Dodge Ram 3500 1996 1997 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 3500 Years Covered: 1996, 1997 Codes Chassis Code Generation: Second Generation Ram Trucks (1994-2001, DB platform) 👋 Introduction Market Position Segment: Heavy-duty...

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Type: Truck

Vendor:

Sku: 449108

Tags: 1996 1997 Cars Dodge Misc Ram 3500 Truck

Product variants

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram 3500

Years Covered:

1996, 1997

Codes

Chassis Code Generation:

Second Generation Ram Trucks (1994-2001, DB platform)

👋 Introduction

Market Position

Segment:

Heavy-duty pickup truck

Target Audience:

Commercial users, fleet operators, and truck enthusiasts requiring robust towing and hauling capabilities

Competitive Analysis

Primary Competitors 1996 1997:

Ford F-350 Super Duty, Chevrolet Silverado 3500, GMC Sierra 3500

Key Features

Truck Type:

Full-size heavy-duty pickup truck

Capability:

Emphasis on towing, hauling, and durability for demanding work applications

Engine Options:

Powerful V8 gasoline and Cummins turbodiesel engines

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair and overhaul of Dodge Ram 3500 vehicles

Assumed User Knowledge:

Fully conversant with general automobile practices

Page Count

Estimated Page Count:

N/A (PDF format implies variable, but typically extensive for workshop manuals)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine diagnosis, overhaul, and repair for all available gasoline and diesel engines

Engine Electrical:

Ignition system, fuel injection system (EFI/MPI), starting and charging systems, emissions control system diagnostics

Transmission:

Service and repair for automatic and manual transmissions, including torque converter, clutch, and transfer case (if applicable)

Drivetrain:

Front and rear axle service, drive shafts, universal joints, propeller shafts, differentials

Suspension:

Front and rear suspension system diagnosis, repair, and alignment specifications (leaf springs, shocks, control arms, steering linkage)

Brakes:

Hydraulic brake system service (master cylinder, lines, calipers, wheel cylinders), ABS system diagnostics and repair, parking brake system

Steering:

Power steering system diagnosis and repair, steering column, steering gear/rack and pinion

Electrical System:

Wiring diagrams, lighting systems, instrument cluster, body electrical components, power windows, locks, mirrors

HVAC:

Heating, ventilation, and air conditioning system diagnosis, repair, and refrigerant handling

Body And Frame:

Body panel repair, door and window mechanisms, interior trim, chassis frame inspection and repair

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter replacement and diagnosis

Cooling System:

Radiator, water pump, thermostat, hoses, cooling fan diagnosis and repair

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, pipes, hangers inspection and replacement

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation and pressure checks, spark plug replacement

Troubleshooting:

Diagnostic procedures for common and uncommon drivability issues, electrical faults, and mechanical failures

Component Repair:

Detailed step-by-step instructions for the removal, installation, and overhaul of virtually all vehicle components

Rebuilding Procedures:

Comprehensive rebuild procedures for engines, transmissions, and differentials

Specifications Data:

Torque specifications, clearances, fluid capacities, resistance values, voltage readings

Wiring Diagrams:

Detailed electrical schematic diagrams for all vehicle systems

Special Tools:

Identification and usage of specialized tools required for specific repair procedures

Technical Depth

Depth:

Full workshop level, covering everything from basic maintenance to complete engine and transmission rebuilds and complex electrical diagnostics

📊 Manual Specifications

File Format

Type:

Searchability:

Likely text-searchable if properly created OCR

Print Quality

Quality:

N/A (dependent on source document quality)

Binding Type

Type:

N/A (Digital PDF)

Paper Type

Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Gasoline Option 1:

8.0L Magnum V10 (488 cid)

Gasoline Option 1 Hp:

Approx. 300-310 hp @ 4000-4400 rpm (depending on specific year/tune)

Gasoline Option 1 Torque:

Approx. 450-470 lb-ft @ 2800-3200 rpm (depending on specific year/tune)

Gasoline Option 2:

5.9L Magnum V8 (360 cid)

Gasoline Option 2 Hp:

Approx. 230-245 hp @ 4000 rpm

Gasoline Option 2 Torque:

Approx. 330-345 lb-ft @ 3200 rpm

Diesel Option 1:

5.9L Cummins Turbodiesel I6 (359 cid)

Diesel Option 1 Hp:

Approx. 215-235 hp @ 2500-2700 rpm (depending on specific year/tune)

Diesel Option 1 Torque:

Approx. 420-475 lb-ft @ 1600 rpm (depending on specific year/tune)

