🏷️ Basic Information

Make:

Dodge

Model:

Ram 3500

Model Years Covered:

1998, 1999, 2000, 2001

👋 Introduction

Segment:

Heavy-Duty Pickup Truck

Target Audience:

Owners, technicians, fleet managers, DIY enthusiasts requiring in-depth repair and maintenance information.

Key Competitors:

Ford F-250/F-350 Super Duty, Chevrolet Silverado 3500 HD, GMC Sierra 3500 HD.

Manual Value Proposition:

Provides comprehensive, expert-level repair and maintenance guidance for a significant period of the Ram 3500's history, enabling cost-effective upkeep and complex repairs.

Digital Access:

Instant download eliminates shipping delays and costs, offering immediate access to critical repair data.

📋 Manual Details

Manual Type:

Workshop Service Repair Manual

Page Count:

2889

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, diagnostics, timing, lubrication, cooling system, fuel system (excluding fuel injection control electronics), exhaust system.

Engine Electrical:

Ignition system, starting and charging system, engine control sensors and actuators, wiring diagrams.

Transmission Manual:

Disassembly, inspection, assembly, troubleshooting, fluid specifications, operation of NV4500 and G360 transmissions.

Transmission Automatic:

Diagnosis, repair, fluid specifications, torque converter operation, troubleshooting of 47RE automatic transmission.

Drivetrain:

Front and rear axle assemblies, differentials, driveshafts, U-joints, transfer case (NP241 HD), wheel bearings, hub units.

Suspension:

Front and rear suspension components, springs (leaf), shock absorbers, control arms, bushings, steering knuckles, alignment specifications.

Steering:

Power steering system components, steering gear, steering column, power steering fluid, troubleshooting.

Brakes:

Front and rear brake systems (disc/drum), hydraulic system, ABS components, master cylinder, calipers, wheel cylinders, brake fluid specifications, bleeding procedures, parking brake.

Electrical System:

Battery, charging system, lighting, instruments, gauges, horn, wipers, washers, power windows, power locks, interior lighting, fuse panel locations, wiring diagrams for all circuits.

Body And Chassis:

Body construction, doors, hood, tailgate, windows, exterior trim, interior trim, frame diagnosis and repair, cab mounting, sheet metal repair.

HVAC:

Heating, ventilation, and air conditioning system diagnosis, repair, refrigerant specifications, component replacement (compressor, evaporator, condenser).

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter replacement, diesel fuel system specifics (if applicable for engine variants).

Exhaust System:

Exhaust pipes, muffler, catalytic converter, hangers, gaskets, torque specifications.

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, lubrication points, fluid level checks and top-offs.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts, diagnostic trouble codes (DTCs).

Repair:

Step-by-step repair instructions for all major components and systems, including engine teardown, transmission rebuild, brake caliper replacement, suspension component replacement.

Diagnostics:

Detailed diagnostic procedures for electrical and mechanical systems, use of diagnostic tools, sensor testing, actuator testing.

Specifications:

Torque specifications for all fasteners, fluid capacities, component clearances, alignment angles, electrical resistance values.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, including component locations and connector pinouts.

Depth Of Coverage:

Comprehensive, covering routine maintenance to major component overhauls and troubleshooting.

Rebuild Procedures:

Includes detailed procedures for engine and transmission rebuilding.

Diagnostic Tools:

Information on using common diagnostic tools and interpreting sensor data.

📊 Manual Specifications

File Format:

PDF

Searchable Text:

Likely searchable due to PDF format, but depends on original scan quality.

Printable:

Yes, PDF format allows for printing of pages.

Print Quality:

Dependent on original source scan quality; typically good for professional manuals.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Options 1:

8.0L (488 cu in) V10 Magnum (2001 model year had a revised version).

Engine Options 2:

5.9L (359 cu in) Cummins Turbo Diesel (various iterations including 12-valve and 24-valve).

Engine Options 3:

5.2L (318 cu in) Magnum V8 (less common in 3500 models, primarily found in earlier years or lighter configurations).

V10 Horsepower Est:

Approx. 300-310 hp

V10 Torque Est:

Approx. 450-460 lb-ft

Cummins 24V Horsepower Est:

Approx. 235-245 hp (later models)

Cummins 24V Torque Est:

Approx. 460-475 lb-ft (later models)

V10 Fuel System:

Multi-Point Fuel Injection (MPI)

Cummins Fuel System:

High-pressure injection pump (VE or P7100 depending on year/spec), direct injection.

