Vehicle Segment:
Heavy-Duty Pickup Truck
Target Audience:
Owners, professional mechanics, fleet managers, DIY enthusiasts working on Dodge Ram 3500 trucks.
Competitors:
Ford F-350 Super Duty, Chevrolet Silverado 3500 HD, GMC Sierra 3500 HD.
Manual Utility:
Essential resource for maintaining, troubleshooting, and repairing the Dodge Ram 3500 during its 1994-2002 production run. Provides tested techniques for effective service.
Powertrain:
Engine mechanical, fuel system, ignition system, lubrication, cooling system, exhaust system, clutch, manual transmission, automatic transmission, transfer case.
Chassis:
Frame and body, suspension (front and rear), steering, wheels and tires, brakes (front, rear, parking), drivetrain (propeller shafts, differentials).
Electrical:
Battery, charging system, starting system, ignition system, lighting, instruments and gauges, warning indicators, horn, wipers and washers, power windows, power door locks, power mirrors, seat heaters, trailer wiring harness, diagnostic connector.
Body And Interior:
Body panels, doors, hood, tailgate, bumpers, glass, interior trim, seats, seat belts, HVAC system (heating, ventilation, air conditioning).
Maintenance:
Fluid level checks and changes, filter replacements, lubrication, tire rotation, belt inspection and replacement, brake pad/shoe replacement, battery maintenance.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts, diagnostic trouble codes (DTCs) and their meanings.
Repair:
Detailed step-by-step repair procedures for all major components and systems, including engine disassembly/assembly, transmission overhaul, brake system repair, electrical component replacement, body panel repair.
Diagnostics:
On-board diagnostics (OBD-I and early OBD-II), scan tool usage, wiring diagrams, component testing procedures.
Depth Level:
Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and detailed bodywork.
Binding Type:
Perfect bound or saddle-stitched (typical for print manuals)
Paper Type:
High-quality, durable paper designed for shop environments.
Print Quality:
Professional printing with clear diagrams, illustrations, and text.
Engine Options:
5.2L Magnum V8 (318 ci), 5.9L Magnum V8 (360 ci), 5.9L Cummins Turbo Diesel I6 (24-valve in later years).
5.2L Magnum V8:
Approx. 230 hp, 330 lb-ft torque
5.9L Magnum V8:
Approx. 245-250 hp, 330-345 lb-ft torque
5.9L Cummins Turbo Diesel:
Approx. 215-235 hp, 420-460 lb-ft torque (varies by year and configuration)
Gasoline Engines:
Sequential Electronic Fuel Injection (SEFI)
Diesel Engine:
Bosch P7100 injection pump (early years), VP44 injection pump (later years), direct injection.
Manual Options:
Getrag NV4500 5-speed manual transmission.
Automatic Options:
Chrysler 47RH 4-speed automatic (diesel), 47RE 4-speed automatic (diesel/gasoline), 46RE 4-speed automatic (gasoline).
Transfer Case:
New Process (NP) 241DHD manual shift or optional electric shift transfer case for 4WD models.
Wheelbase Options:
134.5 inches (Regular Cab), 154.5 inches (Club Cab), 164.5 inches (Regular Cab Long Bed), 178.4 inches (Mega Cab - later model years).
Overall Length:
Varies by cab and bed configuration (e.g., approx. 230-250 inches).
Curb Weight:
Approx. 5,500 - 7,500 lbs (varies significantly by configuration and engine)
Gross Vehicle Weight Rating Gvw:
Up to 11,000 lbs (GVWR)
NHTSA Ratings:
NHTSA ratings vary by year and specific test data, generally focused on frontal impacts for this era.
Braking System:
Front: Vented disc brakes. Rear: Solid disc or drum brakes depending on configuration. Anti-lock braking system (ABS) typically on rear wheels for 2WD, 4-wheel ABS on 4WD.
Airbags:
Driver-side airbag standard, passenger-side airbag optional or standard in later years.
Seat Belts:
Three-point front seat belts, lap belts in rear.
Audio System:
Factory AM/FM radio with cassette tape player, optional CD player. Basic analog gauges.
ABS:
Anti-lock Braking System (ABS) available, typically on rear wheels for 2WD and 4-wheel for 4WD models.
Trailer Options:
Provisions for trailer brake controllers and trailer wiring harnesses were common options.
Oil Change:
Every 3,000-7,500 miles or 6 months, depending on engine type (gas vs. diesel) and oil specification used. Diesel engines, especially with high-quality synthetic oil, can extend intervals.
Tire Rotation:
Every 5,000-7,500 miles.
Transmission Fluid Change:
Automatic transmissions: 30,000-60,000 miles. Manual transmissions: Check manual for specific recommendations, typically longer intervals.
Engine Oil Gasoline:
API SG or higher, SAE 5W-30 or 10W-30 (refer to owner's manual for specific viscosity based on temperature).
Engine Oil Diesel:
API CG-4 or CH-4, SAE 15W-40 or 5W-40 (synthetic recommended for better performance and longevity).
Coolant:
Ethylene glycol based, Mopar OAT (Orange) or HOAT (Yellow) coolant recommended for post-1994 vehicles. Capacity approx. 20-23 quarts.
Transmission Fluid Automatic:
Chrysler ATF+4 (or equivalent) for 47RE/48RE. Earlier 47RH may use Dexron II/III. Capacity approx. 11-13 quarts.
Transmission Fluid Manual:
NV4500: GL-4 rated manual transmission fluid, SAE 75W-90 or 50W. Capacity approx. 2.5-3 quarts.
Differential Fluid:
API GL-5 gear oil, SAE 75W-90 or 80W-90. Capacity approx. 2-3 quarts per axle.
Cummins Vp44 Pump:
The VP44 injection pump on later 5.9L Cummins engines is a known failure point, often due to fuel starvation or contamination. Related issues include lift pump failures.
Nv4500 5Th Gear Nut:
The 5th gear nut on the NV4500 manual transmission can loosen, leading to gear damage. A common fix involves using a retaining nut with a locking mechanism.
Dodge Transfer Case:
Various transfer case issues, including chain stretch or worn internal components, particularly with heavy use.
Dodge Brake Actuator:
ABS actuator failures can occur, leading to ABS warning lights and loss of braking assist.
Exhaust Manifold Cracks:
Cracked exhaust manifolds, especially on the 5.9L Cummins, can lead to exhaust leaks and reduced performance.
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, with the Ram line becoming a distinct brand in 1993.
Second Generation Ram:
The BR/BE generation (1994-2001/2002) represented a complete redesign of the Ram truck, featuring a more aerodynamic and aggressive styling, significant chassis and suspension improvements, and the introduction of the then-new 24-valve Cummins Turbo Diesel engine.
Mid-Cycle Refresh:
A minor facelift occurred in 1998, with updated interior features and subtle exterior styling tweaks. The Mega Cab model was introduced for the 2002 model year.
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan.
Cummins Diesel Reputation:
The 5.9L Cummins Turbo Diesel engine is widely regarded as one of the most durable and reliable diesel engines ever produced for pickup trucks, contributing significantly to the Ram 3500's popularity and reputation.
Consumer Reports Reliability:
Reliability ratings varied by model year and specific powertrain, with the Cummins diesel generally performing better than the gasoline V8s in some aspects.