Performance

Engine Management:

Electronic Fuel Injection (EFI) for gasoline, Bosch P7100 injection pump for Cummins diesel

Fuel System

Gasoline Fuel Delivery:

Multi-Point Fuel Injection (MPFI)

Diesel Fuel Delivery:

Direct Injection, Mechanical Injection Pump (P7100)

🔧 Transmission

Standard

Manual Option:

5-speed manual transmission (e.g., NV4500)

Optional

Automatic Option 1:

4-speed automatic transmission (e.g., 47RH/48RE for diesel, 46RE for gasoline)

Features

Transfer Case:

Part-time 4WD with manual or electronic shift transfer case (NV231/NV241)

📐 Dimensions

Exterior

Body Styles:

Regular Cab, Club Cab (extended cab)

Wheelbase Options:

134.7 inches (Regular Cab), 154.7 inches (Club Cab), 170.7 inches (Long Bed Regular Cab)

Bed Length Options:

8.0 ft (standard), 9.25 ft (long bed)

Weights

Gvwr:

Up to 11,000 lbs (depending on configuration)

Curb Weight:

Approx. 5,500 - 7,000 lbs (depending on configuration)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not specifically rated for this era of heavy-duty truck in the same way as passenger cars

IIHS Crash Test:

N/A (IIHS testing primarily focused on smaller vehicles in this period)

Active Features

Anti-lock Braking System (ABS) standard on rear wheels, optional or standard on all four wheels depending on year/trim

Passive Features

Airbags:

Driver and passenger airbags (front)

Seatbelts:

Front and rear seat belts

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM radio with cassette player, optional CD player available

Display:

Analog gauges and indicator lights

Driver Assistance

Cruise Control:

Available optional feature

Towing Features:

Integrated trailer wiring harness provisions, heavy-duty frames designed for towing

Connectivity

Auxiliary Ports:

N/A (No standard auxiliary or USB ports in this era)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-7,500 miles or 6 months, depending on driving conditions and oil type (consult manual for specifics).

Transmission Fluid Change:

Every 30,000-60,000 miles for automatic, 60,000-100,000 miles for manual (consult manual).

Coolant Flush:

Every 30,000-60,000 miles or 2-4 years.

Fluid Specifications

Engine Oil Gasoline V8:

API Certified SAE 10W-30 or 10W-40 (consult manual for exact viscosity and API service classification)

Engine Oil Gasoline V10:

API Certified SAE 10W-30 (consult manual for exact viscosity and API service classification)

Engine Oil Diesel Cummins:

API CG-4 or CH-4 SAE 15W-40 (Heavy Duty Diesel Oil) (consult manual for exact specification)

Transmission Fluid Auto 46Re:

ATF+3 (Mopar)

Transmission Fluid Auto 47Re/48Re:

ATF+3 (Mopar) or equivalent specification for heavy-duty applications

Transmission Fluid Manual Nv4500:

GL-3 or GL-4 SAE 75W-90 or 80W-90 gear oil (consult manual)

Coolant:

Chrysler/Mopar Antifreeze/Coolant (Ethylene Glycol based, green type) (50/50 mix)

Known Issues

Diesel Injector Pump:

Potential issues with the Bosch P7100 injection pump on early Cummins engines, though generally robust.

Automatic Transmission:

Torque converter lock-up issues, overdrive issues on 47RH/RE and 48RE can occur with high mileage or heavy use.

Front Suspension:

Wear in ball joints, tie rod ends, and bushings due to heavy loads and towing.

Rear Axle:

Bearing wear or differential issues with excessive towing or hauling.

Body Rust:

Common on vehicles used in areas with road salt, especially around wheel wells, rocker panels, and frame rails.

📚 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

Ram Trucks Separation:

The 'Ram' nameplate was fully separated from Dodge in 2010, becoming its own brand. However, in 1996-1997, they were Dodge Ram trucks.

Production

Generation:

Second generation (DB platform), introduced for the 1994 model year.

Design Era:

Known for its distinctive "big rig" styling introduced in 1994.

🏆 Awards & Recognition

Recognitions

Truck Of The Year:

While specific awards for the 3500 model are not prominently cited, the Ram truck line has historically been recognized for its capability and design.

Ratings

Diesel Engine Reputation:

The 5.9L Cummins turbodiesel engine of this era is widely regarded as one of the most reliable and durable diesel engines ever put in a pickup truck.

Certifications

Emission Standards:

Designed to meet EPA emission standards for the respective model years.