Positioning:
Essential tool for owners and independent repair shops seeking to maintain and repair Dodge's heavy-duty pickup trucks of the early 1990s.
Competitors:
Directly competes with factory service manuals from Chrysler Corporation and aftermarket repair manuals like Chilton or Haynes, offering a more in-depth and factory-level detail.
Features:
Step-by-step instructions, detailed diagrams and illustrations, comprehensive troubleshooting guides, diagnostic procedures, torque specifications, wiring diagrams, and all factory recommended maintenance schedules.
Powertrain:
Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, powertrain control modules (PCM), engine diagnostics.
Transmission Drivetrain:
Manual transmissions (e.g., NV4500, NP435), automatic transmissions (e.g., A500, A727, A770), transfer cases, drivelines, axles, differentials, driveshafts, CV joints.
Brakes:
Front disc brakes (ventilated), rear drum brakes, parking brake system, ABS (if equipped), hydraulic lines, master cylinder, power booster.
Suspension Steering:
Front independent suspension (Torsion Bar), rear solid axle leaf springs, steering gear, power steering system, tie rods, ball joints, shock absorbers, sway bars.
Electrical Electronics:
Battery, charging system (alternator), starting system (starter motor), ignition system, lighting, wipers, horn, instrument cluster, wiring diagrams, fuses, relays, power windows/locks (if equipped), radio.
Body Chassis:
Frame, body panels, doors, hood, tailgate, bumpers, interior trim, seats, glass, weatherstripping, structural components, chassis lubrication.
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotations, brake inspections, tune-ups, spark plug replacement, belt inspections/replacement, cooling system flush.
Troubleshooting:
Diagnostic charts for common drivability issues, electrical faults, cooling system problems, brake noise, steering issues, transmission shifting problems.
Repair Rebuild:
Engine overhaul, transmission overhaul, brake caliper/wheel cylinder replacement, suspension component replacement (ball joints, tie rods), steering gearbox rebuild, starter/alternator replacement, fuel pump replacement, exhaust system repair.
Component Replacement:
Detailed instructions for removing and installing all major and minor components, including radiators, alternators, starters, fuel injectors, fuel pumps, brake pads, rotors, drums, master cylinders, water pumps, thermostats, power steering pumps, various sensors.
Depth:
Comprehensive from basic scheduled maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and wiring schematics.
Engine Options:
5.2L (318) V8 Magnum, 5.9L (360) V8 Magnum, 8.0L V10 Magnum (introduced later in the generation, but potentially covered for late 94 models), 5.9L Cummins Turbo Diesel I6 (for W250/W350).
Hp Torque 5 2L:
Approximately 230 hp @ 4400 rpm, 330 lb-ft @ 3200 rpm (Magnum update)
Hp Torque 5 9L:
Approximately 245 hp @ 4000 rpm, 375 lb-ft @ 3200 rpm (Magnum update)
Hp Torque 5 9L Cummins:
Approximately 160-180 hp, 400-420 lb-ft torque (specific figures vary by year and tuning)
Fuel Delivery Gas:
Multi-point Fuel Injection (MPI) for Magnum V8s.
Fuel Delivery Diesel:
Bosch VE Rotary injection pump, direct injection.
Spark Plugs 5 2L 5 9L:
Champion Copper Plus (e.g., RC12LYC) or equivalent, typically gapped to 0.035 inches.
Ignition Timing:
Computer controlled, requires diagnostic scan tool for adjustment/verification.
Coolant Type:
Chrysler Antifreeze/Coolant (ethylene glycol based), or equivalent meeting MS-7170 specification (typically green coolant).
Standard Transmission:
5-Speed Manual (e.g., NP435 for earlier models, NV4500 for later models).
Automatic Transmission:
3-Speed Automatic (A727), 4-Speed Automatic (A500/A770 - Overdrive).
Transmission Fluid Auto:
ATF+3 (MS-9229) or equivalent.
Transmission Fluid Manual:
Typically GL-3 or GL-4 gear oil, viscosity dependent on temperature (e.g., 75W-90 or 80W-90).
Transfer Case:
New Process NP241 (manual or electric shift) common for 4x4 models.
Transfer Case Fluid:
ATF+3 (MS-9229) or equivalent for NP241.
Oil Change Interval Gas:
Every 3,000 miles or 3 months (standard) or 6,000 miles/6 months (severe service/synthetic oil).
Oil Change Interval Diesel:
Every 3,000-5,000 miles depending on duty cycle and oil type.
Transmission Fluid Change:
Automatic: 30,000-60,000 miles; Manual: Typically every 60,000-100,000 miles.
Coolant Flush Interval:
Every 30,000 miles or 2-3 years for conventional coolant.
Filter Replacement:
Engine oil filter with every oil change. Fuel filter replacement interval varies (e.g., 15,000-30,000 miles).
Engine Oil Capacity 5 2L 5 9L:
5 Quarts (with filter) of SAE 10W-30 or 10W-40 (check owner's manual for temperature specifics).
Engine Oil Capacity Diesel:
10 Quarts (with filter) of 15W-40 heavy-duty diesel engine oil (e.g., API CG-4 or CH-4 rated).
Brake Fluid Type:
DOT 3 Hydraulic Brake Fluid.
Power Steering Fluid:
ATF+3 (MS-9229) or equivalent power steering fluid.
Common Failures Gas:
Distributor/pickup coil failure, fuel injector clogging, intake manifold gasket leaks, EGR valve issues, exhaust manifold cracks (especially on Magnum engines).
Common Failures Diesel:
Lift pump failure, injector pump issues (VE pump), injector line leaks, potential for head gasket issues on high-mileage engines, vacuum pump leaks.
Chassis Common Issues:
Ball joint wear, tie rod end wear, exhaust system rust/corrosion, frame rust in certain climates, AC system leaks, door hinge wear.
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable pickup trucks, often positioned as workhorses and performance vehicles.
Third Generation D W Series:
The 1993-1994 models represent the final years of the third generation (NN/AN) D/W series, characterized by a significant update in 1987 with the introduction of the 'Ram' styling and the Magnum engine lineup.
Manufacturing Location:
Primarily St. Louis, Missouri, and Warren, Michigan.
Production Years:
Third generation: 1972-1993 (though 1994 models exist with minor updates).
