🏷️ Basic Information

Make:

Dodge

Model:

Ram 3500

Year:

1996-1997

Platform Code:

Second Generation Ram (BR/BE)

👋 Introduction

Market Segment:

Heavy-duty pickup truck

Target User:

Mechanics, service technicians, fleet operators, and knowledgeable DIY owners.

Competitors:

Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD.

Vehicle Strengths:

Renowned for its powerful engines, robust chassis, and towing/hauling capabilities.

Manual Value Proposition:

Provides in-depth, factory-level repair and maintenance information crucial for this heavy-duty vehicle.

📋 Manual Details

Manual Type:

Workshop Service Manual / Repair Manual

Language:

English

Format:

PDF

Page Count:

1985

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul, diagnostics, and component specifications for all gasoline and diesel engines.

Engine Management:

ECU diagnostics, sensor testing, fuel injection system repair, ignition system troubleshooting.

Transmission Manual:

Repair and overhaul procedures for NV4500 manual transmissions.

Transmission Automatic:

Diagnostics, repair, and overhaul for 46RE and 47RE automatic transmissions.

Drivetrain:

Front and rear axle repair, differentials, transfer case service, driveshaft balancing and U-joints.

Suspension:

Front and rear suspension component replacement, alignment procedures, shock absorber and spring service.

Steering:

Power steering system repair, steering column, tie rod, and ball joint replacement.

Brakes:

Front and rear disc brake systems, anti-lock braking system (ABS) diagnostics and repair, parking brake.

Electrical System:

Complete wiring diagrams, starter, alternator, battery service, lighting systems, accessory circuits.

Body And Frame:

Body panel repair, door and window mechanisms, interior trim removal and installation, frame inspection.

HVAC:

Air conditioning system diagnostics and repair, heater core replacement, ventilation system servicing.

Restraints:

Airbag system diagnostics and component replacement.

Diagnostics Troubleshooting:

Systematic diagnostic procedures and troubleshooting charts for common and intermittent faults.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, lubrication points.

Component Overhaul:

Detailed step-by-step instructions for rebuilding engines, transmissions, and differentials.

Diagnosis Testing:

Troubleshooting guides for electrical faults, engine performance issues, and mechanical failures.

Component Replacement:

Removal and installation procedures for all major vehicle components.

Specifications Data:

Torque specifications, clearance measurements, fluid capacities, and electrical resistance values.

Wiring Diagrams:

Comprehensive and detailed electrical schematic diagrams for all vehicle systems.

Depth Level:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High-resolution, designed for clear printing of text and diagrams.

Binding Type:

N/A (Digital Download - PDF)

Paper Type:

N/A (Digital Download - PDF)

⚙️ Engine Specifications

Engine Options:

5.2L V8 Magnum, 5.9L V8 Magnum, 8.0L V10 Magnum, 5.9L Cummins I6 Turbo Diesel.

Engine Code:

P52

Displacement:

5.2 L (318 cu in)

Horsepower:

230 hp @ 4000 rpm

Torque:

295 lb-ft @ 3200 rpm

Engine Code:

P59

Displacement:

5.9 L (360 cu in)

Horsepower:

245 hp @ 4000 rpm

Torque:

345 lb-ft @ 3200 rpm

Engine Code:

V10

Displacement:

8.0 L (488 cu in)

Horsepower:

300 hp @ 4000 rpm

Torque:

450 lb-ft @ 2400 rpm

Engine Code:

53C

Displacement:

5.9 L (359 cu in)

Configuration:

Inline 6-cylinder, Turbocharged Diesel

Horsepower:

180-215 hp @ 2500 rpm (depending on model year and tune)

Torque:

400-420 lb-ft @ 1600 rpm (depending on model year and tune)

Gasoline Injection Type:

Multi-point Fuel Injection (MPI)

Diesel Injection Type:

Bosch VE Rotary Injection Pump (for 1996), Bosch VP44 Injection Pump (for 1997 models)

🔧 Transmission

Transmission Type:

NV4500 5-speed Manual Transmission (standard on many models)

Transmission Type:

46RE 4-speed Automatic Transmission (optional)

Transmission Type 2:

47RE 4-speed Automatic Transmission (optional on heavier duty models, esp. diesel)

Transfer Case Options:

New Process Gear (NP) 241, 241HD (Heavy Duty) manual shift transfer case.

