Segment:
Full-size pickup truck and SUV segment.
Target Audience:
Dodge Ram and Ramcharger owners, independent repair shops, fleet maintenance.
Competitors:
Ford F-Series, Chevrolet C/K series (Silverado/Sierra).
Utility:
Designed for heavy-duty work, towing, and off-road capability, especially with diesel engines.
Powertrain Emphasis:
Focus on durable diesel powertrains known for torque and longevity.
Cost Savings:
Enables owners to perform their own maintenance and repairs, significantly reducing labor costs.
Years Covered:
1990, 1991, 1992, 1993, 1994
Models Covered:
All Ram Pickup Truck and Ramcharger models equipped with diesel engines.
Trim Levels Covered:
All trim levels (e.g., base, SE, SLT, Laramie).
Engine Variants Covered:
Diesel engines only.
Transmission Types Covered:
All transmission types (manual and automatic).
Estimated Page Count:
Over 1000 pages (typical for comprehensive factory-style manuals).
Type:
Complete Workshop Service and Repair Manual.
Format:
Digital Download (PDF)
Engine:
Diesel engine mechanical (including fuel injection, lubrication, cooling, intake, exhaust), diesel engine electrical (ECU, sensors, wiring).
Transmission:
Manual transmission (clutch, gearbox, driveline) and automatic transmission (torque converter, hydraulic control, valve body).
Drivetrain:
4WD system (transfer case, front axle, rear axle), limited-slip differentials, driveshafts, CV joints.
Suspension:
Front suspension (twin-traction beam, coil springs, shock absorbers, control arms), rear suspension (leaf springs, shock absorbers).
Steering:
Power steering system (pump, gearbox, steering column, linkage).
Brakes:
Front disc brakes, rear drum brakes, anti-lock braking system (ABS) if equipped, parking brake.
Electrical:
Battery, charging system (alternator), starting system (starter motor), lighting system, ignition system (glow plugs), instrument cluster, body electricals (power windows, locks), trailer wiring.
HVAC:
Heating, ventilation, and air conditioning (compressor, evaporator, condenser, blower motor, controls).
Fuel:
Diesel fuel tank, fuel lines, fuel filter, lift pump.
Body:
Body panels, doors, hood, tailgate, bumpers, glass, interior trim, frame and chassis components.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) if applicable, testing procedures for various systems.
Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug/glow plug replacement, belt inspection/replacement, brake pad/shoe replacement, tire rotation, battery maintenance.
Repair:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair.
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon faults.
Component Removal Installation:
Detailed instructions for removing and installing all major components.
Torque Specifications:
Essential torque values for critical fasteners across all systems.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems.
Depth:
Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, and detailed electrical diagnostics.
Engine Code Examples:
5.9L Cummins Turbo Diesel (P-Pump, ISB generation before common rail).
Displacement:
5.9 Liters (359 cubic inches)
Horsepower Approximate:
160-180 hp (depending on year and specific tuning).
Torque Approximate:
400-470 lb-ft (depending on year and specific tuning).
Injection Type:
Bosch P-7100 Inline Injection Pump (or earlier VE rotary pump on some earlier models, though this manual focuses on the era likely to have the P7100).
Air Intake:
Naturally aspirated or turbocharged (most common).
Type:
Pressurized liquid cooling system.
Oil Capacity Approximate:
10 quarts (with filter).
Function:
Essential for cold starting diesel engines.
Manual Transmission Options:
Getrag 5-speed manual (G360).
Automatic Transmission Options:
Chrysler A518 (3-speed with overdrive) or A727 (3-speed non-overdrive).
Overdrive:
Available on A518 automatic and Getrag 5-speed manual for improved fuel economy.
Manual Transmission Fluid:
API GL-5, SAE 75W-90 or 80W-90 gear oil.
Automatic Transmission Fluid:
Chrysler ATF+3 or equivalent.
Engine Oil Change:
Every 3,000 - 5,000 miles or 6 months (diesel specific, depending on oil quality and operating conditions).
Fuel Filter Replacement:
Every 15,000 - 30,000 miles.
Transmission Fluid Change:
Every 30,000 - 50,000 miles (manual and automatic).
Engine Oil:
Cummins CES 20078 (or equivalent heavy-duty diesel engine oil, e.g., 15W-40). Check manual for specific year recommendations.
Coolant:
Chrysler/Mopar Antifreeze/Coolant (typically a green ethylene glycol based).
Injector Pump Problems:
Potential wear on P7100 pump; maintenance of fuel system cleanliness is key.
Heater Grid Failure:
Can lead to difficult cold starts.
Radiator Support Rust:
Common on older trucks, check for integrity.
Transmission Overdrive Issues:
Common on A518 automatics if fluid is neglected or solenoids fail.
