner to remove loose dust
and dirt from upholstery and floor. Vinyl and woven plastic
upholstery can be washed with warm water and mild soap.
Wipe dry. If commercial cleaners are used, follow instructions
supplied with cleaner.
3812586R1
PLASTIC BUMPER AND SIDE SKIRT PROTECTION
To better protect plastic surfaces from fading, use Meguiar’s
#40 vinyl and rubber cleaner/ conditioner. Spread evenly with
sponge or towel and allow to penetrate. Buff off excess product
with clean cloth.
Air Conditioning System Checks
Have your air conditioning system checked each spring. The
refrigerant charge, cleanliness of the condenser-evaporator
cores and belt condition are essential to air conditioning
performance.
Front Axle - General Service Information
Maintaining the front axle alignment to specifications is very
important and should only be performed by a qualified
technician. Toe-in adjustment is particularly important with
radial tires.
Check to make sure that the axle mounting U-bolt nuts, attaching
or mounting bolts and nuts are securely tightened. Regularly
check front axle for damage, binding, worn parts and adequate
lubrication.
At regular intervals, or during other scheduled maintenance,
(tire rotation/service, wheel bearing service, alignment, etc.) the
kingpins should be checked for excessive wear. Refer to the
service manual for proper procedures.
71
Vehicle Maintenance, Service Intervals and Specifications
Toe-In Setting - General Inspection
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
wearing normally.
Rapid outside shoulder wear on both tires indicates too much
toe-in. Rapid inside shoulder wear on both tires indicates too
much toe-out. In P&D-type service, left-to-right steer tire tread
life differentials up to 40% can be observed depending on routes
and other variables.
Follow the tire manufacturer’s recommended cold inflation
pressure for the tire size, load range (ply rating) and steer axle
loading typical for their operation (each steer axle tire will equal
½ steer axle loading).
Special applications may warrant a setting based on past
experience with the type of tire operating loads and conditions.
Radial tires are more sensitive to toe-in setting than bias ply
tires.
It is essential that correct toe-in and tire pressure be maintained
for optimum tire wear.
Rear Axle - General Inspection
Check to make sure that the axle mounting U-bolts, attaching or
mounting bolts and nuts are securely tightened. Refer to U-bolt
nut torque chart in this chapter. Regularly check the rear axle for
damaged, binding or worn parts.
Check the rear axle oil level. Proper oil level minimizes gear
wear, heat and damage to the wheel bearings and seals. The
72
oil level should be at the lower edge of the level inspection hole
when the vehicle is on level ground. Add oil as necessary.
REAR AXLE LUBRICANT
Refer to Vehicle Maintenance, Service Intervals and
Specifications chapter for rear axle lubricant level checks and
lubricant change intervals.
NOTE: Axle operating temperature normally will not exceed
100°F (38°C). If the operating temperature exceeds 230°F
(110°C), the rate of axle lubrication oxidation will increase
and shorten the life of the lubricant and seals, requiring axle
lubrication changes to become more frequent to preserve the
axle. Extreme Pressure (EP) lubricants should not be run
consistently above 230°F (110°C).
The rear axle may be filled with an optional synthetic lubricant
which allows the use of extended service intervals. A tag on the
filler plug will identify the use of synthetic lubricant.
Use only a lubricant that meets manufacturer specifications
(refer to Lubricant specifications in this chapter).
Use of a non-approved rear axle lubricant may cause
internal axle component damage.
Check your rear axle lubricant level using the following
procedure:
1. Park the vehicle on level ground.
2. Set the parking brake and shift into P (Park) and turn the
engine off.
3. Clean any dirt from around the rear axle filler plug.
3812586R1
 Vehicle Maintenance, Service Intervals and Specifications
4. Remove the filler plug and inspect the lubricant level.
5. The lubricant level should be up to the bottom of the filler
plug opening.
6. If necessary, add enough lubricant through the filler plug
opening so that the lubricant level is at the bottom of the
opening.
7. Clean and install the filler plug securely.
Drain and refill your rear axle lubricant using the following
procedure:
Note: The rear axle lubricant should only be drained when the
lubricant is warm.
1. Park the vehicle on level ground.
2. Set the parking brake and shift into P (Park) and turn the
engine off.
3. Clean any dirt from around the rear axle filler plug and
remove.
4. Remove the two lower carrier to housing bolts from their
through holes and drain the lubricant into a suitable
container. Dispose all used automotive fluids in a
responsible manner following your local authorized
standards.
5. Re-install the two bolts removed. Use Loctite 270 and
torque to 142 — 158 lbf-ft (193 — 214 Nm).
6. Add enough lubricant through the filler plug opening so
that the lubricant level is up to the bottom of the opening.
7. Clean and install the filler plug securely.
3812586R1
Brake System - General Inspection
WARNING
Always check and maintain brakes in proper
condition and adjustment. Out of adjustment
brakes could cause reduced braking ability and
result in property damage, personal injury, or
death.
Your vehicle is equipped with non-asbestos brake linings.
However, exposure to excessive amounts of brake material
(whether asbestos or non-asbestos, fiberglass, mineral wool,
aramid or carbon) may be a potentially serious health hazard.
WARNING
Avoid breathing brake lining fiber dust as it
may be hazardous to your health. Always use a
respirator while performing brake maintenance.
Follow precautions listed below.
A. Always wear a respirator approved by the National
Institute of Occupational Studies of Health (NIOSH)
or Mine Safety and Appliance (MSA) during all brake
service procedures. Wear the respirator from removal
of the wheels through assembly.
B. Never use compressed air or dry brushing to clean
brake parts or assemblies.
73
Vehicle Maintenance, Service Intervals and Specifications
C. Clean brake parts and assemblies in open air. During
assembly, carefully place all parts on the floor to avoid
getting dust in the air. Use an industrial vacuum cleaner
with a HEPA filter system to clean dust from the brake
drums, backing plates and other brake parts. After
using the vacuum, remove any remaining dust with a
rag soaked in water and wrung until nearly dry.
D. Never use compressed air or dry sweeping to clean the
work area. Use an industrial vacuum cleaner with a
HEPA filter system and rags soaked in water until wrung
until nearly dry. Dispose of used rags with care to avoid
getting dust in the air. Use an approved respirator when
emptying vacuum cleaners and handling used rags.
E. Worker clean-up: Wash your hands before eating,
drinking or smoking. Vacuum your work clothes after
use and then launder them separately, without shaking
them, to prevent fiber dust getting into the air.
Hydraulic Brakes - General Inspection And Adjustment
A regular schedule for periodic cleaning, lubrication, adjustment
and inspection should be established based on the type of
vehicle operation. It is difficult to predetermine an exact
maintenance interval (time or mileage), since vehicles will be
used in a wide variety of applications and conditions. If you
are uncertain of the proper schedule and procedures for your
vehicle, contact your dealer.
Inspect the brake lining every maintenance interval. Establish
inspection intervals that provide for lining replacement before
damage to the disc occurs. Excessive lining wear may expose
the backing plate to the disc causing scoring of the disc faces.
74
This inspection should be performed by a qualified technician
and must be in accordance with instructions provided by the
service manual.
Hydraulic Brakes - Fluid Level
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
reservoir.
NOTE: If brake fluid requires attention to maintain a proper
master cylinder level, this is an indication of either severe
operation (pad wear) or fluid system leakage. A more frequent
and thorough brake inspection will be required.
Hydraulic brakes - Fluid Precautions
The Hydroboost brake system consists of two completely
separate hydraulic systems operating with two different
and incompatible fluids; power steering fluid and hydraulic
brake fluid. Failure to observe precautions preventing the
contamination of either system with fluid from the other will
result in swelling and deterioration of rubber parts leading to
reduced brake performance and eventual brake failure.
To avoid fluid contamination, the following should always be
observed:
A. Use only fluids specified (or equivalent) and properly
identified.
B. Add fluids only to the following locations:
C. Power steering fluid to the power steering fluid pump
reservoir.
3812586R1
 Vehicle Maintenance, Service Intervals and Specifications
D. Brake fluid to the brake master cylinder.
Brake Fluid Reservoir
The reservoir is located behind a panel on the far left side of the
instrument panel, accessible by opening the driver’s door and
removing the end panel.
Check and refill the brake fluid reservoir using the following
procedure.
1. Clean the reservoir caps before removal to prevent dirt
or water from entering the reservoir.
2. Visually inspect the fluid level; the level should be
between the MIN/MAX marks on the reservoir.
3812586R1
3. If necessary, add brake fluid from a clean unopened
container until the level reaches the bottom of the fill
ports. Do not fill above this line.
4. Use only a DOT 3 brake fluid certified to meet
manufacturer specifications. Refer to Lubricant
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
Parking brake adjustment should only be performed by a
qualified technician, and in accordance with the instructions in
the service manual.
See VEHICLE INSPECTION GUIDE section for proper parking
brake inspection procedure.
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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
hook D is locked.
3. Lower handle B securely to its original position.
Engine Oil
CHECKING ENGINE OIL LEVEL
Engine oil level should be checked daily.
1. Park the vehicle on level ground.
2. Set the parking brake and shift into P (Park).
3. Turn off engine.
4. Locate and carefully remove the engine oil dipstick. The
dipstick is located between the air filter housing and the back
of the cab; you do not need to tilt the cab to access it.
3812586R1
5. Wipe the dipstick clean. Insert the dipstick fully, then remove
it again.
• If the oil level is between ADD and OPERATING RANGE,
the oil level is acceptable. DO NOT ADD OIL.
• Maintain the oil level between ADD and OPERATING
RANGE on the dipstick by adding oil as required.
• The distance from ADD to OPERATING RANGE on the
dipstick represents 1.0 quart (1.0L).
• Oil levels above OPERATING RANGE may cause engine
damage. Some oil must be removed from the engine by a
qualified service technician.
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:
• Use only engine lubricating oils and oil filters of the proper
quality.
• 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
vehicle operation includes extended periods of idling
or low-speed operation, driving for a long time in cold
temperatures or short driving distances.
Engine Coolant
CHECKING ENGINE COOLANT
The engine coolant reservoir is located behind the passenger
side of the cab.
The reservoir has two see-through level indicators on it. The top
indicator is the FULL mark and the bottom indicator is the ADD
mark. If engine coolant is visible through either indicator, it will
appear red in color. The engine coolant should be kept at a level
that is visible through the bottom indicator.
78
NOTE: The engine coolant reservoir requires air space for
expansion volume. The proper fill level is identified on the
reservoir; do not overfill the reservoir.
CAUTION
If the coolant should get extremely low and
the engine very hot, let the engine cool for
approximately 15 minutes before adding coolant.
After the engine has cooled, start the engine
and add coolant slowly. Adding coolant to a hot
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.
Push down, loosen cap slowly to its first notch
position; then pause a moment to allow pressure
to release through the overflow tube. After the
pressure has been released, the pressure cap
may be removed.
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 Vehicle Maintenance, Service Intervals and Specifications
Fill the coolant reservoir slowly with the proper coolant mixture
(see above), to the appropriate level (top indicator).
Replace the cap. Turn until tightly installed. (Cap must be tightly
installed to prevent coolant loss.)
After any coolant has been added, check the coolant
concentration. If the concentration is not 50/50 (protection to
–34° F/–36° C), drain some coolant and adjust the concentration.
It may take several drains and additions to obtain a 50/50 coolant
concentration.
Whenever coolant has been added, the coolant level in the
coolant reservoir should be checked the next few times you
drive the vehicle. If necessary, add enough 50/50 concentration
of engine coolant and distilled water to bring the liquid level to
the proper level.
If you have to add more than 1.0 liter (1.0 quart) of engine coolant
per month, have your dealer check the engine cooling system.
Your cooling system may have a leak. Operating an engine
with a low level of coolant can result in engine overheating and
possible engine damage.
EXTENDED LIFE COOLANT
The cooling system of your new vehicle is filled at the factory
with Shell Rotella Extended Life Coolant (ELC). Refer to the
Engine Operation and Maintenance Manual for specific coolant
requirements and for maintaining/servicing the cooling system.
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COOLANT CONCENTRATION FREEZE POINT
Cooling systems should be checked twice a year to assure
proper coolant/water concentrations.
CAUTION
Always use premixed ELC or equivalent to top
off the cooling system. Failure to do so may
result in the loss of extended life properties and
will require testing for SCA levels. Should top
off occur with conventional coolant(s) exceeding
10% of the total cooling system capacity, either
drain and refill with ELC or maintain as a
conventional coolant system using SCA’s at
the recommended levels.
RECYCLED ENGINE COOLANT
The use of recycled engine coolant is not recommended.
Used engine coolant should be disposed of in an appropriate
manner. Follow your community’s regulations and standards for
recycling and disposing of automotive fluids.
ENGINE COOLANT CAPACITIES AND PART NUMBERS
For cooling system capacities, refer to Refill capacities in
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.

