1992 Dodge W350 Service & Repair Manual Software

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🏷️ Basic Information Identification Make: Dodge Model: W350 Year: 1992 Codes Platform: DR Chassis Code: W350 👋 Introduction Market Position Vehicle Class: Heavy Duty Pickup Truck Target Audience: Commercial users,...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Year:

Codes

Platform:

Chassis Code:

👋 Introduction

Market Position

Vehicle Class:

Heavy Duty Pickup Truck

Target Audience:

Commercial users, tradespeople, fleet owners, serious DIY mechanics

Competitive Analysis

Competitors:

Ford F-250/F-350, Chevrolet/GMC C/K 2500/3500

Key Features

Robustness:

Renowned for its rugged construction and heavy-duty capabilities

Engine Options:

Choice between the potent 5.9L Magnum V8 and the legendary 5.9L Cummins Turbo Diesel

📋 Manual Details

Coverage Areas

Primary Coverage:

1992 Dodge W350 Service & Repair

Engine Coverage:

5.9L V8 Magnum, 5.9L Cummins Turbo Diesel

Transmission Coverage:

A518 Automatic, NV4500 Manual

Drivetrain Coverage:

2WD, 4WD (Part-time)

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual Software

Language

Language:

English

Format

Format:

Digital Software (likely PDF or proprietary viewer)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Disassembly, inspection, assembly, torque specifications, timing, cooling, lubrication

Engine Fuel System:

Gasoline Injection (MPI), Diesel Injection Pump and Injectors

Engine Ignition System:

Distributor ignition system, spark plugs, coils, timing

Transmission Automatic:

A518: Component identification, hydraulic controls, torque converter, valve body, overhaul procedures

Transmission Manual:

NV4500: Gearbox assembly, clutch, flywheel, overhaul procedures

Drivetrain:

Transfer case (New Process NP205 for 4x4), driveshafts, U-joints, rear axle, front axle (if applicable)

Suspension:

Front: Independent Front Suspension (IFS) with torsion bars; Rear: Leaf springs

Steering:

Power steering system, steering gear, tie rods, alignment specifications

Brakes:

Front: Disc brakes; Rear: Drum brakes. ABS (if equipped), hydraulic system, parking brake

Electrical System:

Battery, charging system (alternator), starting system (starter), lighting, accessories, wiring diagrams

HVAC:

Heating, Ventilation, and Air Conditioning system components and service

Body And Frame:

Body panels, doors, interior trim, frame construction, corrosion protection

Diagnostics:

Troubleshooting guides, symptom charts, diagnostic trouble codes (DTCs) if applicable

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, fluid checks, lubrication points, belt inspection

Troubleshooting:

Step-by-step diagnostic procedures for common issues

Repair Procedures:

Detailed, illustrated instructions for component removal, repair, and installation

Rebuild Procedures:

Complete overhaul instructions for engines and transmissions

Alignment:

Wheel alignment specifications and procedures

Wiring Diagrams:

Comprehensive electrical system schematics

Technical Depth

Depth:

Comprehensive (factory-level detail)

Detail Level:

Includes disassembly, assembly, specifications, and diagnostic information for major components

📊 Manual Specifications

File Format

Digital Format:

Likely a compiled digital archive or executable application. Searchable text is probable.

Print Quality

Printability:

Designed for digital viewing, but printable pages would be a feature.

Binding Type

Binding:

N/A (Digital Software)

Paper Type

Paper:

N/A (Digital Software)

⚙️ Engine Specifications

Primary Engine

Gasoline Engine:

5.9L (360 cu in) V8 Magnum

Diesel Engine:

5.9L (359 cu in) Cummins Turbo Diesel (12-valve, mechanically injected)

Performance

Gasoline Horsepower:

~230 hp @ 4000 rpm

Gasoline Torque:

~330 lb-ft @ 3200 rpm

Diesel Horsepower:

~160-180 hp @ 2500 rpm (varies by rating)

Diesel Torque:

~400-420 lb-ft @ 1700 rpm (varies by rating)

Fuel System

Gasoline Fuel Injection:

