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DODGE 3500 RAM Truck 1995 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 3500 Year: 1995 Codes Chassis Code: BR/BE Series 👋 Introduction Market Position Segment: Heavy-duty pickup truck, positioned for commercial and demanding personal...
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DODGE 3500 RAM Truck 1995 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram 3500
Year:
1995
Codes
Chassis Code:
BR/BE Series
👋 Introduction
Market Position
Segment:
Heavy-duty pickup truck, positioned for commercial and demanding personal use.
Competitive Analysis
Competitors:
Ford F-350 Super Duty, Chevrolet Silverado 3500.
Key Features
Durability:
Renowned for its robust construction and heavy-duty capabilities.
Engine Options:
Available with powerful gasoline and the highly regarded Cummins turbodiesel engine.
Towing Hauling:
Designed for significant towing and payload capacities.
📋 Manual Details
Coverage Areas
Coverage:
Complete Service and Repair Procedures
Page Count
Pages:
Estimated 1500-2000+ (Typical for a comprehensive factory service manual of this era)
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Likely Print (Original) or Digital Reproduction (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, repair for all available engines.
Engine Performance:
Fuel system, ignition system, emission control systems, cooling system, lubrication system diagnosis and repair.
Transmission Manual:
Service and repair procedures for manual transmissions (e.g., NV4500).
Transmission Automatic:
Service and repair procedures for automatic transmissions (e.g., A518/46RH).
Drivetrain:
Front and rear axle service, differential repair, transfer case service (if applicable).
Suspension:
Front and rear suspension system diagnosis, repair, and component replacement (leaf springs, shocks, etc.).
Steering:
Power steering system diagnosis, repair, steering gear and linkage service.
Brakes:
Hydraulic brake system, ABS (if equipped), disc and drum brake service, parking brake.
Electrical System:
Battery, charging system, starting system, lighting system, wiring diagrams, component testing.
Body And Frame:
Body panel repair, door mechanisms, interior trim, glass replacement, frame inspection and repair.
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) for OBD-I and early OBD-II systems.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, lubrication, tire rotation.
Component Replacement:
Detailed steps for replacing major and minor components across all systems.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for identifying and resolving common and complex issues.
Rebuilding Overhaul:
Instructions for rebuilding engines, transmissions, axles, and other major mechanical assemblies.
Specifications Torque:
Critical torque specifications for all fasteners and assembly points.
Wiring Diagrams:
Comprehensive electrical system wiring schematics for various configurations.
Technical Depth
Depth:
Comprehensive, factory-level detail suitable for professional technicians and experienced DIYers.
📊 Manual Specifications
File Format
Digital Format:
PDF (if digital reproduction) - typically high-resolution scans of original pages.
Print Quality
Print Quality:
High-resolution for clarity of diagrams and text (if printed reproduction).
Binding Type
Binding:
Perfect bound or spiral bound for ease of use in a workshop setting (if printed).
Paper Type
Paper:
Durable, thick paper stock suitable for workshop environments (if printed).
⚙️ Engine Specifications
Primary Engine
Gasoline Option 1:
5.2L V8 Magnum (Engine Code: Y, P)
Gasoline Option 1 Hp:
Approx. 230 hp @ 4400 rpm
Gasoline Option 1 Torque:
Approx. 300 lb-ft @ 2800 rpm
Gasoline Option 2:
5.9L V10 Magnum (Engine Code: Z)
Gasoline Option 2 Hp:
Approx. 300 hp @ 4000 rpm
Gasoline Option 2 Torque:
Approx. 450 lb-ft @ 3200 rpm
Diesel Option:
5.9L Cummins Turbo Diesel (12-Valve, ISB) (Engine Code: C)
Diesel Option Hp:
Approx. 180 hp @ 2500 rpm (standard duty) / 215 hp @ 2500 rpm (heavy duty)
Diesel Option Torque:
Approx. 420 lb-ft @ 1600 rpm (standard duty) / 440 lb-ft @ 1600 rpm (heavy duty)
Fuel System
Gasoline Fuel System:
Electronic Fuel Injection (EFI) - Sequential Multi-port Fuel Injection (MPI)
Diesel Fuel System:
Inline Injection Pump (VE or P7100 depending on configuration), Turbocharged
🔧 Transmission
Standard
Manual Transmission:
Getrag/New Venture Gear NV4500 5-speed manual transmission.