80 3812586R1
 Vehicle Maintenance, Service Intervals and Specifications
WARNING
Do not use the washers in freezing weather
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.
Battery
WARNING
Keep lighted tobacco, flames, sparks or other
ignition sources away from the batteries. Gas
from the battery cells is flammable and can ignite
and/or explode. This is particularly true when
jumper cables are being used. Battery fires or
explosions could cause severe injury to the face,
eyes, limbs and body.
In addition, inhaling the hydrogen gas produced
by the normal operation of the battery could
result in partial or permanent damage to the
respiratory system.
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WARNING
Whenever disconnecting battery terminals,
always disconnect ground terminal first. When
reconnecting, always connect ground terminal
last. Failure to follow this procedure could result
in a short to ground and cause property damage,
personal injury, or death.
Always wear eye protection when working
around batteries. Do not attempt to jump-start a
vehicle with a frozen battery because the battery
may rupture or explode. If a frozen battery is
suspected, thaw out battery and recharge.
WARNING
Do Not Check Battery Condition By Shorting
(Flashing) Across Terminals.
Failure to observe these warning could result in
personal injury and/or damage to the vehicle.
Battery cable terminals must be clean and tight. Use hot water
and common baking soda for removing terminal corrosion and
for cleaning the top of the battery. Brighten the contact surface
with steel wool, apply a light coat of lubricant sealing grease such
as Fleetrite® 472141-C1 or equivalent and reassemble. Be sure
the terminals are clamped tightly and that the battery is clamped
securely in the battery box.
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Vehicle Maintenance, Service Intervals and Specifications
When working around the terminals and battery, use extra care
to avoid shorting. A good practice is to insulate pliers and
screwdrivers. Do Not Check Battery Condition By Shorting
(Flashing) Across Terminals.
Steering - General Inspection
• Ask your service technician to examine the steering
mechanism. Only minor adjustments may be necessary.
• Check tie rod ends, drag link end clamp bolts and king pins.
Joints and fasteners must be tight. Articulating joints must
be well lubricated.
• Check for installation and spread of cotter pins and tightness
of nuts at both ends of the tie rod and drag link.
• Check that pitman arm (steering arm at steering gear)
mounting is tight and locked. Check system for leaks or
hose chafing. Repair at once, if necessary.
• Maintain proper steering gear and power steering pump
lubricant levels.
• Regularly inspect steering column joint bolts and steering
linkage, particularly for body-to-chassis clearance.
Note: Have any steering problems corrected at once by a
qualified service technician.
82
WARNING
Always follow recommended procedures for
steering system maintenance. Failure to maintain
the steering system in proper condition can
cause reduced steering ability resulting in
property damage, personal injury or death.
TIGHTENING STEERING COLUMN JOINT BOLTS
As a good maintenance practice, it is recommended that
steering column joint bolts be checked for tightness every
60,000 miles (96,000 km) or annually, whichever occurs first.
Do not overtighten.
POWER STEERING
Whenever the power steering system has been drained and
refilled for any reason, air must be bled from the system before
returning the vehicle to service. Failure to properly bleed the
system can result in degradation of power steering performance.
Consult your dealer who is aware of the proper procedures for
filling and bleeding the system.
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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.
NOTE: Use only Mercon® SP transmission fluid. Use of
a non-approved automatic transmission fluid may cause
internal transmission component damage.
If necessary, add fluid in ½ pint (250 ml) increments through the
filler tube until the level is correct.
3812586R1
If an overfill occurs, excess fluid should be removed by a
qualified technician.
An overfill condition of transmission fluid may cause shift
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.
To replace the transmission filter, refer to the service manual.
85
Vehicle Maintenance, Service Intervals and Specifications
Engine and Subsystem Maintenance
CAUTION
To prevent damage to the International Engine
Control Module it should never be spray-washed
directly. Never spray any connector.
For effective emissions control and low operating cost, it is
important that maintenance operations listed in this section and
those in the Engine Operation and Maintenance Manual be
performed at the specified periods or mileage intervals indicated
(kilometers, miles, hours, or months, whichever comes first).
Service intervals are based upon average operating conditions.
Where dusty, frequent start-and-stop or heavily laden operations
are encountered, more frequent servicing will be required.
The vehicle owner is responsible for the performance of
all scheduled maintenance. The required maintenance
operations may be performed by the owner at a service
establishment of the owner’s choosing. Any replacement parts
used for required maintenance services or repairs should be
genuine manufacturer service parts or equivalent in quality and
performance to genuine manufacturer service parts. Use of
inferior parts hinders operations of the engine and emissions
controls and can reduce engine life and/or jeopardize the
warranty.
Receipts covering the performance of regular maintenance
should be retained in the event questions arise concerning
maintenance. The receipts should be transferred to each
subsequent owner of the vehicle.
86
For information regarding routine scheduled maintenance such
as replacement of oil, filters, coolant, belts, belt tensioners, etc.,
and inspection and adjustment of items such as valve lash, etc.
refer to the Engine Operation and Maintenance Manual supplied
with the vehicle.
AIR INDUCTION SYSTEM
WARNING
To avoid property damage, personal injury or
death when performing maintenance and repairs
to any turbocharged engine with engine air inlet
piping disconnected, a turbocharger compressor
air inlet protective shield should be installed over
the turbocharger air inlet. Order protective shield
J-26554 for International engines from your local
International dealer.
Once each year, perform a complete inspection of the air
induction system. In areas where road salt is used, the
inspection consists of disassembling the joints of each aluminum
component and inspecting for salt build-up and presence of
chlorine that can cause aluminum particles to flake off and enter
the engine combustion chambers.
If evidence of corrosion is found (usually at the pipe
connections), use a wire brush to clean the inside of the
pipes and inside the rubber hoses.
If the intake pipes are pitted at the joint ends, use RTV silicone to
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
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
International Truck and Engine Corporation does not
recommend the blending of gasoline, and/or alcohol with diesel
fuel due to the hazards of fire/explosion and the detrimental
effects on engine performance.
WARNING
Never add gasoline, gasohol and/or alcohol to
diesel fuel. This mixture creates an extreme
fire and explosion hazard, which could result in
property damage, personal injury, or death.
As little as two percent volume gasoline mixed with diesel fuel
will create a flammable/explosive mixture in the fuel tank vapor
space, which will pose an extreme fire/explosion hazard during
refueling or engine operation.
Fuel and Lubricant Additives
International Trucks are designed and built to operate
satisfactorily on fuels and lubricants of good quality marketed
by the petroleum industry. International Truck and Engine
Corporation does not recommend the use of any supplementary
fuel or lubricant additives. Malfunctions attributed to the use of
such additives or failure to follow recommended fuel or lubricant
recommendations may not be covered by any applicable
warranty. Refer to the Engine Operation and Maintenance
Manual for specific fuel requirements.
88
Fueling Precautions
According to the Federal Motor Carrier Safety Regulations,
no driver or any employee of a motor carrier shall:
1. Fuel a motor vehicle with the engine running, except
when it is necessary to run the engine to fuel the vehicle.
2. Smoke or expose any open flame in the vicinity of a
vehicle being fueled.
3. Fuel a motor vehicle unless the nozzle of the fuel hose
is continuously in contact with the intake pipe of the fuel
tank.
4. Permit, insofar as practicable, any other person to
engage in such activities as would be likely to result in
fire or explosion.
Reserve Fuel
No extra supply of fuel for the propulsion of the vehicle or for the
operation of accessories shall be carried on any motor vehicle
except in a properly mounted fuel tank or tanks.
Running Out of Fuel
Avoid running out of fuel as this can allow air to enter the fuel
system, which will make restarting the vehicle difficult.
If you have run out of fuel, refer to the Engine Operation and
Maintenance Manual for specific restarting instructions.
3812586R1
 Vehicle Maintenance, Service Intervals and Specifications
Fuel Filter/Water Separator
Your vehicle is equipped with two fuel filters; one is mounted
on top of the engine, the second one is mounted inside the
Horizontal Fuel Conditioner Module (HFCM) on the inside of the
left frame rail by the transmission. The fuel filter/water separator
removes any contaminated particles and/or water from the fuel
before the fuel enters the engine.
The fuel filter/water separator should be drained whenever the
water in fuel warning light comes on or at the intervals specified
in the Engine Operation and Maintenance Manual. Refer to
the Engine Operation and Maintenance Manual for specific
instructions.
NOTE: If the water in fuel warning light comes on frequently,
water should be drained from the fuel tank(s) every 3 months.
Fuel Filter Replacement
Both filters should be replaced at the same time. Refer to
the Engine Operation and Maintenance Manual for specific
instructions.
3812586R1
Chassis-Mounted Charge Air Cooler
The charge air cooler should be inspected daily. With the
engine off, visually inspect the charge air cooler core assembly
for debris and clogging of external fins. Prior to engine operation,
remove any debris blocking the core.
• Turbocharger-to-charge air cooler
• Charge air cooler-to-intake manifold pipe
• Mounting bracket
• Chassis-mounted charge air cooler core
AIR INTAKE PIPING INSPECTION
• Check for accumulation of salt deposits (where applicable).
If present, disassemble and clean the complete air intake
piping system. If the intake piping is pitted, use RTV silicone
to seal joints against leakage.
• Check for loose hoses and clamps.
• Check for ruptured or collapsed hoses.
• Check air filter housing for cracks.
89
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.

