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1996 Dodge Ram Truck 1500-3500 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Year: 1996 Series: 1500, 2500, 3500 Codes Platform: BR/BE Body Style 👋 Introduction Market Position Market Segment: Full-size pickup truck, competing...
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Type: Truck
Vendor:
Sku: 380834
1996 Dodge Ram Truck 1500-3500 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram Truck
Year:
1996
Series:
1500, 2500, 3500
Codes
Platform:
BR/BE Body Style
👋 Introduction
Market Position
Market Segment:
Full-size pickup truck, competing with Ford F-Series, Chevrolet Silverado/GMC Sierra, and Toyota Tundra.
Competitive Analysis
Strengths:
Known for robust construction, powerful engine options (especially Magnum V8s), and towing capability.
Key Features
Design:
Second-generation Ram, known for its distinctive 'big rig' styling and available Quad Cab configuration.
Powertrain:
Offered with a range of gasoline and diesel engines, including the popular 5.2L and 5.9L Magnum V8s, and the Cummins turbodiesel.
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive service and repair for 1996 Dodge Ram Trucks (1500, 2500, 3500 models).
Page Count
Pages:
Estimated 1500+ pages (typical for a full factory service manual set).
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Print
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emission control systems.
Transmission:
Manual and automatic transmission repair, service, and diagnostics.
Drivetrain:
Front axle, rear axle, driveshafts, differentials, transfer case (if applicable).
Suspension:
Front and rear suspension components, steering system, wheel alignment.
Brakes:
Brake system diagnosis, service, ABS components, hydraulic systems.
Electrical:
Battery, charging system, starting system, lighting, instrumentation, body electrical, power accessories.
Body:
Body panels, interior trim, doors, windows, glass, seats, HVAC system.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system service and repair.
Diagnostics:
Diagnostic trouble codes (DTCs), testing procedures, wiring diagrams, component testing.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication.
Repair:
Step-by-step repair instructions for all major components and systems.
Troubleshooting:
Troubleshooting charts, symptom analysis, diagnostic flowcharts.
Rebuilds:
Detailed procedures for engine, transmission, and axle rebuilds.
Specifications:
Torque specifications, clearances, fluid capacities, and other critical data.
Wiring Diagrams:
Complete electrical schematics and wiring diagrams for all circuits.
Technical Depth
Depth:
Factory-level detail, suitable for professional technicians and experienced DIY mechanics.
📊 Manual Specifications
File Format
File Format:
Print (Paperback/Hardcover)
Print Quality
Print Quality:
High-quality paper with clear, detailed illustrations and diagrams.
Binding Type
Binding:
Likely bound for durability in a workshop environment.
Paper Type
Paper Type:
Durable paper stock suitable for shop use.
⚙️ Engine Specifications
Primary Engine
Engine 1 Code:
318 (5.2L) Magnum V8
Engine 1 Displacement:
5.2 Liters / 318 Cubic Inches
Engine 1 Configuration:
Overhead Valve (OHV), V8
Engine 1 Horsepower:
Approx. 230 hp @ 4400 rpm
Engine 1 Torque:
Approx. 300 lb-ft @ 3200 rpm
Optional Engine 1
Engine 2 Code:
360 (5.9L) Magnum V8
Engine 2 Displacement:
5.9 Liters / 360 Cubic Inches
Engine 2 Configuration:
Overhead Valve (OHV), V8
Engine 2 Horsepower:
Approx. 245 hp @ 4000 rpm
Engine 2 Torque:
Approx. 330 lb-ft @ 3200 rpm
Optional Engine 2
Engine 3 Code:
5.9L Cummins Turbo Diesel (I6)
Engine 3 Displacement:
5.9 Liters / 359 Cubic Inches
Engine 3 Configuration:
Inline 6-cylinder, Turbocharged, Overhead Valve (OHV)
Engine 3 Horsepower:
Approx. 180-215 hp (depending on trim/application)
Engine 3 Torque:
Approx. 420-475 lb-ft (depending on trim/application)
Fuel System
Fuel System Type:
Electronic Fuel Injection (EFI) for gasoline engines; Direct Injection (DI) for Cummins diesel.
