Engine Mechanical:
Detailed procedures for engine removal/installation, internal component inspection and repair, timing systems, cooling system, lubrication system.
Engine Performance:
Fuel injection systems (MPI), ignition systems, exhaust systems, emission controls, diagnostics and troubleshooting.
Transmission Manual:
Service and repair procedures for NV3500 5-speed manual transmission, including clutch system.
Transmission Automatic:
Service and repair procedures for 46RH, 47RH (4-speed automatic transmissions), including torque converter, valve body, and internal components.
Drivetrain:
Front and rear axle assemblies, differential service, propeller shafts, U-joints, 4WD transfer case (New Process NP231, NP241).
Suspension:
Front independent suspension (torsion bar), rear leaf spring suspension, steering system components, wheel alignment specifications.
Brakes:
Front disc brakes, rear drum brakes (or optional rear discs), ABS system (if equipped), hydraulic system, parking brake.
Electrical System:
Battery, charging system (alternator), starting system, ignition system, lighting, instrument cluster, power accessories, wiring diagrams.
Body And Frame:
Body panel repair, door mechanisms, interior trim, chassis and frame inspection, corrosion protection.
HVAC:
Heating, ventilation, and air conditioning system service, diagnosis, and component replacement.
Diagnostics:
On-board diagnostics (OBD-I), diagnostic trouble codes (DTCs), troubleshooting procedures using diagnostic tools.
Scheduled Maintenance:
Detailed service intervals for oil changes, filter replacements, fluid checks, tune-ups, and inspections.
Engine Repair:
Engine rebuild procedures, cylinder head service, piston and connecting rod replacement, crankshaft service.
Transmission Overhaul:
Complete overhaul procedures for both manual and automatic transmissions, including component replacement and adjustment.
Brake System Repair:
Brake pad/shoe replacement, caliper/wheel cylinder service, rotor/drum resurfacing/replacement, brake line repair, ABS bleeding.
Electrical Troubleshooting:
Step-by-step troubleshooting guides for electrical issues using wiring diagrams and diagnostic techniques.
Steering And Suspension Repair:
Replacement of ball joints, tie rods, control arms, shock absorbers, steering box service.
Body Work:
Panel alignment, door hinge adjustment, glass replacement, bumper repair.
Diagnostics And Testing:
Procedures for testing sensors, actuators, and electrical components.
Depth:
Comprehensive: Covers basic maintenance to full engine and transmission overhauls, complex electrical diagnostics, and chassis work.
Diagnostic Capabilities:
Detailed diagnostic flowcharts and troubleshooting trees for various systems.
Rebuild Procedures:
Includes detailed specifications and procedures for rebuilding major components like engines and transmissions.
Base Engine:
5.2L Magnum V8 (318 ci)
Base Engine Hp:
Approx. 230 hp @ 4,800 rpm
Base Engine Torque:
Approx. 295 lb-ft @ 3,200 rpm
Optional Engine:
5.9L Magnum V8 (360 ci)
Engine Code Optional 1:
Z
Optional Engine 1 Hp:
Approx. 245 hp @ 4,500 rpm
Optional Engine 1 Torque:
Approx. 330 lb-ft @ 3,200 rpm
Optional Engine 2:
8.0L Magnum V10 (488 ci) - Introduced in 1996
Engine Code Optional 2:
W
Optional Engine 2 Hp:
Approx. 300 hp @ 4,500 rpm
Optional Engine 2 Torque:
Approx. 450 lb-ft @ 2,400 rpm
Optional Engine 3:
5.9L Cummins Turbo Diesel I6 (359 ci) - Introduced in 1994
Engine Code Optional 3:
C
Optional Engine 3 Hp:
Approx. 160-175 hp @ 2,500 rpm (depending on year/spec)
Optional Engine 3 Torque:
Approx. 400-420 lb-ft @ 1,600 rpm (depending on year/spec)
Fuel Delivery:
Multi-Point Fuel Injection (MPI) for gasoline engines; Bosch VE rotary injection pump for Cummins Diesel.