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Vehicle Maintenance, Service Intervals and Specifications
Re-install the panel in the reverse order of the removal
procedure.
Electrical System Inspections
Periodically inspect electrical connectors on the engine, Power
Distribution Center (PDC), battery and frame for corrosion and
tightness. Inspect exposed cables and harnesses for fraying or
signs of abrasion. Exposed terminals such as the fuel sender,
cranking motor, alternator and feed-through studs should be
cleaned and re-coated with a lubricant sealing grease such as
Fleetrite® 472141–C1, or equivalent. This should include feed
through connections, power and ground cable connections for
batteries, engine and cab as well as the jump starting stud.
92
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
Circuit Diagram Manuals, available from International®,
to assure that any additional body lights and accessories
are connected to circuits that are both appropriate and not
overloaded. No modification should be made to any vehicle
control system without first contacting your dealer.
Noise Emissions — Exterior
Instructions For Proper Maintenance
In order to comply with federal exterior noise regulations, your
vehicle may be equipped with noise emission items. Depending
upon the vehicle configuration, it may incorporate all or some of
the following.
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 Vehicle Maintenance, Service Intervals and Specifications
Air Intake System:
• Air Cleaner — should be inspected and its location should
not be altered. Do not alter inlet and outlet piping.
Body:
• Wheel Well — splash shields, cab shields and under-hood
insulation should be inspected for deterioration, dislocation,
and orientation.
Cooling System:
• Check fan for damage to blades; replace, if damaged, with
manufacturer recommended parts. Inspect for fan to shroud
interference, and any damage to shroud such as cracks and
holes.
• Fan ratio should not be changed and fan spacer dimensions
and position should not be altered.
• Inspect for proper operation of fan clutch making sure that
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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Engine and Driveline System:
• Transmission enclosure — inspect for cracks, holes, and
tears. Clean any deposits such as oil, dirt, and stones.
• Engine valve covers and block covers are made to damp out
engine mechanical noise and, if needed, should be replaced
with recommended parts. Check for mechanical isolations.
Exhaust System:
• Inspect for leaks at various joint connections and tighten
clamps. Make visual inspection for cracks or holes in
aftertreatment system and tail pipe. Always replace with
manufacturer recommended parts. Tail pipe elbow or offset
tail pipe orientation must not be changed from standard
position as originally received.
• To avoid abnormal changes in vehicle sound level, it
is necessary for the owner to perform inspections and
necessary maintenance at the intervals shown in the
maintenance schedules, and record on the inspection
verification form provided.
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Vehicle Maintenance, Service Intervals and Specifications
Suspension Inspection
Periodically:
• Check condition of spring leaves for evidence of fatigue,
bending or breaks.
• Check condition of suspension mounting brackets and
bushings.
• Check that suspension mounting fasteners (brackets,
bushings, etc.) are tight.
• Check that torque rod mounting fasteners are tight.
• Check to be sure the suspension alignment is maintained at
all time.
• Check U-bolts after the chassis has been operating under
load for 1,000 miles (1,600 km) or six months, whichever
comes first, the U-Bolt nuts must be re-torqued. The U-Bolt
nuts thereafter must be re-torqued every 36,000 miles
(58,000 km). The U-Bolt and nut threads and seats should
be cleaned and lubricated to assure a “like new” condition
when re-torquing.
Note: See the U-Bolt Nut Torque chart.
Frame and Tow Hooks
The vehicle chassis is manufactured with frame rails of either
mild carbon steel, or HSLA steel. Each must be handled in
94
a specific manner to assure maximum service life. Before
attempting frame repair or modification, consult the service
manual or your dealer.
It is important, particularly on vehicles where the tow hooks are
used frequently to inspect the tow hooks for damage or a loose
mounting.
Propeller Shaft
At the regular lubrication interval, check the universal joints,
slip joints, slip joint boot for any evidence of wear or looseness.
Should propeller shaft vibrations occur, stop the vehicle
immediately to avoid possible hazardous consequences or
damage to other components.
Wheels
General
Wheel bearings should be inspected, lubricated and adjusted
at regular intervals. This is especially important if operating in
deep sand, mud, or water. Refer to Lubricant specifications in
this chapter.
When installing wheel balance weights, they must be mounted
on the dome-side of the wheel only. Failure to do so may result
in loss of wheel weight and/or damage to brakes or wheels.
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 Vehicle Maintenance, Service Intervals and Specifications
Wheel Installation, Tightening And Alignment
WARNING
To avoid personal injury or death, always follow
these instructions when mounting radial tires on
wheels:
• Only personnel that have had proper training and
experience should mount or remove tires from rims or
wheels.
• Use only heavy-duty rims or approved rims for radial
tires. It may be necessary to contact your wheel and
rim distributor to determine if your rims are approved
for radial tires.
• 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.
• Never use anti-freeze, silicones, or petroleum based
lubricants when mounting radial tires. Only an
approved lubricant should be used as an aid for
mounting tires.
• Always inflate tires in a safety cage.
3812586R1
WARNING
• Do not attempt to mix stud piloted wheels or fasteners
with hub piloted wheels or fasteners. To do so may
cause premature wheel failure resulting in property
damage, personal injury, or death.
• Do no mix foreign (not made in North America)
wheel mounting parts with domestic (made in North
America) parts. Many foreign wheel components look
similar to, but not exactly the same as domestic made
components. Mixing components could cause wheel
or fastener failures and result in property damage,
personal injury, or death.
• Do not change from aluminum wheels to steel wheels
or vice-versa without changing the mounting hardware
where required or, in some cases with flange nut
mounting systems, changing the hub and stud
assembly. Mixing components could cause wheel
or fastener failures and result in property damage,
personal injury, or death.
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Vehicle Maintenance, Service Intervals and Specifications
WARNING
When installing the tire and rim assembly on
disc - brake equipped axles, make sure the tire
valve stem clears the brake caliper. The use of
either an International® valve stem retainer or a
tire manufacturer’s stem forming tool is the only
acceptable method of obtaining clearance when
necessary. Failure to obtain proper clearance
may result in rapid tire deflation and cause
property damage, personal injury, or death.
Tighten and maintain wheel and rim mounting nuts to the proper
torque. Loose nuts or over-tightened nuts can lead to premature
wear and possible failure of the wheel, rim and/or mounting
hardware.
NOTE: Do not use lubrication on dry threads, however where
excessive corrosion exists, a light coat of lubricant on first three
threads of stud bolt is permitted. Keep lubricant away from:
• Hex nut and rim clamp contact surfaces;
• Flange nut washer surface and flat on disc wheel.
96
Installation Procedures
WARNING
Use only the same type and style wheels and
mounting hardware to replace original parts.
Failure to do so may result in an assembly, which
looks fine, but does not fit together properly. This
could cause wheel or fastener failures and result
in property damage, personal injury or death.
When installing wheels, make sure the threads on studs and
nuts are clean to permit correct torquing of nuts. The mounting
surfaces of wheels, spacer rings and clamps must be free of dirt,
rust, lubricants or damage.
Use a wire brush to clean mounting contact surfaces. Do not
use lubricant on threads.
After the wheel has been properly tightened, check it for
alignment. Rotate the wheel and tire with the tire sidewall in
close proximity to a stationary object. If the distance between
the tire sidewall and the stationary object varies more than
3/16 inch (4 mm). Check the tire, wheel, and wheel mounting
surfaces for possible damage or improper installation.
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 Vehicle Maintenance, Service Intervals and Specifications
Wheel Mounting Nuts Torque Sequence
Tightening procedure for disc wheels with flange nuts (hub
piloted):
1. Slide inner rear tire and wheel or front tire and wheel in
position over studs and push back as far as possible.
Do not damage the stud threads.
2. Position the outer rear tire and wheel in place over the
