🏷️ Basic Information

Make:

Dodge

Model:

Ram 2500 / Ram 3500

Years:

1994, 1995, 1996, 1997

Chassis Code:

Second Generation (BR/BE Ram)

👋 Introduction

Positioning:

Targeted at owners of the second-generation Dodge Ram trucks (1994-1997) seeking to perform their own maintenance and repairs, DIY enthusiasts, and independent repair shops.

Competitors:

Haynes Manuals, Chilton Manuals, factory service bulletins, and other aftermarket repair guides. This manual often represents a higher level of detail and factory accuracy.

Features:

Comprehensive coverage of all engine options, including the sought-after Cummins turbodiesel; detailed electrical schematics; step-by-step repair procedures with illustrations; troubleshooting guides; and specifications.

📋 Manual Details

Engine Coverage:

5.2L Magnum V8, 5.9L Magnum V8, 8.0L Magnum V10, 5.9L Cummins Turbo Diesel

Transmission Coverage:

4-speed Automatic (46RH, 47RH), 5-speed Manual (NV4500)

Drive Type Coverage:

2WD and 4WD

Major Systems:

Engine, Transmission, Drivetrain, Brakes, Steering, Suspension, Electrical, HVAC, Body, Fuel System, Cooling System, Exhaust System, Interior, Exterior

Estimated Page Count:

1500-2000+ (estimated across multiple volumes or a comprehensive single volume)

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Digital (PDF) or Printed Book

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, assembly, inspection, and repair procedures for all engine variants, including cylinder head, block, pistons, crankshaft, camshaft, valve train, timing components, seals, and gaskets.

Engine Performance:

Diagnosis and repair of fuel delivery, ignition system, emissions control, cooling system, and lubrication system issues. Includes specifications for ignition timing, fuel pressure, and sensor readings.

Transmission Manual:

Complete overhaul and repair procedures for the NV4500 manual transmission, including clutch system, gear sets, synchronizers, shift forks, and PTO (if applicable).

Transmission Automatic:

Detailed diagnosis, repair, and overhaul procedures for the 46RH and 47RH automatic transmissions, including valve body, torque converter, clutch packs, bands, and hydraulic controls.

Drivetrain And Axles:

Service and repair for transfer cases (NV241DLD, NV241DHD), rear differentials (Dana 60, Dana 70HD), front differentials (for 4WD), driveshafts, U-joints, and wheel bearings.

Brakes:

Front and rear brake system diagnosis and repair, including disc brake pads/rotors, drum brake shoes/drums, hydraulic lines, master cylinder, brake booster, ABS system (if equipped), parking brake.

Steering:

Diagnosis and repair of steering gear, power steering pump, hoses, steering linkage, tie rod ends, steering column, and steering wheel.

Suspension:

Service and repair for front and rear suspension components, including ball joints, control arms, leaf springs, shocks/struts, sway bars, and bushings.

Electrical System:

Comprehensive wiring diagrams, component location, diagnosis of starting and charging systems, lighting, instrumentation, power windows, locks, mirrors, audio systems, and trailer wiring.

HVAC System:

Diagnosis and repair of air conditioning (A/C) and heating systems, including refrigerant servicing, compressor, condenser, evaporator, blower motor, heater core, and climate controls.

Body And Frame:

Body panel repair, door, hood, tailgate mechanisms, glass replacement, interior trim, seat mechanisms, and basic frame inspection.

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel injectors (for gasoline engines), injection pump (for diesel), fuel filter replacement, and emissions components.

Cooling System:

Radiator, water pump, thermostat, hoses, fan, fan clutch, coolant specifications, and diagnosis of overheating issues.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, tailpipe, and mounting hardware replacement and repair.

Maintenance:

Routine maintenance procedures such as oil changes, filter replacements, fluid checks and top-offs, tire rotations, brake inspections, and general vehicle upkeep.

Troubleshooting:

Systematic diagnostic flowcharts and symptom-based troubleshooting guides for common and uncommon issues across all vehicle systems.

Repair And Overhaul:

Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation, covering everything from minor adjustments to complete component overhauls.

Wiring Diagrams:

Detailed, vehicle-specific wiring schematics for all electrical systems, including component identification, wire colors, and connector pinouts.

Torque Specifications:

Comprehensive listing of all critical torque specifications for engine, transmission, suspension, drivetrain, and chassis components.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair or diagnostic procedures.

Depth:

Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics and bodywork.

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format), typically optimized for searchability and printing.

Print Quality:

High-resolution scans or digitally created files suitable for clear printing of text and diagrams.

Binding Type:

N/A (for digital format); Typically spiral-bound or perfect-bound for printed versions to allow for lay-flat use.

Paper Type:

N/A (for digital format); Printed manuals often use durable, matte paper to reduce glare and facilitate note-taking.