Multi-Point Fuel Injection (MPI)

Diesel Fuel System:

Bosch inline fuel injection pump, mechanical injectors

Cooling System

Coolant Type:

Ethylene Glycol based (e.g., Mopar Antifreeze/Coolant)

Lubrication

Oil Type Gasoline:

API SG, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on temp)

Oil Type Diesel:

API CD or CE, SAE 15W-40 (diesel specific)

Oil Capacity Gasoline

Oil Capacity V8:

5 Quarts (4.7 Liters) with filter

Oil Capacity Diesel

Oil Capacity Cummins:

12 Quarts (11.4 Liters) with filter

🔧 Transmission

Standard

Automatic:

A518 TorqueFlite (3-speed with overdrive)

Optional

Manual:

New Venture Gear NV4500 (5-speed manual)

Features

Automatic Fluid Type:

ATF+3 (or equivalent, e.g., ATF Dexron III)

Manual Fluid Type:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 Gear Oil

📐 Dimensions

Exterior

Wheelbase Single Rear Wheel:

131 inches (3327 mm)

Wheelbase Dually:

131 inches (3327 mm) or 149 inches (3785 mm)

Body Styles:

Standard Cab, Extended Cab (Club Cab)

Weights

Gvwr:

Up to 10,000 lbs (depending on configuration)

🛡️ Safety Features

Ratings

Crash Test Data:

Limited publicly available official NHTSA crash test data for this specific year and heavy-duty configuration.

Active Features

Available on rear wheels only for some models, optional four-wheel ABS on certain configurations.

Passive Features

Seatbelts:

Three-point front seat belts

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM radio, cassette player, optional CD player (early generations)

Gauges:

Basic analog gauges for speed, RPM, fuel, oil pressure, coolant temperature. Some may have tachometers.

Driver Assistance

Cruise Control:

Optional

Connectivity

Power Options:

Optional power windows and door locks on higher trim levels.

🔧 Maintenance

Service Intervals

Oil Change Gasoline:

Every 3,000-5,000 miles or 3-6 months, whichever comes first.

Oil Change Diesel:

Every 5,000-7,500 miles or 6 months, whichever comes first (using diesel-rated oil).

Transmission Fluid Change:

Every 30,000-60,000 miles for automatic; Check manual for manual transmission fluid change intervals.

Coolant Flush:

Every 30,000 miles or 2 years.

Fluid Specifications

Brake Fluid Type:

DOT 3

Power Steering Fluid:

ATF+3 (or equivalent)

Transfer Case Fluid:

New Process NP205: ATF (Dexron II/III)

Rear Axle Fluid:

API GL-5, SAE 75W-90 or 80W-90 (check differential cover for specific requirements)

Known Issues

Diesel Injection Pump:

Potential for aging seals on the Bosch VE injection pump (common on earlier 12V Cummins).

Frame Rust:

Corrosion, particularly in areas with road salt, can affect frame rails and body mounts.

Exhaust Manifold Cracks:

Cracks in the exhaust manifold are not uncommon, especially on the Cummins diesel due to thermal cycling.

A518 Transmission:

Early versions could experience issues with the torque converter lock-up clutch or valve body.

Suspension Wear:

Torsion bar front suspension can wear out bushings and ball joints over time.

📚 Vehicle History

Brand Heritage

Dodge Trucks:

Dodge has a long history of producing robust and reliable trucks, known for their workhorse capabilities.

Model Evolution

Ram Trucks:

The 'W' series trucks were part of Dodge's heavy-duty lineup, evolving into the Ram trucks brand starting with the 1994 model year.

Production

Production Era:

The second generation of Dodge trucks (DN platform) ran from 1972 to 1993, with significant updates in 1993. The W350 is part of this generation.

Manufacturing Location:

St. Louis Assembly Plant, Missouri; Warren Truck Assembly Plant, Michigan

🏆 Awards & Recognition

Recognitions

Diesel Engine Recognition:

The 5.9L Cummins Turbo Diesel gained a reputation as one of the most reliable and durable diesel engines of its era, often praised for its longevity and rebuildability.