studs and push back as far as possible. Again, do not
damage the stud threads.
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
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.
Aluminum Disc Wheels with Flange Nuts (Hub Piloted)
Prior to reinstalling rear aluminum hub-piloted wheels, clean
each wheel locator pad on the hub of dirt, rust and foreign
material. Apply a light coat of chassis grease, anti-seize
compound, or disc brake corrosion control grease only to the
wheel locator pad. This reduces the likelihood of the wheel
getting stuck on the wheel hub due to corrosion.
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Vehicle Maintenance, Service Intervals and Specifications
Tires
Inflation
WARNING
Due to tire manufacturers re-marking tires to
conform to the SI (metric) system, tires marked
with old and new loads or inflation pressures
could be placed on the same vehicle. For field
maintenance, only inflate and load tires to the
maximum of the least-rated tire on the axle.
Failure to adhere to this warning could possibly
result in tire malfunction, damage to your vehicle,
personal injury, or death.
WARNING
Always maintain your tires in good condition.
Frequently check and maintain correct inflation
pressures as specified by tire manufacturers.
Inspect periodically for abnormal wear patterns
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
WARNING
To avoid personal injury or death, always follow
these instructions when mounting radial tires on
wheels:
• Only personnel that have had proper training and
experience should mount or remove tires from rims or
wheels.
• Use only heavy-duty rims or approved rims for radial
tires. It may be necessary to contact your wheel and
rim distributor to determine if your rims are approved
for radial tires.
• 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.
• Never use anti-freeze, silicones, or petroleum based
lubricants when mounting radial tires. Only an
approved lubricant should be used as an aid for
mounting tires.
• Always inflate tires in a safety cage.
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 Vehicle Maintenance, Service Intervals and Specifications
WARNING
• Do not attempt to mix stud piloted wheels or fasteners
with hub piloted wheels or fasteners. To do so may
cause premature wheel failure resulting in property
damage, personal injury, or death.
• Do no mix foreign (not made in North America)
wheel mounting parts with domestic (made in North
America) parts. Many foreign wheel components look
similar to, but not exactly the same as domestic made
components. Mixing components could cause wheel
or fastener failures and result in property damage,
personal injury, or death.
• Do not change from aluminum wheels to steel wheels
or vice-versa without changing the mounting hardware
where required or, in some cases with flange nut
mounting systems, changing the hub and stud
assembly. Mixing components could cause wheel
or fastener failures and result in property damage,
personal injury, or death.
WARNING
Do not mount tube type tires on tubeless wheels
or tubeless tires on tube type wheels. To do so
could result in tire or wheel failure and cause
property damage, personal injury or death.
Preserving proper inflation pressure is a very important
maintenance practice to insure safe vehicle operation and long
life for the tires.
3812586R1
Failure to maintain correct inflation pressure may result in
sudden tire destruction, improper vehicle handling, and may
cause rapid and irregular tire wear. Therefore, inflation
pressures should be checked daily and always before long
distance trips.
Follow the tire manufacturer’s recommended cold inflation
pressure for the tire size, type, load range (ply rating) and axle
loading typical for your operation. (Each steer axle tire load will
equal 1/2 steer axle loading; each drive tire load will be 1/4 the
axle loading if fitted with four tires).
Checking Inflation
Always check inflation pressure when tires are cold. Never bleed
air from hot tires to relieve normal pressure build-up. Normal
increases in pressure due to service conditions will be 10 to 15
psi, which is allowable in truck tires.
It is particularly important to keep moisture from the inside
of tires, and proper selection of air compressor equipment,
proper air line routing, and the use of shop air dryers is strongly
recommended to avoid moisture in the high pressure air used
for tire inflation.
Under Inflation
Tires should not be permitted to become under-inflated.
Increased flexing due to under-inflation causes heat build-up
within the tire components. This leads to reduced strength,
breakdown of the rubber compounds, and possible separation of
the tire components (i.e., ply and tread separation and reduced
retreadability).
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Vehicle Maintenance, Service Intervals and Specifications
Under-inflation is also the primary cause of blowouts. In addition,
low inflation causes an increase in rolling resistance. This results
in reduced fuel mileage, a loss in tread mileage, and uneven
wear due to increased tread movement. To determine proper
inflation refer to the tire inflation range stated on the tire sidewall.
Inspection
Check condition of tires for abnormal wear patterns, and proper
inflation pressures. Cut or broken tire casing must be repaired
or replaced.
Tires should be inspected for the following conditions. If any are
present, the tire should be removed and repaired, retreaded or
scrapped as the condition indicates.
• Any blister, bump or raised portion anywhere on the surface
of the tire tread or sidewall (other than a bump made by a
repair). These indicate the start of internal separation.
• Any cut that reaches to the belt or ply cords, or any cut that
is large enough to grow in size and depth.
• Any nail or puncturing object.
• If any stone or object is held by a tread groove and is starting
to drill into the tread base, remove the object.
Proper tire inflation, toe-in adjustment, loads, and road speeds
are important factors governing tire mileage, steering ease and
maneuverability.
100
Loads
WARNING
Loading tires beyond their rated capacity
decreases tire life requiring more frequent
replacement of tires. Overloading creates an
unsafe condition that may result in sudden air
loss from a tire failure resulting in an accident
that could cause property damage, personal
injury or death.
NOTE: Your GAW / GVW rating is correct at the time of your
vehicle production, and reflects the exact rating of the tires
specified. When replacing tires be sure that the replacement tire
load rating (listed in pounds and kilograms on the tire sidewall)
is the same or higher than the tire that is removed. Failure to do
so will adversely affect maximum load carrying capacity. Tires
with the same size specification do not always have the same
load specification.
Matching
Dual Tires
Dual tires should be matched using tires of equivalent size. Tires
which differ more than 1/4 inch (6mm) in diameter or 3/4 inch
(19mm) in circumference should not be mounted on the same
dual wheel assembly.
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 Vehicle Maintenance, Service Intervals and Specifications
Mixing
NOTE: Never mix bias and radial tires on this vehicle.
It is recommended for best overall performance that only radial
tires be used on this vehicle.
Never mix different tire sizes or constructions on the same axle.
Rotation
Rotation Is Always Advisable:
1. If front (steering) axle tires become irregularly worn,
move to rear position.
2. In a dual assembly, reverse the position of the tires if
one tire wears much faster than its mate.
3. On the drive axle, if heel and toe wear or alternate lug
wear occurs, rotating the tires from one end of the axle
to the other end of the axle may help even out this wear.
Rotation May Not Be Advisable:
• Front (Steering) Axle — Tires must be removed when tread
is worn to 4/32 inch (3mm) or less. Retread or rotate worn
tires to drive position. Retreaded tires are not recommended
to be used on steering axles.
• Rear Axles — Tires must be removed when tread is worn
to 2/32 inch (2mm).
3812586R1
If rib tire is used on front axle and lug or off-road type on
rear axle positions:
• Front (Steering) Axle — Replace tires at front wheels when
tread is worn to 4/32 inch (3mm) or less.
• Rear Axles — Tires must be removed when the tread
is worn to 2/32 inch (2mm) or less. Tires identified with
the word “re-groovable” molded on the sidewall can be
re-grooved. A minimum of 3/32 of under-tread must be left
at the bottom of the grooves.
Wheel And Tire Balancing
Out-of-round or out-of-balance wheels or tires can cause
vehicle vibration, bounce and shimmy. Replace damaged or
out-of-round wheels. Out-of-round tires and wheel assemblies
can be corrected by re-clocking the tire relative to the wheel.
The tire and wheel assembly should then be dynamically
balanced.
Wear
Radial tires can exhibit three types of normal wear patterns: 1)
Even, 2) Erosion, 3) Chamfer.
Even Wear is a sign that the tire is being properly used and
maintained.
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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.