Fuel Type:
Unleaded gasoline (87 octane recommended); Diesel fuel for Cummins.
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual (NV3500 for light duty, Getrag G360 for heavy duty)
Optional
Optional Transmission 1:
4-Speed Automatic (46RE for gasoline V8s, 47RH for Cummins diesel)
Features
Transmission Features:
Overdrive gears on automatics for improved fuel economy; Lock-up torque converter on automatics.
📐 Dimensions
Exterior
Wheelbase:
Varies by model and cab configuration (e.g., 117.7" for regular cab short bed, 134.5" for regular cab long bed, 140.5" for Quad Cab models).
Overall Length:
Varies by bed length and cab configuration.
Overall Width:
Approx. 79.4 inches
Overall Height:
Approx. 74.5 inches
Cargo
Bed Lengths:
Available in 6.5 ft (short bed) and 8 ft (long bed) configurations.
Weights
Curb Weight:
Varies significantly by engine, drivetrain, and cab configuration (typically 4500 - 6000+ lbs).
Gvwr:
Gross Vehicle Weight Rating varies by model (e.g., 6200 lbs for 1500, 8800+ lbs for 2500/3500).
🛡️ Safety Features
Ratings
NHTSA Ratings:
As with most vehicles of this era, specific NHTSA ratings may not be readily available or may vary by test year and configuration. Generally considered robust for its class.
Active Features
Active Safety:
Four-wheel Anti-lock Braking System (ABS) typically standard on front wheels, optional on rear, and standard on all four for some configurations.
Passive Features
Passive Safety:
Driver-side airbag, three-point seat belts, reinforced passenger compartment.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio, cassette player, optional CD player. Analog gauges and controls.
Driver Assistance
Driver Assistance Features:
Limited by era. Cruise control, power steering. ABS is the primary advanced system.
Connectivity
Connectivity Features:
No integrated connectivity features like Bluetooth or USB. Optional dealer-installed phone systems possible.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles or 6 months, depending on driving conditions and oil type (refer to manual for specific recommendations).
Tune Up Interval:
Spark plugs and filters typically at 30,000-60,000 miles.
Fluid Specifications
Engine Oil:
SAE 10W-30 or 10W-40 for gasoline engines (check manual for exact viscosity based on temperature); SAE 15W-40 for Cummins diesel.
Transmission Fluid Auto:
ATF+4 (or equivalent) for 46RE/47RH transmissions.
Transmission Fluid Manual:
GL-3 or GL-4 gear oil (specific weight varies by transmission type, consult manual).
Coolant:
Ethylene glycol-based antifreeze/coolant, typically 50/50 mix with distilled water.
Brake Fluid:
DOT 3 brake fluid.
Known Issues
Common Issues Gas:
Intake manifold gasket leaks, distributor issues, rear main seal leaks, fuel pump failures, rust on fenders/rockers.
Common Issues Diesel:
Injector pump issues, overheating (especially with heavy towing), potential for head gasket failure if maintained poorly, wear on front suspension components.
Common Issues General:
Cracked dashboard, HVAC blend door actuator failure, worn U-joints, power window regulator issues.
📚 Vehicle History
Brand Heritage
Dodge Truck History:
Dodge has a long and storied history in the truck market, known for its robust designs and powerful engines.
Model Evolution
Ram Generation 2:
The 1996 model is part of the second generation (1994-2001) of the Dodge Ram, which marked a significant redesign with its distinctive 'big rig' styling and introduction of the Quad Cab.
Production
Manufacturing Location:
Produced primarily in North America.
Production Years:
Second Generation: 1994-2001
🏆 Awards & Recognition
Recognitions
Truck Of The Year 1994:
While not specifically for 1996, the second-generation Ram was awarded Motor Trend's 'Truck of the Year' for 1994, highlighting its revolutionary design and capability.
Ratings
Diesel Engine Reputation:
The 5.9L Cummins Turbo Diesel engine is renowned for its durability, longevity, and exceptional towing power, making it a highly sought-after powerplant.
Certifications
Manual Quality Certification:
Factory Original Equipment Manufacturer (OEM) quality ensures accuracy and completeness for repair and maintenance tasks.
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