Fuel Type:
Unleaded gasoline (87 octane recommended for 5.2L, 89 octane for 5.9L V8 and V10); Diesel fuel for Cummins.
Wheelbase Regular Cab:
117.7 inches (2990 mm)
Wheelbase Club Cab:
134.7 inches (3421 mm)
Wheelbase Crew Cab:
134.7 inches (3421 mm) (Less common/available in early second gen, more prevalent later)
Overall Length:
Varies by cab and bed configuration, typically 210-235 inches (5334-5969 mm).
Overall Width:
Approx. 79.1 inches (2009 mm)
Overall Height:
Approx. 73.5-77.5 inches (1867-1969 mm), depending on 2WD/4WD and configuration.
Bed Length Short:
6.5 feet (1981 mm)
Bed Length Long:
8.0 feet (2438 mm)
Curb Weight:
Varies widely, typically 4,500-6,000 lbs (2041-2722 kg) depending on configuration.
Gross Vehicle Weight Rating Gvw:
Ranges from 6,050 lbs (2744 kg) for light-duty models up to 9,500 lbs (4309 kg) for heavy-duty configurations (3500 series).
Towing Capacity:
Up to approximately 10,000-11,000 lbs (4536-4990 kg) for properly equipped heavy-duty models.
Oil Change Gasoline:
Every 3,000 miles (4,800 km) or 3 months for severe service; 7,500 miles (12,000 km) or 6 months for normal service (check manual for specific recommendations).
Oil Change Diesel:
Every 5,000 miles (8,000 km) or 6 months (severe service) or 10,000 miles (16,000 km) or 12 months (normal service) using appropriate diesel oil.
Tire Rotation:
Every 7,500 miles (12,000 km)
Transmission Fluid Change Automatic:
Every 30,000 miles (48,000 km) or 24 months (severe service), 60,000 miles (96,000 km) or 48 months (normal service).
Transmission Fluid Change Manual:
Every 60,000 miles (96,000 km) or 48 months.
Engine Oil Viscosity:
SAE 10W-30 for 5.2L/5.9L V8; SAE 5W-30 or 10W-30 for V10; SAE 15W-40 for Cummins Diesel.
Engine Oil Type:
API Service SG or higher for gasoline; API Service CD or CE for diesel.
Coolant:
Mopar 5/150 Antifreeze/Coolant (Ethylene Glycol) or equivalent, mixed 50/50 with distilled water.
Transmission Fluid Automatic:
ATF+3 (Chrysler spec) or equivalent.
Transmission Fluid Manual:
NV3500: SAE 75W-90 Synthetic Gear Oil; NV4500 (often found in diesel conversions): SAE 75W-90 Synthetic Gear Oil.
Transfer Case Fluid:
Mopar NV241/NP231 Transfer Case Lubricant or Dexron III ATF.
Common Problems 1:
Cracked exhaust manifolds (especially 5.2L/5.9L V8), plenum gasket leaks, differential pinion seal leaks, death wobble (front suspension/steering component wear), heater core issues, automatic transmission valve body problems.
Common Problems 2:
Cummins: Injector pump failures, older turbocharger issues, radiator hose leaks. Electrical gremlins can occur in aging vehicles.
Dodge Trucks:
Dodge has a long history of producing reliable and capable trucks, dating back to the 1930s.
Ram Design Philosophy:
The second-generation Ram was designed to be bolder and more distinct than its predecessors, targeting a more style-conscious buyer while retaining traditional truck capabilities.
Generation Launch:
The second generation (BR/BE platform) debuted for the 1994 model year, representing a complete overhaul.
Manufacturing Location:
Saltillo Truck Assembly, Mexico; Warren Truck Assembly, Michigan, USA.
Production Span:
1994-2001 (This manual covers the early part of this generation).