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Lubrication and Maintenance Intervals
New vehicles are lubricated at the factory. After the vehicle
is placed in operation, regular lubrication and maintenance
intervals, based on the type of service and road conditions,
should be established. The loads carried, speed, road and
weather conditions all contribute to the frequency of lubrication
periods. Thorough lubrication and maintenance at the specified
intervals will insure Outstanding Life Cycle Value (OLCV) and
will reduce overall operating expense.
In some types of operation, and where operating conditions
are extremely severe (such as in deep water, mud or unusually
dusty conditions), the vehicle may require lubrication after every
twenty-four (24) hours of operation.
Only lubricants of superior quality, such as Fleetrite lubricants,
should be used. The use of inferior products will reduce the
service life of the vehicle or result in failure of its components.
International recommends the use of Fleetrite lubricants.
Maintenance Intervals
Maintenance intervals are provided for normal service. In all
applications the actual interval is determined by monitoring
miles (kilometers), hours of operation and the passage of time
(months).
The following LUBRICATION AND MAINTENANCE INTERVAL
CHART contains an extensive list of components and systems
that must be regularly inspected, serviced, and or replaced to
3812586R1
maximize vehicle availability and minimize unexpected failures.
Recommended synchronized intervals are shown for each item.
Synchronized “A” Service and “B” Service intervals are designed
to coordinate maintenance activities to provide appropriate
levels of service for components while minimizing the number of
times per year that the vehicle must be brought into the shop for
service. A “Special” Service Interval column is provided for those
items that are infrequently serviced or have an initial service
requirement that may be less than the standard A interval.
These are the recommended maximum intervals. Specific fleets
may find that due to the severity of their environment and duty
cycle that the intervals should be shortened.
Lubrication and Maintenance Interval Chart Symbols Key
Symbol Interval Definition (Whichever comes
first)
A 10,000 miles (16,000 km)
300 hours
See Note
6 months
B 20,000 miles (32,000 km)
600 hours
12 months
NOTE: Be sure to check the Lubrication and Maintenance Interval
Chart and also the Maintenance Schedule in the Engine Operation
and Maintenance Manual for items that may require initial servicing
prior to the standard A interval.
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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