⚙️ Engine Specifications

Gasoline Engines:

5.2L (318 ci) Magnum V8, 5.9L (360 ci) Magnum V8, 8.0L (488 ci) Magnum V10

Diesel Engine:

5.9L (359 ci) Cummins 12-valve Turbo Diesel (B-Series)

5.2L Magnum V8:

Approx. 230 hp @ 4,400 rpm, 295 lb-ft @ 3,200 rpm

5.9L Magnum V8:

Approx. 245 hp @ 4,000 rpm, 330 lb-ft @ 3,200 rpm

8.0L Magnum V10:

Approx. 300 hp @ 4,000 rpm, 450 lb-ft @ 3,200 rpm

5.9L Cummins Turbo Diesel:

Approx. 180-215 hp @ 2,500 rpm, 420-470 lb-ft @ 1,600 rpm (depending on year and model specifics)

Gasoline Injection:

Multi-point Fuel Injection (MPI)

Diesel Injection:

Inline injection pump (Bosch VE or P7100 for later models), mechanical injectors

🔧 Transmission

Transmission Options:

4-speed Automatic (46RH, 47RH), 5-speed Manual (NV4500)

4Wd Transfer Case:

New Process NP241DLD (Light Duty) and NP241DHD (Heavy Duty) manual shift transfer cases

Automatic Transmission Features:

Electronic overdrive, torque converter lock-up

Manual Transmission Features:

Overdrive gear, robust design suitable for heavy-duty applications

📐 Dimensions

Body Styles:

Regular Cab, Club Cab (Extended Cab)

Bed Lengths:

6.5 ft (78.0 in), 8 ft (96.0 in)

Gross Vehicle Weight Rating Gvwr:

Ranges from approximately 8,500 lbs to over 11,000 lbs depending on configuration (2500 vs 3500, axles, springs).

🛡️ Safety Features

NHTSA Crash Test Results:

Information may vary by specific test year and configuration. Generally, second-gen Rams offered dual front airbags and seat belts.

Anti Lock Brakes ABS:

Available, typically on rear wheels for earlier models and all wheels for later models or specific configurations.

Airbags:

Dual front airbags standard on most models.

💡 Technology Features

Audio System:

Factory AM/FM cassette or CD player, optional premium sound systems.

Cruise Control:

Available on most models.

Trailer Wiring:

Standard trailer wiring harness connectors.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000 miles for gasoline engines under severe use, or 5,000-7,500 miles under normal use. Diesel engines may have longer intervals (e.g., 7,500-15,000 miles) depending on oil type and filter.

Transmission Fluid Change:

Automatic: Approximately every 30,000-60,000 miles. Manual: Less frequent, but check for leaks and condition.

Coolant Flush:

Every 30,000-50,000 miles or 2-3 years for conventional coolant; longer for extended-life coolants.

Engine Oil Gasoline:

SAE 5W-30 or 10W-30, API SG/SH or higher (refer to owner's manual for specific viscosity based on temperature).

Engine Oil Diesel:

Diesel Engine Oil (DEO) API CH-4 or CJ-4 rated, SAE 15W-40 is common (refer to manual for specific Cummins recommendations).

Automatic Transmission Fluid:

Chrysler ATF+3 (or equivalent).

Manual Transmission Fluid:

API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 (specific type for NV4500 may vary, consult manual).

Coolant:

Conventional Green Ethylene Glycol based coolant, typically a 50/50 mix with distilled water.

Common Problems Gas:

Cracked exhaust manifolds (especially on 5.9L V8), intake manifold gasket leaks, distributor issues, radiator leaks, PCM (Powertrain Control Module) failures.

Common Problems Diesel:

Lift pump failures, injector line leaks, injection pump (VE or P7100) issues, front main seal leaks, water separator issues, vacuum pump leaks.

Common Problems General:

Front suspension wear (ball joints, tie rods), universal joint wear, rear main seal leaks (especially on transmission side), HVAC blower motor failures, power window regulators.

📚 Vehicle History

Dodge Trucks:

Dodge has a long history of producing robust and capable trucks, with the Ram line establishing itself as a significant player in the heavy-duty segment.

Second Generation Ram:

The second generation (1994-2001) marked a significant redesign with a more aerodynamic and muscular appearance, a much-improved interior, and the introduction of the powerful Magnum V8 and V10 engines, as well as the highly regarded Cummins turbodiesel.

Manufacturing Location:

Primarily Saltillo, Mexico, and Warren, Michigan, USA.

🏆 Awards & Recognition

Diesel Engine Reputation:

The 5.9L Cummins turbodiesel from this era is highly regarded for its durability, reliability, and performance, often considered one of the best diesel engines ever put into a light-duty truck.