Engine Mechanical:
Complete disassembly, assembly, inspection, and repair of all engine components (e.g., cylinder head, block, pistons, crankshaft, camshaft, valvetrain).
Engine Performance:
Fuel injection system, ignition system, emissions control, cooling system, lubrication system, turbocharger (if applicable).
Transmission Manual:
Service and repair for NV3500, NV4500 manual transmissions (disassembly, component inspection, clutch system).
Transmission Automatic:
Service and repair for 46RE, 47RE, 48RE automatic transmissions (disassembly, torque converter, valve body, electronic controls).
Drivetrain:
Front and rear axle service, differentials, transfer case (New Process NP241DHD), driveshafts, U-joints, CV joints.
Brakes:
Front and rear brake system (disc/drum), ABS system, hydraulic lines, calipers, master cylinder, power booster, parking brake.
Suspension Steering:
Front and rear suspension components (leaf springs, shocks, control arms, ball joints, steering linkage, power steering pump, steering gear).
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting, power distribution, wiring diagrams, fuses, relays.
HVAC:
Heating, ventilation, and air conditioning system components, refrigerant charging, diagnostics.
Body Chassis:
Frame, body panels, doors, tailgate, bumpers, interior trim, glass, weatherstripping.
Diagnostics Troubleshooting:
Fault code interpretation, diagnostic procedures, symptom-based troubleshooting guides.
Preventative Maintenance:
Oil changes, filter replacements, fluid checks and flushes, tire rotations, brake inspections.
Major Repairs:
Engine rebuilds, transmission overhauls, differential repair, suspension component replacement, brake system overhauls.
Component Replacement:
Step-by-step instructions for replacing virtually all serviceable parts.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Torque Specifications:
Detailed torque values for all critical fasteners and bolts.
Diagnostic Capabilities:
Advanced diagnostic procedures, including wiring diagrams, component testing, and scan tool data interpretation.
Repair Complexity:
Covers everything from basic DIY maintenance to complex engine and transmission rebuilds.
Information Format:
Clear, concise text, detailed diagrams, exploded views, and schematics.
Engine Options:
8.0L V10 Magnum (370 hp, 450 lb-ft torque), 5.9L Cummins Turbo Diesel (235 hp, 460 lb-ft torque), 5.9L V8 Magnum (245 hp, 345 lb-ft torque).
Engine Cooling:
Pressurized system with thermostat, radiator, fan, and coolant reservoir.
Fuel Delivery Gas:
Multi-point fuel injection (MPI).
Fuel Delivery Diesel:
Bosch VE or P7100 injection pump (depending on specific 5.9L Cummins variant), direct injection.
Oil Change Interval:
3,000-7,500 miles (depending on oil type and driving conditions). Diesel Cummins engines often have longer intervals (e.g., 5,000-10,000 miles).
Transmission Fluid Change:
Every 30,000-60,000 miles for automatic transmissions; check clutch fluid for manuals.
Engine Oil Gas:
API SJ or higher, SAE 5W-30 or 10W-30 (refer to manual for specific engine recommendation).
Engine Oil Diesel:
API CH-4 or higher, SAE 15W-40 (Cummins recommended).
Coolant:
Mopar Antifreeze/Coolant (50/50 mix) or equivalent HOAT coolant.
Transmission Fluid Automatic:
Chrysler ATF+4 (46RE/47RE/48RE).
Transmission Fluid Manual:
GL-3 or GL-4 gear oil (refer to manual for specific viscosity).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Heater Core Leaks:
Common issue in older models, leading to coolant loss and interior fogging.
Transmission Hard Shifting:
Can occur in automatic transmissions due to valve body issues or low fluid pressure.
Front End Component Wear:
Ball joints, tie rods, and steering components can wear prematurely due to the weight and usage of these trucks.
Cummins Injector Issues:
While robust, early 5.9L Cummins can experience injector pump or injector seal issues over time.
Rear Main Seal Leaks:
Can occur on both gas and diesel engines, particularly with higher mileage.