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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
coolant remaining in the system after draining.
2
Use only MERCON® SP transmission fluid. Check the
container to verify the fluid being added is of the correct type.
MERCON®, MERCON® V and MERCON® SP are not
interchangeable. DO NOT mix MERCON®, MERCON® V
and MERCON® SP. Use of dual usage fluids in an automatic
transmission application requiring MERCON® SP may
cause transmission damage. Use of a transmission fluid
other than the recommended fluid may cause transmission
damage.
3
Indicates approximate refill capacity (less than initial dry fill
capacity). Refill capacity may vary depending on the amount
of fluid remaining in the system after draining. The amount of
fluid and fluid level should always be set by the indication on the
dipstick’s normal operating range.
4
Quantities listed are approximate. Fill axle until the lubricant
level is at the bottom of the filler hole, with the vehicle on level
ground.
5
If hubs are removed, add an additional 1.6 pints (0.75L) of axle
lubricant. Add lubricant through the axle vent.

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.

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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.

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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:
• 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.
• Press the DSPL TM SET button again and the minutes digits
will flash. Press either the TUNE or SEEK buttons to set the
minutes.
7. SCAN: Press to search the current band for all
listenable stations. Press again to stop the scan.
8. Memory preset buttons (1–6): To set a
station: Select frequency band AM/FM;
tune to a station, press and hold a preset
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:
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.
Press and hold the button again for more than two seconds;
“12” will blink indicating the time setting mode has been
activated.
• To set the hour, press TUNE ↑ or ↓.
• To set the minutes, press the clock button again, then press
TUNE ↑ or ↓.
• When the time has been set, press the clock button again.
If you need to reset the time, press and hold the clock button
for more than two seconds to activate the time setting mode,
then follow Steps 2 through 4 as shown under Setting the
clock.
Press the clock button to alternate between radio, tape and
clock modes.
4. TUNE: Press ↑ or ↓ to manually go up or down the
radio frequency.
5. SEEK: Press and hold (for more than ½ second) ↑ or
↓; the radio will automatically stop at the next radio
station.
124
6. ▲ : Press to eject the cassette.
7. << / >>: When the program indicator lights ▲, press
<< to fast forward or >> to rewind. To stop rewind or
fast forward, press the button that is not in use.
Changing cassette sides: Press << and >> at the
same time. The program indicator (▲ / ▼) will change
directions.
8. Memory preset buttons (1–6): To manually
set a station: Select frequency band
AM/FM1/FM2/FM3; tune to a station, press
and hold a preset button until the display blinks.
To automatically set a station: press BAND for more than
two seconds; the six strongest stations will be automatically
set in the six memory preset buttons.
9. MONO/ST: Press for monaural reception in case
a lot of interference is present in an FM stereo
signal or to improve the listening quality of weak
FM broadcasts.
10. BASS/TREBLE: Turn to adjust the amount of
bass output. Pull the control out fully (to lock it)
and turn to adjust the amount of treble output.
After adjusting the treble, push the control back
in.
3812586R1

AM/FM Stereo/CD (if equipped)
1. PWR: Press to turn the audio system on or off.
3. CLK: Press to see the time or to set the clock.
2. VOL BASS/TREB/BAL/FADER: Pressing the
control (SEL) will switch between Bass, Treble,
Balance and Fade. Volume: Turning the
control left or right will adjust the volume level.
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
Entertainment Systems
speakers. Fader: Adjust the audio between front and rear
speakers.
To set the clock: Press and hold CLK to set the
time. The display will flash indicating time setting
mode is activated. Press ٧ to set the hour and ٨ to
set the minute. (Press and hold ٧ or ٨ to change the numbers
rapidly.) Once the time has been set, release CLK. If the time
has not been stored in the radio, “SET” will be displayed.
125
Entertainment Systems
4. ALM: Press and hold ALM to set the alarm. The
display will flash indicating alarm time setting mode
is activated. Press ٧ to set the hour and ٨ to set
the minute. (Press and hold ٧ or ٨ to change the
numbers rapidly.) Once the alarm time has been set, release
ALM. If the alarm time has not been stored in the radio, “AM
12:00” will be displayed.
The alarm is turned on or off each time ALM is pressed.
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,
press ALM.
You can also select alarm volume by selecting ALARM VOL
1 or ALARM VOL 2 when pressing ALM. The volume for
ALARM VOL 2 is higher than ALARM VOL 1, which is the
default setting.
5. ▲: Press to eject a CD. “EJ” will display while the
disc is being ejected.
6. CD door: Insert a CD into the CD door. “LOAD” will
be displayed until the CD is fully loaded.
7. MUTE: Press to mute the playing media; press
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.
126
8. TUNE٨ / ٧:
In radio mode: Press to manually go up or
down the radio frequency.
In CD mode: Press once to go to the beginning
of the current track; press twice to go to the
previous next track.
9. SEEK٨ / ٧:
In radio mode: Press and hold for more than
½ second to have the radio automatically search
for the next strongest radio station.
In CD mode: Press and hold for more than
½ second to activate fast forward or reverse.
Release to resume normal CD play.
10. SCAN: Press SCAN and each station will be
scanned sequentially and the display will blink for
5 seconds. Press SCAN again to stop scanning
and the last station will continue to broadcast.
ILLUMINATION switching: Press SCAN for more
than 2 seconds to switch radio illumination between green
and amber.
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:
3812586R1

Press TUNE/SEEK to manually find a station to be stored
and pressing and holding one of the preset station buttons
until the display blinks once.
In CD mode: press preset 4 to hear the first 10 seconds of
each CD track. Press preset 4 to select a track. Press preset
5 to repeat the current CD track. Press again to turn the
repeat function off. Press preset 6 to randomly play tracks
on the CD. Press again to play the CD tracks in order.
12. MODE: Switches between radio and CD.
13. BAND: Switches between AM, FM, FM2 and WB
(Weather Band). APM: Press BAND for more than
two seconds to activate Auto Preset Memory; this
will automatically store the six strongest stations
into memory preset 1 through 6.
Note: During APM activity
• When APM is active, only FM2 is available for FM stations.
• APM does not work in Weather Band mode.
• When selecting APM, any existing preset stations will be
erased in favor of the automatically selected stations.
3812586R1
Entertainment Systems
14. If the radio does not respond when any of the buttons are
pressed, press the reset using a small pointed object such
as a pencil point or similar object. Pressing the reset will
erase all preset radio stations, clock and alarm settings.
If resetting the radio does not restore normal operation,
have your vehicle inspected by your dealer or a qualified
technician.
Radio Frequencies
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
FM- 87.7, 87.9–107.7, 107.9 MHz
Radio Reception Factors
There are three factors that can affect radio reception:
• Distance/strength: The further you travel from an FM station,
the weaker the signal and the weaker the reception.
• Terrain: Hills, mountains, tall buildings, power lines, electric
fences, traffic lights and thunderstorms can interfere with
your reception.
127
Entertainment Systems

• Station overload: When you pass a broadcast tower, a
stronger signal may overtake a weaker one and play while
the weak station frequency is displayed.
Cassette/Player Care
Do:
• Use only cassettes that are 90 minutes long or less.
• Tighten very loose tapes by inserting a finger or pencil into
the hole and turning the hub.
• Remove loose labels before inserting tapes.
• Allow tapes which have been subjected to extreme heat,
humidity or cold to reach a moderate temperature before
playing.
• Clean the cassette player head with a cassette cleaning
cartridge after 10–12 hours of play to maintain good
sound/operation.
Don’t:
• Expose tapes to direct sunlight, extreme humidity, heat or
cold.
• Leave tapes in the cassette player for a long time when not
being played.
• Inspect discs before playing. Clean only with an approved
CD cleaner and wipe from the center out.
Don’t:
• Expose discs to direct sunlight or heat sources for extended
periods of time.
• Clean using a circular motion.
CD units are designed to play commercially pressed 4.75
inch (12 cm) audio compact discs only. Due to technical
incompatibility, certain recordable and re-recordable
compact discs may not function correctly when used in
the CD players. Irregular shaped CDs, CDs with a scratch
protection film attached, and CDs with homemade paper
(adhesive) labels should not be inserted into the CD player.
The label may peel and cause the CD to become jammed.
It is recommended that homemade CDs be identified with
permanent felt tip marker rather than adhesive labels. Ball
point pens may damage CDs. Please contact your dealer
for further information.
Audio System Warranty and Service
Refer to the Warranty Guide for audio system warranty
information. If service is necessary, see your dealer or qualified
technician.

