Positioning:
Essential diagnostic and repair resource for owners and independent repair facilities of the 1991 Dodge W250.
Comparison:
Offers a modern, accessible alternative to out-of-print or difficult-to-source physical manuals, providing licensed, OE-derived data.
Features:
Instant online access, compatibility with multiple devices, licensed OE information, comprehensive coverage, user-friendly interface.
Systems Covered:
Engine Mechanical, Fuel System, Cooling System, Ignition System, Lubrication System, Exhaust System, Clutch, Transmission (Manual & Automatic), Transfer Case, Driveshaft, Axles, Suspension (Front & Rear), Steering System, Brakes (Front & Rear), Electrical System, Body & Sheet Metal, HVAC, Wiring Diagrams, Diagnostic Procedures, Maintenance Schedules, Troubleshooting Guides
Type:
Service and Repair Manual Software
Format:
Online Software (Web-based Access)
Engine Mechanical:
Detailed disassembly, inspection, assembly, and torque specifications for all internal engine components.
Fuel System:
Fuel injection system diagnostics, fuel pump pressure testing, injector testing, fuel filter replacement, and vapor recovery system.
Cooling System:
Radiator, water pump, thermostat, hoses, coolant specifications, pressure testing, and fan clutch.
Lubrication System:
Oil pump, oil pan, oil filter, oil specifications, and oil change intervals.
Drivetrain:
Manual and automatic transmission service, transfer case service, differential service, CV joint and U-joint replacement.
Suspension And Steering:
Ball joint replacement, tie rod end replacement, shock absorber and strut replacement, power steering system diagnosis and repair, wheel alignment specifications.
Brakes:
Front and rear brake system service (disc and drum), brake fluid specifications, bleeding procedures, parking brake adjustment.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting systems, instrument cluster, power windows, power locks, horn, wiper system.
HVAC:
Air conditioning system diagnosis and repair, heater core replacement, blower motor, refrigerant types, and system charging.
Body And Sheet Metal:
Door panel removal, interior trim, glass replacement, bumper service, fender replacement, and panel alignment.
Major Repairs:
Engine overhaul, transmission rebuild, differential overhaul, cylinder head replacement, clutch replacement.
Maintenance:
Oil change, filter replacement, fluid level checks, brake pad replacement, belt replacement, spark plug replacement, tune-up procedures.
Diagnostics:
Troubleshooting guides for common drivability issues, electrical faults, HVAC problems, and brake system malfunctions.
Troubleshooting:
Systematic diagnostic flowcharts and symptom-based troubleshooting for various vehicle systems.
Depth:
Factory-level detail, including torque specifications, clearances, diagnostic trouble codes (DTCs), and detailed component testing procedures.
Engine Code:
318 (5.2L V8 Magnum)
Engine Type:
Overhead Valve (OHV), V8
Displacement:
5.2 Liters / 318 Cubic Inches
Bore X Stroke:
3.91 in x 3.31 in
Compression Ratio:
8.8:1 (typical)
Horsepower Gross:
170 HP @ 4000 RPM (approx.)
Torque Gross:
260 lb-ft @ 2000 RPM (approx.)
Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Ignition Type:
Distributorless Ignition System (DIS) or Distributor type
Valve Train:
Overhead Valve (OHV), Pushrod actuated, 2 valves per cylinder
Oil Capacity:
5 Quarts (with filter) - Check manual for exact capacity and type
Coolant Capacity:
Approx. 15 Quarts (check manual for exact capacity and type)
Engine Code:
360 (5.9L V8 Magnum)
Displacement:
5.9 Liters / 360 Cubic Inches
Horsepower Gross:
179 HP @ 3600 RPM (approx.)
Torque Gross:
285 lb-ft @ 2000 RPM (approx.)
Type:
4-Speed Manual Transmission (NV4500 available on some models, or previous NP435)
Type:
4-Speed Automatic Transmission (A518)
Transmission Fluid:
ATF+3 or Dexron III (check manual for specific recommendations and capacities)
Transfer Case:
New Process NP241, Gear-driven, 2-speed with 2.72:1 low range ratio
Transfer Case Fluid:
ATF+3 or Dexron III (check manual for specific recommendations and capacities)
Oil Change:
Every 3,000 miles or 3 months (typical for this era, refer to manual for specific recommendations based on driving conditions).
Transmission Fluid Change:
Every 30,000-60,000 miles (automatic transmission, refer to manual).
Coolant Flush:
Every 30,000 miles or 2 years (typical, refer to manual).
Engine Oil:
API SG or higher, SAE 10W-30 or 10W-40 (check manual for precise viscosity based on temperature)
Power Steering Fluid:
Dexron III or equivalent
Common Problems:
Radiator leaks, water pump failure, fuel pump issues, exhaust manifold cracks (especially on 360), aging electrical connectors, suspension wear (ball joints, bushings).
Heritage:
Dodge has a long-standing reputation for building robust and capable trucks, particularly in the heavy-duty segment.
Evolution:
The 1991 W250 is part of the second generation of Dodge D-series trucks, introduced in 1972 and heavily revised throughout its lifespan. This generation is known for its durable chassis and powertrain options.
Manufacturing Location:
Various Dodge assembly plants in North America (e.g., Warren, Michigan; St. Louis, Missouri)
