Engine Mechanical:
Complete engine overhaul, disassembly, assembly, diagnostics for all applicable engines.
Fuel System:
Fuel injection, fuel pump, lines, tank, evaporative emissions control.
Cooling System:
Radiator, water pump, thermostat, hoses, fan, coolant specifications.
Ignition System:
Spark plugs, ignition coils, distributor (if applicable), timing specifications.
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, pipes, oxygen sensors.
Transmission Automatic:
Disassembly, assembly, repair, diagnostics, fluid specifications for Aisin AX-15, 42RE, 44RE.
Transmission Manual:
Disassembly, assembly, repair, diagnostics for NV3500.
Drivetrain:
Front axle, rear axle, differentials, driveshafts, U-joints, CV joints (if applicable).
Suspension:
Front independent suspension, rear solid axle, springs, shocks, control arms, bushings.
Steering:
Power steering system, steering gear/rack and pinion, steering column, tie rods.
Brakes System:
Front disc brakes, rear drum brakes (or disc), ABS system, hydraulic lines, master cylinder, calipers, wheel cylinders.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), fuses, relays, wiring diagrams.
Lighting System:
Headlights, taillights, interior lights, auxiliary lighting.
Instrument Panel:
Gauges, warning lights, instrument cluster removal and repair.
Body Exterior:
Body panels, doors, hood, tailgate, bumpers, glass, trim, rust repair.
Body Interior:
Seats, dashboard, door panels, headliner, carpeting, climate control system.
Climate Control:
HVAC system, A/C compressor, refrigerant, heater core, blower motor, controls.
Safety Systems:
Airbags, seat belts, ABS.
Routine Maintenance:
Oil changes, fluid checks and changes, filter replacements, lubrication.
Troubleshooting:
System-specific diagnostic procedures, symptom-based troubleshooting charts.
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment.
Diagnostics:
OBD-II diagnostic trouble codes (DTCs), scan tool usage, sensor testing.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Depth Level:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, and advanced electrical diagnostics.
Base Engine:
2.5L (150 ci) Magnum 4-cylinder
Optional Engine 1:
3.9L (239 ci) Magnum V6
Optional Engine 2:
5.2L (318 ci) Magnum V8
Optional Engine 3:
5.9L (360 ci) Magnum V8 (introduced later in the generation, potentially 2000/2001 model years, manual should cover it if applicable)
2.5L Horsepower:
Approx. 120 hp @ 4800 rpm
2.5L Torque:
Approx. 145 lb-ft @ 3200 rpm
3.9L Horsepower:
Approx. 175 hp @ 4800 rpm
3.9L Torque:
Approx. 230 lb-ft @ 3200 rpm
5.2L Horsepower:
Approx. 220 hp @ 4400 rpm
5.2L Torque:
Approx. 300 lb-ft @ 3200 rpm
Injection Type:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
ECU Type:
Chrysler's NGC (Next Generation Controller) or PICO (Powertrain Integrated Control) based systems.
Standard Transmission:
5-Speed Manual (NV3500) for 4-cyl and V6 models, potentially 4-speed Auto for V8.
Optional Transmission 1:
4-Speed Automatic (42RE) for 3.9L V6 and 5.2L V8.
Optional Transmission 2:
4-Speed Automatic (44RE) for 5.2L V8 and potentially 5.9L V8 models.
Overdrive:
All automatic transmissions feature overdrive (4th gear).
Automatic Transmission Fluid:
Chrysler ATF+4 (or equivalent specification like Mercon V, but ATF+4 is preferred for these transmissions).
Manual Transmission Fluid:
API GL-5, SAE 75W-90 synthetic gear oil for NV3500.
Wheelbase Regular Cab Short Bed:
Approx. 111.9 inches
Wheelbase Club Cab Short Bed:
Approx. 111.9 inches
Wheelbase Regular Cab Long Bed:
Approx. 124.9 inches
Wheelbase Club Cab Long Bed:
Approx. 124.9 inches
Bed Length Short:
Approx. 6.3 feet
Bed Length Long:
Approx. 7.3 feet
Curb Weight Range:
Approx. 3,500 - 4,500 lbs (varies by configuration and engine)
Towing Capacity Max:
Up to 7,000 lbs (with V8 engine, proper equipment, and towing package)
Payload Capacity Max:
Up to 1,500 lbs (approximate, varies by configuration)
Oil Change Interval:
Every 3,000-7,500 miles or 3-6 months, depending on oil type and driving conditions (check manual for specifics).
Transmission Fluid Change:
Every 30,000-60,000 miles for automatic transmissions, check manual for manual transmission.
Coolant Change Interval:
Every 30,000 miles or 2-3 years (initially with conventional coolant, extended life coolant if used).
Spark Plug Replacement:
2.5L I4: Approx. 100,000 miles (if platinum/iridium); 3.9L/5.2L V6/V8: Approx. 30,000-100,000 miles depending on plug type specified.
Engine Oil Type 4Cyl:
API SN or newer, SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on temperature).
Engine Oil Type V6 V8:
API SN or newer, SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on temperature).
Engine Oil Capacity 3.9L:
Approx. 5 quarts (with filter)
Engine Oil Capacity 5.2L:
Approx. 5 quarts (with filter)
Coolant Type:
Chrysler Long Life Antifreeze/Coolant (or equivalent HOAT).
Common Problems Engine:
Intake manifold gasket leaks, oil pan gasket leaks, minor piston slap on cold starts (especially with V8s), occasional ignition coil failures.
Common Problems Transmission:
Slipping in automatic transmissions (especially 42RE), torque converter issues, manual transmission clutch wear.
Common Problems Suspension:
Ball joint wear, tie rod end wear, control arm bushing wear, front shock absorber leaks.
Common Problems Electrical:
Instrument cluster failures (odometer, gauges), power window motor issues, blower motor resistor failure.
Common Problems Body:
Radiator support rust, cab corner rust, tailgate rust, door hinge wear.