CD/CD Player Care

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

128 3812586R1

SECTION 7 — CUSTOMER ASSISTANCE
Service Information
The continued premium performance of this International truck
can best be assured through proper vehicle servicing. This can
be accomplished in several ways.
International Truck Dealers ... Your local International
truck dealer provides an excellent resource — through his
knowledgeable, experienced, and well equipped service staff —
to handle all your maintenance, repair and replacement work;
International Master Service Manual ... Those persons who
are properly trained technicians with the facilities, equipment,
tools, safety instructions and know-how to properly and safely
service a bus, medium duty and/or heavy duty chassis can
purchase the appropriate individual printed Service Manual
sections applicable to specific vehicle component groups for
this International vehicle;
International Engine Diagnostic and Service Manuals ...
Engine diagnostic and engine service manuals for all current
International engines are also available to these trained persons
for purchase.
These service resources are also available in CD-ROM
format with quarterly updates. The Diamond ISIS® CD-ROM
set contains all recent available chassis and component
service information, including TSI Letters, Circuit Diagrams,
Troubleshooting Guides and other technical information for
virtually all International models and engines.
Information can also be obtained by calling Moore Wallace
North America, International Order Desk at (630) 313–7507
3812586R1
Customer Assistance
(Toll-Free Fax Order phone number — 1-800-882-0484) or by
visiting www.internationaldelivers.com
NOTE: When ordering any service information, be sure to
provide your truck’s model designation, build date, engine
series, and the Vehicle Identification Number (VIN).
To obtain Caterpillar® or Cummins® engine service publications,
contact your local International truck dealer or the nearest
Caterpillar or Cummins authorized service facility.
International® Warranty Program
Standard Warranty • Optional Service Contracts • Custom
Service Contracts • Performance PM
The International Warranty Program provides International
customers with a better choice when it comes to Standard
Warranty and Service Contract Coverage. The Standard
Warranty is the first tier of the International Warranty Program.
It provides the foundation for all extended coverages.
Vehicle Coverage, Towing, Engine and Engine Electronics,
Major Component, and Pre-Packaged System Component
protection can be obtained under the International Warranty
Program through Optional Service Contracts.
Custom Service Contracts, the most flexible aspect of
the International Warranty Program, can provide extended
protection that is specifically tailored to meet each customer’s
specific requirements.
129
Customer Assistance
Finally, through Performance PM, customers can obtain a
comprehensive preventative maintenance program designed to
ensure consistency in pricing and the level of service received.
ADVANTAGES of International Warranties
* Extends warranty protection to specified length and
component coverage to suit individual needs
* Honored at over 1,000 International Dealer locations in
North America
* Stabilized and predictable maintenance costs
* Increased owner confidence and peace of mind
* Improved resale value on your vehicle – International
Warranties are transferable for a nominal fee
* Most coverage is 100% parts and labor with NO
DEDUCTIBLES
* International offers a customized warranty program to suit
your needs – your specification – your vocation
* International, North America’s leader in truck manufacturing,
is also North America’s leader in warranty value
130
* International provides Optional Service Contracts, Custom
Service Contracts, and Performance PM designed to assure
the lowest possible cost of ownership
* Optional Service Contracts have been pre-packed by
International to fit most common applications
* Custom Service Contracts are designed to meet your
individual needs
HOW TO OBTAIN International Warranties
* Standard Warranty: Your new International vehicle is
automatically registered in the International Warranty
system at the time of delivery. No further action on your part
is required.
* Optional Service Contracts, Custom Service Contracts,
or Performance PM: These programs are sold exclusively
through your International Dealer. To be eligible, your
vehicle must have been delivered less than six months ago
and still be covered under the Standard Warranty. If you
would like the predictable cost of ownership and peace
of mind provided by the International Warranty Program,
please contact your International Dealer today!
3812586R1

SECTION 8 — INDEX
A B
ABS Warning Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Add Layers of Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Adding Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Adjusting Automatic Transmission Fluid Levels. . . . . . . . . . . . . . . .85
ADVANTAGES of International Warranties. . . . . . . . . . . . . . . . . . . .130
Air Conditioning System Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Air Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Air Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Air Intake Piping Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Air Intake System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Aluminum Disc Wheels with Flange Nuts (Hub Piloted). . . . . . .97
AM/FM Stereo (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
AM/FM Stereo/Cassette (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . .123
AM/FM Stereo/CD (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Antilock Brake System (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
ABS Warning Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Using ABS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Assistance Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Audio System Warranty and Service. . . . . . . . . . . . . . . . . . . . . . . . . . .128
Automatic Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Brake-Shift Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
If Vehicle Gets Stuck In Mud Or Snow. . . . . . . . . . . . . . . . . . . . . . . .61
Understanding Shift Positions of the 5–speed Automatic
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Automatic Transmission Fluid Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Axle Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
3812586R1
Index
Backing up/Electric Back-up Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Body:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Brake Fluid Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Brake System - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Brake Fluid Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Hydraulic Brakes - Brake Lines, Hoses And Fittings. . . . . . . .75
Hydraulic Brakes - Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Hydraulic brakes - Fluid Precautions. . . . . . . . . . . . . . . . . . . . . . . . . .74
Hydraulic Brakes - General Inspection And Adjustment. . . .74
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Brake-Shift Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Antilock Brake System (ABS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
ABS Warning Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Using ABS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Hydraulic Brake Booster System (HydroBoost). . . . . . . . . . . . . .55
If Brakes Do Not Grip Well. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Bright Metal Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Bulb Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Bulb Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
C
Cab Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Cab/Fuel Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Canadian Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Care of Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
131
Index
C (CONT.)
Care Of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Bright Metal Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Plastic Bumper and Side Skirt Protection. . . . . . . . . . . . . . . . . . . . .71
Upholstery Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Washing and Waxing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Cassette/Player Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Cautions and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
CD/CD Player Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Chassis Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Chassis-Mounted Charge Air Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Air Intake Piping Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Checking Automatic Transmission Fluid. . . . . . . . . . . . . . . . . . . . . . . . .83
Adjusting Automatic Transmission Fluid Levels. . . . . . . . . . . . . .85
Correct Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
High Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Low Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Checking Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Checking Engine Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Engine Oil and Filter Recommendations. . . . . . . . . . . . . . . . . . . . . .77
Checking Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Climate Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Heater and Air Conditioning System (Optional). . . . . . . . . . . . . .28
Heater Only System (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Combination Lap and Shoulder Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Component Code Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Connecting the Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Coolant Concentration Freeze point. . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Cooling System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Correct Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
132
D
Daytime Running Lamps (DRL) (If Equipped). . . . . . . . . . . . . . . . . .30
Disc Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Downhill Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Driver Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Power Windows (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Regeneration Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Speed Control (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Tilt/Telescope Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Windshield Wiper/Washer Controls. . . . . . . . . . . . . . . . . . . . . . . . . . .33
Dual Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
E
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Electrical System Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Electrical System Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Accessory Feed Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Emission Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Verification of Inspection — Noise Emissions. . . . . . . . . . . . . . . . .4
Engine and Driveline System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Engine and Subsystem Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Air Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Air Induction System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Engine Compartment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Adding Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Checking Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Coolant Concentration Freeze point. . . . . . . . . . . . . . . . . . . . . . . . . . .79
3812586R1

E (CONT.)
Engine Coolant (cont.)
Engine Coolant Capacities and Part Numbers. . . . . . . . . . . . . . .79
Extended Life Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Fan Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Recycled Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Engine Coolant Capacities and Part Numbers. . . . . . . . . . . . . . . . . .79
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Checking Engine Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Engine Oil and Filter Recommendations. . . . . . . . . . . . . . . . . . .77
Engine Oil and Filter Recommendations. . . . . . . . . . . . . . . . . . . . . . . .77
Engine Start with Parking Brake(s) Applied. . . . . . . . . . . . . . . . . . . . .12
Exhaust Filter Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Parked Regeneration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Regeneration Inhibit Switch (Optional). . . . . . . . . . . . . . . . . . . . . . . .53
Exhaust System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Extended Life Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Exterior Noise Emissions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
F Power Distribution Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Fan Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Fog Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Frame and Tow Hooks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Front Axle - General Service Information. . . . . . . . . . . . . . . . . . . . . . . .71
Toe-In Setting - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . .72
Front Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Front of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Front Safety Belt Height Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Front Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3812586R1
Index
F (CONT.)
Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Fuel and Lubricant Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Fuel Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Fueling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Reserve Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Running Out of Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Hazards Of Diesel Fuel/Gasoline Blends. . . . . . . . . . . . . . . . . . . . .88
Ultra Low Sulfur Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . . . .87
Unacceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Fuel and Lubricant Additives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Fuel Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Fuel Filter/Water Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Fuel Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Fueling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Reserve Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Running Out of Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Fuses and Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90, 116
Relay Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
G
Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
General Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Backing up/Electric Back-up Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Parking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Gross Axle Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Axle Conversions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Vehicle Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
133
Index
H I (CONT.)
Hazard Flasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Hazards Of Diesel Fuel/Gasoline Blends. . . . . . . . . . . . . . . . . . . . . . . .88
Headlamp Aim Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Headlamp Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Daytime Running Lamps (DRL) (If Equipped). . . . . . . . . . . . . . . .30
Fog Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Panel Dimmer Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Heater and Air Conditioning System (Optional). . . . . . . . . . . . . . . . .28
Operating Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Heater Only System (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Operating tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
High Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
HOW TO OBTAIN International Warranties. . . . . . . . . . . . . . . . . . .130
Hydraulic Brake Booster System (HydroBoost). . . . . . . . . . . . . . . . .55
Hydraulic Brakes - Brake Lines, Hoses And Fittings. . . . . . . . . . .75
Hydraulic Brakes - Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Hydraulic brakes - Fluid Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Hydraulic Brakes - General Inspection And Adjustment. . . . . . .74
I Jump Starting Your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
If Brakes Do Not Grip Well. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
If Vehicle Gets Stuck In Mud Or Snow. . . . . . . . . . . . . . . . . . . . . . . . . . .61
Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Checking Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Under Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Instructions For Proper Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Air Intake System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Body:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Cooling System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
134
Instructions For Proper Maintenance (cont.)
Engine and Driveline System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Exhaust System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Gauges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Warning Lights and Chimes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Interior Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
International Customer Security Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Add Layers of Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Layer 1: Common Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Layer 2: Visible or Audible Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Layer 3: Vehicle Immobilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Layer 4: Tracking System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
International® Warranty Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
ADVANTAGES of International Warranties. . . . . . . . . . . . . . . . .130
HOW TO OBTAIN International Warranties. . . . . . . . . . . . . . . . .130
J
Jump Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Connecting the Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Jump Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Preparing Your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Removing the Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
K
Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
L
Lap Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Layer 1: Common Sense. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3812586R1

