Segment:
Heavy-Duty Pickup Truck
Competitors:
Ford F-250 Super Duty, Chevrolet Silverado 2500HD, GMC Sierra 2500HD
Vehicle Strength:
Renowned for its robust construction, powerful engine options (especially the Cummins diesel), and towing/hauling capability.
Purpose:
Essential resource for owners and technicians to maintain, diagnose, and repair the Dodge Ram 2500 Series Truck across multiple model years.
Engines Covered:
5.9L Magnum V8 (250 cu in), 5.9L Cummins Turbo Diesel I6 (359 cu in)
Transmission Types Covered:
4-speed Automatic (47RE, 48RE), 5-speed Manual (NV4500)
Type:
Complete Workshop Service Repair Manual
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, turbocharger system (diesel)
Drivetrain:
Transmission (automatic & manual), transfer case, front & rear axles, driveshafts, CV joints
Chassis:
Suspension (front & rear), steering system, brake system (ABS & non-ABS), wheels, tires
Electrical:
Battery, charging system, starting system, lighting, instrumentation, power windows, power locks, climate control, trailer wiring
Body And Interior:
Body panels, doors, windows, seats, dashboard, HVAC components, interior trim
Maintenance:
Oil changes, filter replacements, fluid checks & top-offs, tire rotation, lubrication points
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, DTC (Diagnostic Trouble Code) interpretation
Repair:
Component removal and installation, assembly and disassembly, adjustments, calibrations
Special Tools:
Identification and usage of specialized tools required for specific procedures
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics)
Gas Engine:
5.9L Magnum V8 (250 cu in)
Diesel Engine:
5.9L Cummins Turbo Diesel I6 (359 cu in)
Horsepower Gas:
Approx. 230-245 hp (Varies by year/tune)
Torque Gas:
Approx. 330-350 lb-ft (Varies by year/tune)
Horsepower Diesel:
Approx. 215-235 hp (Varies by year/tune)
Torque Diesel:
Approx. 420-460 lb-ft (Varies by year/tune)
Gas Fuel System:
Sequential Multi-Port Fuel Injection (MPI)
Diesel Fuel System:
Bosch VP44 Injection Pump (early models), High-Pressure Common Rail (later models - though this manual likely focuses on VP44 era)
Coolant Type:
HOAT (Hybrid Organic Acid Technology) - typically Mopar OAT or equivalent
Manual Transmission:
New Process (NV) NV4500 5-speed Manual
Automatic Transmission:
Chrysler 47RE / 48RE 4-speed Automatic
Overdrive:
Yes (4th gear overdrive)
Torque Converter Lock-Up:
Yes
Automatic Fluid:
ATF+3 or ATF+4 (check specific year recommendations), approx. 11.5 quarts (dry)
Manual Fluid:
NV4500 specific fluid (e.g., Mopar Manual Transmission Lubricant or equivalent GL-3/GL-4)
Wheelbase Options:
Various (e.g., 135.0", 154.5", 169.5" depending on cab and bed configuration)
Bed Length Options:
Various (e.g., 6.5 ft, 8 ft)
Curb Weight Range:
Approx. 5,500 - 7,000 lbs (Varies significantly by configuration)
Gross Vehicle Weight Rating Gvwr:
Over 8,500 lbs (Class 2b/3 rating)
Towing Capacity:
Up to 11,000+ lbs (Varies by configuration and equipment)
Payload Capacity:
Up to 3,000+ lbs (Varies by configuration)
NHTSA Frontal Impact:
Not explicitly rated for this era in the same way as modern vehicles; focus on structural integrity.
ABS:
Anti-lock Braking System (Standard on most models, check specific VIN)
Trailer Brake Controller Provision:
Often available or pre-wired for aftermarket installation
Airbags:
Driver and Passenger Airbags (Standard)
Seatbelts:
Three-point seatbelts
Audio System:
AM/FM Stereo, Cassette/CD Player (options vary by trim)
Navigation:
Not typically integrated from the factory for these years; aftermarket solutions common.
Cruise Control:
Standard on most models
Tow Haul Mode:
Available on automatic transmissions to optimize shift points for towing.
Trailer Connector:
Standard 7-pin trailer connector or 4-pin option available.
Oil Change Interval Gas:
Every 3,000-5,000 miles or 3-6 months (depending on severe/normal use)
Oil Change Interval Diesel:
Every 7,500 miles or 6 months (using diesel-specific oil, refer to manual for exact intervals)
Transmission Fluid Service:
Every 30,000-60,000 miles (depending on use and fluid type)
Coolant Service:
Initial service at 100,000 miles, then every 50,000 miles thereafter (using HOAT coolant)
Engine Oil Gas:
API SJ or higher, SAE 5W-30 (preferred) or 10W-30
Engine Oil Diesel:
API CH-4 or CI-4 rated, SAE 15W-40 (high-quality diesel specific oil)
Power Steering Fluid:
MS-5927 or equivalent (ATF+3 is often acceptable)
Diesel Vp44 Pump:
The Bosch VP44 injection pump is a known failure point, especially with lower lubricity fuel or inadequate lift pump performance.
Automatic Transmission Issues:
Overheating can occur under heavy load; proper fluid maintenance is critical. Torque converter lock-up issues can arise.
Front End Components:
Wear on ball joints, tie rod ends, and steering linkage is common due to the weight and duty cycle of the truck.
Rear Main Seal:
Can develop leaks, especially on the Cummins diesel.
Heater Core:
Can be prone to leaks or clogging over time.
Dodge Truck Legacy:
Dodge has a long history of producing durable and capable trucks, with the Ram nameplate becoming synonymous with strength and utility.
Third Generation Ram:
These model years (1998-2001) fall within the third generation of the Dodge Ram (1994-2001), a significant redesign that introduced the iconic crosshair grille and a more aggressive styling.
Manufacturing Plant:
Saltillo Truck Assembly Plant, Mexico; Warren Truck Assembly Plant, Michigan, USA
Sales Performance:
The Ram pickup line consistently performed well in sales, particularly the heavy-duty 2500 and 3500 models, driven by the popularity of the Cummins diesel.
Diesel Engine Recognition:
The 5.9L Cummins Turbo Diesel is widely regarded as one of the most reliable and durable diesel engines ever put into a pickup truck.
Truck Of The Year:
While specific awards for the 2500 series may vary by publication, the Ram line often received praise for its design and capability during this era.
Emissions Compliance:
Manual will cover diagnostic and repair procedures to maintain emissions compliance as per regulations for the specified years.
