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Dodge Ram 1994-2001 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Dodge Model: Ram Pickup Body Style: Full-size Pickup Truck Chassis Code: Second Generation (DN/DR) Generation Generation Name: Second Generation Generation Years: 1994-2001 Codes Internal Platform...
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Distributeur:
UGS: 468576
Dodge Ram 1994-2001 WSM Service Manual Repair
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram Pickup
Body Style:
Full-size Pickup Truck
Chassis Code:
Second Generation (DN/DR)
Generation
Generation Name:
Second Generation
Generation Years:
1994-2001
Codes
Internal Platform Code:
DN/DR
👋 Introduction
Market Position
Segment:
Full-size pickup truck, commercial vehicle
Reputation:
Known for robust powertrains and heavy-duty capabilities, a favorite for work and towing.
Competitive Analysis
Primary Competitors:
Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra (later years)
Key Features
Design:
Distinctive 'big rig' styling, especially the 1994 redesign which introduced the iconic grille.
Powertrain Options:
Renowned for its Magnum V8 engines and the Cummins turbodiesel option for heavy-duty models.
Durability:
Built to withstand tough conditions, making it a popular choice for commercial use and off-roading.
📋 Manual Details
Coverage Areas
Covered Years:
1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001
Covered Models:
Dodge Ram 1500, 2500, 3500
Page Count
Estimated Page Count:
3000+
Manual Type
Type:
Factory Service Manual (WSM)
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, cooling system, exhaust system, manual transmission, automatic transmission, transfer case, driveline
Chassis:
Suspension (front and rear), steering, brakes (hydraulic, ABS), wheels, tires, frame
Electrical:
Battery, charging system, starting system, ignition system, lighting, instrumentation, power windows, power locks, audio system, multiplexed systems
Body:
Exterior body panels, interior trim, doors, windows, seats, HVAC system, bumpers, tailgate
Procedures Included
Maintenance:
Routine service, fluid changes, filter replacements, lubrication
Diagnostics:
Troubleshooting charts, symptom-based diagnostics, diagnostic trouble codes (DTCs)
Repair:
Component removal and installation, major and minor repairs, adjustments
Rebuilding:
Detailed procedures for engine, transmission, and differential rebuilds
Specifications:
Torque specifications, clearances, fluid capacities, electrical values
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to in-depth diagnostics and complete overhaul procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes
Printable:
Yes
Print Quality
Image Resolution:
High (suitable for detailed diagrams)
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Options:
5.2L Magnum V8 (318 ci), 5.9L Magnum V8 (360 ci), 8.0L V10 Magnum (488 ci), 5.9L Cummins Turbo Diesel I6
Performance
5.2L Magnum V8 (318 Ci) Horsepower:
230 hp @ 4500 rpm
5.2L Magnum V8 (318 Ci) Torque:
295 lb-ft @ 3200 rpm
5.9L Magnum V8 (360 Ci) Horsepower:
245-250 hp @ 4400 rpm
5.9L Magnum V8 (360 Ci) Torque:
330-345 lb-ft @ 3200 rpm
8.0L V10 Magnum (488 Ci) Horsepower:
300 hp @ 4000 rpm
8.0L V10 Magnum (488 Ci) Torque:
450 lb-ft @ 3200 rpm
5.9L Cummins Turbo Diesel I6 Horsepower:
180-215 hp @ 2500 rpm (depending on year/application)
5.9L Cummins Turbo Diesel I6 Torque:
420-440 lb-ft @ 1600 rpm (depending on year/application)
Fuel System
Fuel Delivery:
Multi-port fuel injection (MPI) for gasoline engines; Bosch VE rotary injection pump for early Cummins, Bosch VP44 inline injection pump for later Cummins.
Fuel Type:
Unleaded gasoline (87 octane recommended); Diesel fuel for Cummins
🔧 Transmission
Standard
Standard Transmission:
5-speed manual (NV4500 for HD models, NV3500 for 1500 models)
Optional
Optional Transmission:
4-speed automatic (46RE/47RE for V8/V10, 47RH for earlier diesel, 48RE for later diesel)
Features
Transfer Case:
Part-time 4WD system (New Process NV241DHD, NV243, etc.)
📐 Dimensions
Exterior
Wheelbase Options:
119-inch (standard cab, short bed), 131-inch (standard cab, long bed/Quad Cab, short bed), 134.5-inch (Mega Cab), 155-inch (crew cab, long bed)
Bed Length Options:
6.3 ft, 8.0 ft
Weights
Curb Weight Range:
Approximately 4,500 - 7,500 lbs (depending on configuration)
Gross Vehicle Weight Rating Range:
6,000 lbs (1500) to 11,500 lbs (3500 HD)
🛡️ Safety Features
Ratings
NHTSA Crash Test Ratings:
Varies by year and configuration; generally average to good for its class during the period.
Active Features
ABS:
Standard on 1500 models, optional or standard on heavier duty models. Rear-wheel anti-lock brakes (RWAL) often standard on 2WD and 4WD.
Passive Features
Airbags:
Driver airbag standard, passenger airbag optional on early models, standard on later models.
Seatbelts:
Three-point seatbelts for front occupants, two-point lap belts for rear occupants (if equipped).
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette and/or CD player, optional Infinity speaker system.
Navigation:
Not typically available from the factory in this generation.
Driver Assistance
Cruise Control:
Standard on most models.
Tow Haul Mode:
Available on automatic transmissions for heavy towing.
Connectivity
Trailer Tow Package:
Often available, including trailer brake controller wiring, heavier-duty cooling, and specific hitch receivers.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles for conventional oil, 5,000-7,500 miles for synthetic oil (consult manual for specific engine/oil type).
Engine Coolant Flush:
Every 30,000 miles or 2 years (typically).
Transmission Fluid Change:
Every 30,000-60,000 miles depending on usage (heavy towing/hauling requires more frequent changes).
Fluid Specifications
Engine Oil Type Gasoline:
API Service SG or higher; SAE 5W-30 recommended for most conditions.
Engine Oil Type Diesel:
API Service CG-4 or CH-4; SAE 15W-40 recommended for most conditions.
Automatic Transmission Fluid:
ATF+3 (Mopar designation)
Manual Transmission Fluid:
API GL-5, SAE 75W-90 or 80W-90 gear oil.
Coolant:
Mopar Antifreeze/Coolant (Ethylene Glycol based) or equivalent.
Known Issues
Common Problems:
Lift pump failure on Cummins diesel (VP44 era), plenum gasket leaks on Magnum V8s, ball joint wear, heater core leaks, occasional transmission issues (especially early 46RE), rust on body panels and frame.
Dashboard Cracking:
Common issue for dashboards to crack due to sun exposure.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, dating back to the early 20th century.
Model Evolution
Second Generation Introduction:
The second generation Ram debuted for the 1994 model year with a completely redesigned exterior and chassis, heavily influenced by heavy-duty truck styling.
Key Redesigns Updates:
Mid-cycle refresh in 1998 introduced revised interiors, improved engines, and the optional Quad Cab configuration. The Mega Cab was introduced in 2003, bridging into the next generation.
Production
Manufacturing Locations:
Primarily Warren, Michigan, USA; Saltillo, Mexico
Production Years For Generation:
1994-2001
🏆 Awards & Recognition
Recognitions
Motor Trend Truck Of The Year:
Dodge Ram 1994: MotorTrend Truck of the Year
Cumming Diesel Reputation:
The 5.9L Cummins Turbo Diesel became legendary for its durability and towing prowess, often outlasting the trucks they powered.
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