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Dodge Ram 1996-1997 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Model Generation: Second Generation (BR/BE) Production Years Covered: 1996-1997 Codes Chassis Codes: BR (2WD), BE (4WD) 👋 Introduction Market Position Vehicle Segment:...
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🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram
Model Generation:
Second Generation (BR/BE)
Production Years Covered:
1996-1997
Codes
Chassis Codes:
BR (2WD), BE (4WD)
👋 Introduction
Market Position
Vehicle Segment:
Full-size pickup truck, a segment known for utility, towing, and hauling capabilities.
Competitive Analysis
Key Competitors:
Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra (though Tundra's earlier years were less impactful).
Key Features
Vehicle Strengths:
Robust construction, powerful engine options (especially V8 and Cummins diesel), and strong towing/hauling capacity.
Manual Value Proposition
User Benefit:
Empowers owners and technicians with comprehensive, accurate, and official factory data for efficient maintenance and repair.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete factory service and repair information for Dodge Ram 1500, 2500, and 3500 models.
Secondary Coverage:
Includes all engine, transmission, driveline, suspension, steering, brakes, electrical systems, body, and HVAC.
Page Count
Estimated Page Count:
Hundreds of pages (exact count varies by specific print or digital edition, but described as 'complete').
Manual Type
Type:
Workshop Service Repair Manual
Origin:
Official Factory Service Manual
Language
Language:
English
Format
Format Description:
Digital (likely PDF) allowing for printing of entire manual or specific pages.
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage for all gasoline and diesel engines, including diagnostics, disassembly, assembly, and torque specifications.
Transmission Drivetrain:
Covers manual and automatic transmissions (e.g., NV3500, A500/42RE, A518/46RE, NV4500, NV5600), transfer cases, and differentials.
Suspension Steering:
Includes front and rear suspension components, steering gear, power steering system, and alignment procedures.
Brakes:
Full coverage of front and rear brake systems, including ABS diagnostics and repair procedures.
Electrical Electronics:
Comprehensive wiring diagrams, component testing, diagnostic procedures for lighting, ignition, charging, starting, and accessories.
Body Chassis:
Includes body panel removal/installation, interior trim, door mechanisms, glass, and chassis component repair.
HVAC:
Air conditioning and heating system diagnosis, service, and component replacement.
Procedures Included
Maintenance:
Detailed step-by-step procedures for all scheduled maintenance tasks.
Troubleshooting:
Extensive diagnostic flowcharts and troubleshooting guides for common and uncommon issues.
Repair Rebuild:
Complete instructions for component disassembly, inspection, repair, and reassembly.
Diagnostics:
Covers basic diagnostic tests, OBD-II code interpretation, and specific system diagnostic routines.
Wheel Alignment:
Detailed specifications and procedures for front and rear wheel alignment.
Tire Rotation:
Recommended tire rotation intervals and procedures.
Spark Plug Replacement:
Specific spark plug types, gap settings, and replacement procedures for each engine.
Fuel Filter Replacement:
Procedures for locating and replacing the fuel filter.
Air Filter Replacement:
Instructions for replacing engine air filter.
Cabin Air Filter Replacement:
Information on replacing the cabin air filter (if equipped).
Drive Belt Replacement:
Drive belt routing diagrams and replacement procedures.
Wiper Blade Replacement:
Instructions for replacing wiper blades.
Headlight Bulb Replacement:
Procedures for accessing and replacing headlight bulbs.
Trailer Wiring Diagrams:
May include basic trailer wiring information.
Technical Depth
Depth:
Provides in-depth technical information suitable for professional technicians and advanced DIYers.
Accuracy:
Represents the official factory data, ensuring high accuracy for repairs and specifications.
📊 Manual Specifications
File Format
Format:
Likely PDF (Portable Document Format), optimized for digital viewing and printing.
Searchability:
Typically features searchable text for quick access to specific topics.
Print Quality
Print Recommendation:
Designed for high-quality printing of individual pages or the entire document.
Binding Type
Binding For Print:
If printed, would typically be spiral-bound or three-hole punched for binder storage for ease of use in a workshop.
Paper Type
Recommended Paper:
Heavyweight, durable paper recommended for workshop environments if printing.
⚙️ Engine Specifications
Primary Engine
Engine Options Gas:
3.9L Magnum V6 (175 hp @ 4800 rpm, 230 lb-ft @ 3600 rpm), 5.2L Magnum V8 (230 hp @ 4400 rpm, 300 lb-ft @ 3200 rpm), 5.9L Magnum V8 (245 hp @ 4000 rpm, 335 lb-ft @ 3200 rpm).
Engine Options Diesel:
5.9L Cummins Turbo Diesel I6 (170-215 hp, 420-440 lb-ft torque, depending on year/application).
