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.