📐 Dimensions

Wheelbase Standard:

134.0 inches (Regular Cab)

Wheelbase Long:

160.0 inches (Club Cab)

Overall Length:

Varies by cab and bed configuration (approx. 230-250 inches)

Gvwr Gas Models:

Up to 9,000 lbs

Gvwr Diesel Models:

Up to 10,000 lbs (or higher with specific configurations)

Curb Weight:

Varies significantly based on configuration (approx. 5,500 - 7,000 lbs)

🛡️ Safety Features

NHTSA Frontal Impact:

Not extensively rated by NHTSA for this era of heavy trucks; generally considered robust.

ABS:

Anti-lock Braking System (ABS) available, often standard on 4x4 and some 4x2 models.

Airbags:

Driver's side airbag standard.

Seat Belts:

Three-point front seat belts with pretensioners.

💡 Technology Features

Factory Audio:

AM/FM radio, cassette player, optional CD player. Basic analog gauges.

Cruise Control:

Available as an option on most trims.

OBD Ii:

On-Board Diagnostics II (OBD-II) compliant for emissions and engine diagnostics.

🔧 Maintenance

Oil Change Gasoline:

Every 3,000 miles or 3 months, whichever comes first.

Oil Change Diesel:

Every 5,000-7,500 miles or 6 months, whichever comes first (refer to manual for specific intervals).

Fuel Filter Diesel:

Every 15,000 miles or as recommended by the manual (crucial for diesel longevity).

Transmission Fluid Auto:

Every 30,000-50,000 miles, or more frequently under heavy use.

Transmission Fluid Manual:

Inspect every 30,000 miles, replace as needed or per manual recommendation (typically 60,000-100,000 miles).

Engine Oil Gasoline:

API SG or SH, SAE 10W-30 or 10W-40 (check manual for viscosity based on temperature).

Engine Oil Diesel:

API CG-4 or CH-4, SAE 15W-40 (Cummins recommends specific diesel oils).

Automatic Transmission Fluid:

Mopar ATF+3 (or equivalent Dexron-II/Mercon compatible)

Manual Transmission Fluid Nv4500:

GL-3 or GL-4 rated gear oil, SAE 75W-90 or 80W-90 (specific recommendations vary, check manual).

Coolant:

Ethylene Glycol based coolant meeting Chrysler MS-9769 specifications (typically a green or gold coolant).

Common Diesel Issues:

VP44 injection pump failure (1997+ models), injector line leaks, turbocharger wear, overheating issues on early models.

Common Gasoline Issues:

Intake manifold gasket leaks, exhaust manifold cracks, distributor issues (on earlier 5.2L), starter motor failure.

Common Transmission Issues:

NV4500 issues: 5th gear nut coming loose (requiring upgrade), synchronizer wear. Automatic transmission issues: solenoid pack failure, torque converter issues.

Common Chassis Issues:

Front suspension wear (ball joints, tie rods), brake component wear, rust on frame and body panels in certain climates.

📚 Vehicle History

Dodge Truck Legacy:

Dodge has a long history of producing durable and capable trucks dating back to the 1930s.

Second Gen Ram Introduction:

The second-generation Ram trucks (BR/BE platform) were introduced for the 1994 model year, marking a significant redesign with a more aggressive, aerodynamic styling and improved interiors.

Platform Updates 96 97:

The 1994-1997 models represent the initial phase of the second generation. Key updates in this period included the introduction of the powerful 8.0L V10 engine and the highly regarded 5.9L Cummins turbo-diesel engine. The 1997 model year saw the introduction of the more robust 47RE automatic transmission for diesel models.

Manufacturing Location:

Saltillo Truck Assembly, Mexico; Warren Truck Assembly, Michigan, USA.

🏆 Awards & Recognition

Diesel Engine Reputation:

The 5.9L Cummins inline-6 turbo-diesel engine is widely regarded as one of the most reliable and durable diesel engines ever produced, earning it a cult following.

Truck Of The Year:

While specific awards for 1996-1997 models aren't highlighted, the second-generation Ram platform was generally well-received for its bold styling and robust capabilities.