Performance
Induction System:
Naturally aspirated and turbocharged (for diesel).
Cylinder Head:
Overhead Valve (OHV) for Magnum V6/V8, Overhead Cam (OHC) for Cummins Diesel.
Fuel System
Gasoline Injection:
Multi-point fuel injection (MPI) for Magnum engines.
Diesel Injection:
Direct injection, typically Bosch inline injection pump for Cummins.
Technical Details
Bore Stroke 5.2L:
4.00 in x 3.88 in (101.6 mm x 98.5 mm)
Bore Stroke 5.9L Magnum:
4.02 in x 3.58 in (102.1 mm x 90.9 mm)
🔧 Transmission
Standard
Manual Transmission Options:
NV3500 (5-speed), NV4500 (5-speed Heavy Duty), NV5600 (6-speed, later years for HD).
Optional
Automatic Transmission Options:
A500/42RE (4-speed OD), A518/46RE (4-speed OD Heavy Duty).
Features
Transfer Case Options:
New Process NP231 (2WD/4WD), NP241 (2WD/4WD), NP241DHD (Heavy Duty 4WD).
Fluid Specifications
Automatic Transmission Fluid:
ATF+3 (Chrysler specification) or equivalent.
Manual Transmission Fluid:
API GL-4 or GL-5 gear oil (specific viscosity varies by transmission, e.g., 75W-90 or 75W-140).
📐 Dimensions
Exterior
Wheelbase Options:
Regular Cab (134.7 in), Club Cab (164.5 in), Chassis Cab (various).
Bed Length Options:
6.5 ft (standard), 8 ft (long bed).
Weights
Curb Weight Range:
Approximately 4,000 - 6,500 lbs (depending on configuration).
Gross Vehicle Weight Rating Gvwr:
Ranges from 6,050 lbs (1500) to 8,800 lbs (3500).
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
Typically rated 4 out of 5 stars for driver and passenger in frontal impact (model specific).
Active Features
Braking System:
Front disc, rear drum brakes standard. Optional ABS (Anti-lock Braking System) on front wheels or all four.
Passive Features
Airbags:
Driver and passenger airbags standard.
Seatbelts:
Front lap and shoulder belts, rear lap belts (for extended cabs).
💡 Technology Features
Infotainment
Radio Options:
Factory AM/FM radio with cassette tape player, optional CD player, speaker configurations vary by trim.
Driver Assistance
ABS:
Available Anti-lock Braking System (ABS), primarily on front wheels for 2WD models, and 4WD models.
Connectivity
OBD Standard:
On-Board Diagnostics II (OBD-II) compliant, introduced in 1996.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles or 6 months, depending on engine, oil type, and driving conditions (refer to manual for specific recommendations).
Transmission Fluid Change:
Automatic: 30,000-100,000 miles depending on severe vs. normal service. Manual: Check manually for contamination, typically every 60,000-100,000 miles.
Coolant Flush:
Typically every 30,000-60,000 miles or 2-4 years.
Fluid Specifications
Engine Oil Spec Gasoline:
SAE 5W-30 or 10W-30 (API Service SG or SH) recommended. Check manual for exact specifications and capacities.
Engine Oil Spec Diesel:
API CG-4 or CH-4 rated diesel engine oil, SAE 15W-40 commonly recommended. Check manual for exact specifications.
Coolant Type:
Chrysler (Mopar) OAT (Organic Additive Technology) coolant, or a compatible green ethylene glycol based coolant for older applications. Check manual for specific type and capacity.
Known Issues
Common Problems Gasoline:
Rocker arm wear in Magnum V8s, intake manifold gasket leaks, distributorless ignition system (DIS) coil pack issues, fuel pump failure.
Common Problems Diesel:
Injector line leaks, injection pump issues (VP44 on later models, but earlier ones less prone), exhaust manifold gasket leaks, occasional turbocharger issues.
Common Problems General:
Rust (especially in rocker panels, cab corners, and bed), brake component wear, HVAC blower motor resistor failure, ABS sensor failures.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing durable and capable trucks dating back to the 1930s.
Model Evolution
Second Generation Introduction:
The second generation Ram (BR/BE) was introduced for the 1994 model year, featuring a radical new design ('Big Rig' styling) that significantly boosted sales and market presence.
Production
Manufacturing Locations:
St. Louis, Missouri, and Saltillo, Mexico.
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
The Dodge Ram series, particularly this generation, was highly acclaimed and frequently appeared on '10 Best Trucks' lists from various automotive publications during its run.
Ratings
Popular Mechanics Design And Engineering:
The redesign for the second generation earned significant recognition for its bold styling and improved functionality.