L (CONT.)
Layer 2: Visible or Audible Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Layer 3: Vehicle Immobilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Layer 4: Tracking System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Bulb Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Hazard Flasher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Headlamp Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Interior Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Turn Signal Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Line Set Ticket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Lock and Security. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Power Door Locks (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Remote Entry System (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . .39
Locking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Replacing Lost Remote Entry Transmitters. . . . . . . . . . . . . . . .40
Replacing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Sounding a Panic Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Unlocking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Locking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Low Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10, 76
Lubricant and Sealer Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Lubricant and Sealer Specifications Table. . . . . . . . . . . . . . . . . .113
Lubricant and Sealer Specifications Table. . . . . . . . . . . . . . . . . . . . .113
Lubrication and Maintenance Interval Chart — Recommended
Synchronized Intervals Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Lubrication and Maintenance Interval Chart Symbols Key
Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
3812586R1
Index
L (CONT.)
Lubrication and Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . .103
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
M
Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Lubrication and Maintenance Interval Chart — Recommended
Synchronized Intervals Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Lubrication and Maintenance Interval Chart Symbols Key
Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Matching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Dual Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Mixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
N
Noise Emissions — Exterior. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Instructions For Proper Maintenance. . . . . . . . . . . . . . . . . . . . . . . . .92
Air Intake System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Body:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Cooling System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Engine and Driveline System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Exhaust System:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
O
Operating tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Operating Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Optional Engine Protection System — 3 Way (08WPP). . . . . . .48
135
Index
P R (CONT.)
Panel Dimmer Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Parked Regeneration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Parking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56, 75
Plastic Bumper and Side Skirt Protection. . . . . . . . . . . . . . . . . . . . . . .71
Positions Of The Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Power Distribution Center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Power Door Locks (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Power Steering Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Power Take Off Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Power Windows (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1, 67
Cab Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Chassis Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Supporting Your Vehicle for Service. . . . . . . . . . . . . . . . . . . . . . . . . . .69
Preparing Your Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Propeller Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
R Safety Recalls and Authorized Field Changes. . . . . . . . . . . . . . . . .5
Radio Frequencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Audio System Warranty and Service. . . . . . . . . . . . . . . . . . . . . . . .128
Cassette/Player Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
CD/CD Player Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Radio Reception Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Radio Reception Factors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Rear Axle - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Rear Axle Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Rear Axle Lubricant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
136
Rear Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Rear of Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Rear Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Rear Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Recycled Engine Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Refill Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Regeneration Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Regeneration Inhibit Switch (Optional). . . . . . . . . . . . . . . . . . . . . . . . . .53
Relay Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Remote Entry System (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Locking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Replacing Lost Remote Entry Transmitters. . . . . . . . . . . . . . . . . . .40
Replacing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Sounding a Panic Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Unlocking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Removing the Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Replacing Lost Remote Entry Transmitters. . . . . . . . . . . . . . . . . . . . .40
Replacing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Reporting Safety Defects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Canadian Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
U.S. Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Reserve Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Restarting After Running Out Of Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rotation Is Always Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rotation May Not Be Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rotation Is Always Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rotation May Not Be Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Running Out of Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
3812586R1

S S (CONT.)
Safety Belt Warning Light And Indicator Chime. . . . . . . . . . . . . . . .46
Safety Recalls and Authorized Field Changes. . . . . . . . . . . . . . . . . . .5
Seat Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Care of Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Combination Lap and Shoulder Belts. . . . . . . . . . . . . . . . . . . . . . . . .44
Front Safety Belt Height Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . .45
Lap Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Safety Belt Warning Light And Indicator Chime. . . . . . . . . . . . . .46
Vehicle Sensitive Retractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Seating and Occupant Restraints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Seat Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Care of Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Combination Lap and Shoulder Belts. . . . . . . . . . . . . . . . . . . . . . .44
Front Safety Belt Height Adjustment. . . . . . . . . . . . . . . . . . . . . . . .45
Lap Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Safety Belt Warning Light And Indicator Chime. . . . . . . . . . .46
Vehicle Sensitive Retractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Sounding a Panic Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Speed Control (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Spring U-Bolt Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Cold Weather Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Optional Engine Protection System — 3 Way (08WPP). . . .48
Positions Of The Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Restarting After Running Out Of Fuel. . . . . . . . . . . . . . . . . . . . . . . . .48
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Starting the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Steering - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
3812586R1
Index
Steering - General Inspection (cont.)
Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Tightening Steering Column Joint Bolts. . . . . . . . . . . . . . . . . . . . . . .82
Supporting Your Vehicle for Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Suspension Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
T
Tampering With Noise Control System Prohibited. . . . . . . . . . . . . . .3
Tightening Steering Column Joint Bolts. . . . . . . . . . . . . . . . . . . . . . . . .82
Tilt/Telescope Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Tilting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9, 76
Tilting/Lowering Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9, 76
Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10, 76
Tilting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9, 76
Tire/Wheel Rim Selection And Inflation Pressures. . . . . . . . . . . .109
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Checking Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Under Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Matching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Dual Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Mixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rotation Is Always Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Rotation May Not Be Advisable:. . . . . . . . . . . . . . . . . . . . . . . . . . .101
Use Of Tire Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Tires — Irregular Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Wheel And Tire Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
137
Index
T (CONT.)
Tires — Irregular Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Toe-In Setting - General Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Disc Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Spring U-Bolt Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Tow Hooks (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Towing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Tow Hooks (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Towing Vehicle With Front Wheels Suspended. . . . . . . . . . . . . .65
Towing Vehicle With Rear Wheels Suspended. . . . . . . . . . . . . . .66
Towing Vehicle With Front Wheels Suspended. . . . . . . . . . . . . . . . .65
Towing Vehicle With Rear Wheels Suspended. . . . . . . . . . . . . . . . .66
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Transmission Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Automatic Transmission Fluid Filter. . . . . . . . . . . . . . . . . . . . . . . . . . .85
Checking Automatic Transmission Fluid. . . . . . . . . . . . . . . . . . . . . .83
Adjusting Automatic Transmission Fluid Levels. . . . . . . . . . .85
Correct Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
High Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Low Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Turn Signal Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
U General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
U-Bolt Nut Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
U.S. Registered Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Ultra Low Sulfur Fuel Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Unacceptable Fuel Blends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Under Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Under Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
138
U (CONT.)
Understanding Shift Positions of the 5–speed Automatic
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Unlocking the Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Upholstery Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Use Of Tire Chains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Using ABS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
V
Vehicle Entry and Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Vehicle Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Vehicle Sensitive Retractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Vehicle Storage Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Verification of Inspection — Noise Emissions. . . . . . . . . . . . . . . . . . . .4
W
Warning Lights and Chimes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Washing and Waxing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Tires — Irregular Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Wheel And Tire Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Wheel Installation, Tightening And Alignment. . . . . . . . . . . . . . . . . .95
Wheel Mounting Nuts Torque Sequence. . . . . . . . . . . . . . . . . . . . . . . .97
Wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Aluminum Disc Wheels with Flange Nuts (Hub Piloted). . . .97
Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Wheel Installation, Tightening And Alignment. . . . . . . . . . . . . . . .95
Wheel Mounting Nuts Torque Sequence. . . . . . . . . . . . . . . . . . . . . .97
Windshield Washer Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Windshield Wiper/Washer Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
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.