Engine Coverage:
5.2L Magnum V8, 5.9L Magnum V8, 5.9L Cummins Turbo Diesel
Transmission Coverage:
42RE Automatic, 46RE Automatic, NV3500 Manual, NV4500 Manual, NV5600 Manual
Chassis Coverage:
2WD, 4WD (4x4)
Body Coverage:
Cab & Chassis, Regular Cab, Club Cab
Electrical Coverage:
Wiring Diagrams, Body Control Module (BCM), Powertrain Control Module (PCM), Lighting, HVAC, Audio Systems
Suspension Coverage:
Front Independent Front Suspension (IFS), Rear Solid Axle
Brake Coverage:
Front Disc, Rear Disc/Drum (RWD/4WD Variations)
HVAC Coverage:
Air Conditioning System, Heater System
Total Pages:
Approximately 1800-2200
Type:
Factory Service Manual (FSM) / Repair Manual
Engine Mechanical:
Engine assembly, cylinder head, crankshaft, pistons, connecting rods, camshafts, timing system, lubrication system, cooling system, fuel system (including injectors, fuel pump, pressure regulator), exhaust system.
Engine Performance:
Engine control systems, ignition system, emissions control systems, diagnostic trouble codes (DTCs), data stream analysis.
Transmission And Drivetrain:
Automatic transmission overhaul (42RE, 46RE), manual transmission overhaul (NV3500, NV4500, NV5600), transfer case (New Process NP241DHD), driveshafts, axle assemblies (Dana 44HD/60, Sterling 10.5), differentials.
Suspension And Steering:
Front independent suspension, rear leaf spring suspension, steering gear, power steering system, wheel alignment specifications, shock absorbers, ball joints, tie rod ends.
Brakes:
Front and rear brake systems (disc and drum), hydraulic system, ABS (Anti-lock Braking System) components, parking brake system.
Electrical And Electronics:
Battery, charging system, starting system, lighting circuits, instrument cluster, power windows, power locks, remote keyless entry, interior/exterior lighting, trailer wiring.
HVAC:
Air conditioning system, heater core, blower motor, climate controls, refrigerant R134a.
Body And Frame:
Body panel removal and installation, door mechanisms, interior trim, exterior trim, bumpers, glass, frame inspection and repair.
Diagnostic Tools:
Use of OBD-II scan tools, multimeter, pressure gauges.
Routine Maintenance:
Oil and filter changes, fluid level checks and top-offs, tire rotations, spark plug replacement, air filter replacement, fuel filter replacement.
Engine Repair:
Complete engine disassembly, inspection, reassembly, component replacement (e.g., head gaskets, piston rings, bearings).
Transmission Service:
Fluid and filter changes, solenoid replacement, torque converter replacement, complete transmission rebuilds.
Brake Service:
Brake pad and rotor replacement, caliper servicing, brake line bleeding, ABS module diagnosis and replacement.
Suspension And Steering Repair:
Ball joint replacement, tie rod end replacement, shock absorber replacement, steering gear adjustment and replacement.
Electrical Troubleshooting:
Diagnosis of electrical faults using wiring diagrams, component testing, circuit repair.
HVAC Repair:
Refrigerant system servicing, leak detection, component replacement (compressor, evaporator, condenser).
Body Panel Repair:
Dent removal, panel alignment, rust repair, welding procedures.
Troubleshooting Guides:
Systematic approaches to diagnosing common and uncommon vehicle problems.
Diagnostic Trouble Code Lookup:
Interpretation of OBD-II codes and associated diagnostic steps.
Depth Level:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds).
Detail Level:
Detailed step-by-step instructions, torque specifications, diagrams, schematics, and exploded views.
Diagnostic Capability:
Advanced diagnostics including sensor data interpretation, circuit analysis, and component testing.
Engine 1 Displacement:
5.2L (318 cu in) Magnum V8
Engine 1 Configuration:
Overhead Valve (OHV), V8
Engine 1 Horsepower:
230 hp @ 4,000 rpm (approx.)
Engine 1 Torque:
325 lb-ft @ 3,200 rpm (approx.)
Engine 2 Displacement:
5.9L (360 cu in) Magnum V8
Engine 2 Configuration:
Overhead Valve (OHV), V8
Engine 2 Horsepower:
245 hp @ 4,000 rpm (approx.)
Engine 2 Torque:
345 lb-ft @ 3,200 rpm (approx.)
Engine 3 Displacement:
5.9L (359 cu in) Cummins Turbo Diesel
Engine 3 Configuration:
Inline-6, Turbocharged Diesel
Engine 3 Horsepower:
235 hp @ 2,700 rpm (approx.)
Engine 3 Torque:
460 lb-ft @ 1,600 rpm (approx.)
Fuel Delivery Gasoline:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Delivery Diesel:
Inline Injection Pump (VE or P7100 depending on specific build, typically P7100 for this era)
Fuel Type:
Unleaded gasoline (5.2L, 5.9L Magnum), Diesel Fuel (5.9L Cummins)
ECU Type:
Proprietary Chrysler Powertrain Control Module (PCM)
Transmission Type Gas Std:
42RE 4-speed Automatic (common for 5.2L)
Transmission Type Gas Opt:
46RE 4-speed Automatic (common for 5.9L Magnum), NV3500 5-speed Manual (common for 5.2L)
Transmission Type Diesel Opt:
NV4500 5-speed Manual, NV5600 6-speed Manual (later 2001.5+ models)
Automatic Features:
Electronic governor, overdrive gear.
Manual Features:
Overdrive gear, dual-mass flywheel (NV4500/NV5600).
Automatic Transmission Fluid:
ATF+4 (Mopar)
Manual Transmission Fluid:
NV3500: GL-4 Manual Transmission Lubricant; NV4500/NV5600: GL-3 or GL-4 Manual Transmission Lubricant (specific viscosity applies)
Oil Change Interval Gas:
3,000-7,500 miles or 6 months (depending on oil type and driving conditions)
Oil Change Interval Diesel:
3,000-5,000 miles or 6 months (depending on oil type and driving conditions, often shorter for heavy use).
Transmission Fluid Change Interval:
30,000-100,000 miles (varies significantly based on usage and fluid type; consult specific manual recommendations).
Spark Plug Replacement Interval:
100,000 miles (Platinum or Iridium plugs).
Engine Oil Spec Gas:
API Certified SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity recommendation based on temperature).
Engine Oil Spec Diesel:
API CG-4 or CH-4 rated Diesel Engine Oil, SAE 15W-40 (conventional) or 5W-40 (synthetic).
Coolant Spec:
Mopar OAT (Orange) Antifreeze/Coolant, 5/150,000 miles service interval.
Common Diesel Issues:
Lift pump failure, injector pump (P7100) issues, valve spring issues (common on early 24-valve Cummins), injector line leaks, turbocharger problems.
Common Gas Engine Issues:
Plenum gasket leaks (intake manifold), distributorless ignition system (DIS) issues, exhaust manifold cracks, oil leaks from rear main seal.
Common Transmission Issues:
42RE/46RE solenoids failure, torque converter shudder, 53 block cracking (rare in manual transmission applications but notable in the generation).
Common Chassis Issues:
Ball joint wear, tie rod end wear, front hub bearing failure (especially in 4x4 models), rust on fenders, rocker panels, and cab corners.
Typical Repairs:
Brake pad/rotor replacement, exhaust system repair/replacement, suspension component replacement, front end alignment.