Optional
Automatic Transmission:
Chrysler A518 (46RH) 4-speed automatic transmission with overdrive (colloquially '46RH').
Features
Overdrive:
Both available transmissions feature an overdrive gear for improved fuel economy on the highway.
Transfer Case:
Available 4WD with a 2-speed transfer case (New Process NP241 DHD).
📐 Dimensions
Exterior
Wheelbase 2Wd:
131 inches (Standard Cab), 154.5 inches (Club Cab)
Wheelbase 4Wd:
131 inches (Standard Cab), 154.5 inches (Club Cab)
Bed Length:
8 feet (Fleetside)
Weights
Gvwr:
Varies by configuration, typically ranging from 9,000 lbs to 10,000 lbs and above.
Payload Capacity:
Can exceed 5,000 lbs depending on configuration and axle rating.
Towing Capacity:
Can exceed 10,000 lbs (with appropriate towing package and configuration).
🛡️ Safety Features
Ratings
NHTSA Rating:
Specific NHTSA ratings for 1995 heavy-duty trucks were less comprehensive than modern standards, but generally considered robust.
Passive Features
Seat Belts:
Lap and shoulder belts.
Airbags:
Driver-side airbag.
Active Features
ABS:
Anti-lock Braking System (ABS) available on rear wheels, and potentially 4-wheel ABS on some models.
💡 Technology Features
Infotainment
Radio Options:
Factory AM/FM stereo with cassette player, optional CD player.
Driver Assistance
Cruise Control:
Standard on most trims.
Towing Features:
Trailer brake controller provision, trailer tow mirrors (optional).
🔧 Maintenance
Service Intervals
Oil Change Gasoline:
Every 3,000 miles or 3 months (typical for this era).
Oil Change Diesel:
Every 5,000-7,500 miles or 6 months (diesel specific).
Fuel Filter Diesel:
Every 15,000 miles (Cummins fuel filter).
Air Filter:
Check every 15,000 miles, replace as needed.
Fluid Specifications
Engine Oil Gasoline:
API SG or SH, SAE 10W-30 (check manual for temperature specific viscosity).
Engine Oil Diesel:
API CG-4, SAE 15W-40 (for Cummins).
Transmission Fluid Auto:
Chrysler ATF+3 (or equivalent, e.g., Dexron III for compatible units).
Transmission Fluid Manual:
API GL-5, SAE 75W-90 gear oil (for NV4500).
Coolant:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Mopar OAT or HOAT coolant.
Known Issues
Cummins Lift Pump:
The lift pump on early Cummins can be a weak point; upgrade often recommended.
Nv4500 2Nd Gear Grind:
Some NV4500 transmissions can develop a 2nd gear grind; often related to clutch or synchro issues.
Rear Main Seal Cummins:
Rear main seal leaks can occur on high-mileage Cummins engines.
Radiator Support Corrosion:
Corrosion around the radiator support mounting points can be an issue.
📚 Vehicle History
Brand Heritage
Dodge Trucks:
Dodge has a long-standing history in the truck market, known for durability and power.
Model Evolution
Third Generation Ram:
The 1995 model year is part of the redesigned third-generation Ram trucks (introduced in 1994), which featured a more aggressive, 'big rig' styling.
Production
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan, USA.
🏆 Awards & Recognition
Recognitions
Diesel Engine Reputation:
The 5.9L Cummins Turbo Diesel is widely regarded as one of the most reliable and durable diesel engines ever put in a pickup truck.
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