🔧 Transmission

Standard Transmission:

NV4500 5-Speed Manual Transmission (heavy-duty)

Optional Transmission:

47RE 4-Speed Automatic Transmission

Nv4500 Gear Ratios Example:

Approx. 5.61:1 (1st), 3.04:1 (2nd), 1.67:1 (3rd), 1.00:1 (4th), 0.73:1 (5th OD) - specific ratios varied.

47Re Features:

Electronic overdrive, lock-up torque converter, heavy-duty construction for towing applications.

Nv4500 Fluid:

API GL-3 or GL-4 SAE 75W-90 Synthetic Gear Lubricant (check manual for specific recommendations, some variants preferred specific fluids).

47Re Fluid:

Chrysler ATF+4 (Automatic Transmission Fluid Type 9602 or equivalent).

📐 Dimensions

Wheelbase Options:

Multiple, typically 134.5" (Regular Cab SWB), 149.5" (Regular Cab LWB), 168.5" (Club Cab SWB), 188.5" (Club Cab LWB).

Overall Length Est:

Varies significantly with wheelbase and cab configuration, often exceeding 230 inches.

Body Styles:

Regular Cab, Club Cab (Quad Cab on some models).

Bed Lengths Available:

8-foot (standard), 6.3-foot (short bed, less common on 3500).

Curb Weight Est:

Approx. 6,000 - 7,500 lbs, depending on configuration and powertrain.

Gvwr Range:

Typically 9,750 lbs to 11,500 lbs.

Towing Capacity Est:

Up to 13,000-15,000+ lbs (properly equipped with hitch and trailer brake controller).

Payload Capacity Est:

Approx. 2,500 - 4,000+ lbs.

🛡️ Safety Features

NHTSA Frontal Crash Rating:

Generally rated as acceptable or good for its era, specific ratings may vary by year and configuration. Full data may not be readily available for all HD trucks of this vintage.

IIHS Ratings:

Similar to NHTSA, ratings should be verified for specific configurations. Focus was on capability over comprehensive crash avoidance tech.

ABS:

Standard Anti-lock Braking System (ABS) on rear wheels, optional 4-wheel ABS.

Traction Control:

Limited availability, typically not a standard feature on most configurations.

Airbags:

Driver and passenger airbags.

Seatbelts:

Three-point seat belts with pretensioners for front occupants.

💡 Technology Features

Audio System Options:

AM/FM radio with cassette player, optional CD player, basic speaker configurations.

Climate Control:

Manual climate control with AC, optional automatic temperature control on higher trims.

Cruise Control:

Standard cruise control on most trims.

Towing Features:

Provisions for trailer brake controllers, trailer tow mirrors, and heavy-duty cooling systems.

Connectivity Features:

Minimal by modern standards; primarily focused on basic vehicle operation. No integrated Bluetooth or advanced infotainment systems.

🔧 Maintenance

Oil Change Interval Gas:

Every 3,000-7,500 miles or 6 months, depending on usage and oil type (consult manual for specifics).

Oil Change Interval Diesel:

Every 7,500-15,000 miles or 12 months, depending on oil quality, driving conditions, and type of filter used (synthetic oils and bypass filters extend intervals).

Transmission Fluid Change Auto:

Every 30,000-60,000 miles (ATF+4).

Transmission Fluid Change Manual:

Every 50,000-100,000 miles (gear oil).

Coolant Flush:

Every 30,000-50,000 miles or 2-4 years.

Engine Oil Gas V10:

SAE 10W-30 or 10W-40 (check manual for specific viscosity and API service classification, e.g., API SN or newer).

Engine Oil Diesel Cummins:

CJ-4 or CK-4 rated Diesel Engine Oil (e.g., SAE 15W-40, synthetic 5W-40 for cold weather) - consult manual for specific Cummins rating.

Coolant Type:

Heavy-duty ELC (Extended Life Coolant) or OAT (Organic Acid Technology) type, typically ethylene glycol based, often Mopar OAT or equivalent. Check for correct color and specification.

Brake Fluid:

DOT 3 or DOT 4 Hydraulic Brake Fluid.

Nv4500 5Th Gear Nut:

Failure of the 5th gear locknut due to improper torque or thread wear, leading to loss of 5th gear. Service involves rebuilding the transmission and properly torquing and staking the nut.

Cummins Fuel System Issues:

Wear on the P7100 injection pump (especially early models) and injector issues can occur. Lift pump failure is also noted.

Front End Components:

Wear in ball joints, tie rod ends, and steering linkage due to heavy-duty use and towing.

Body Rust:

Susceptibility to rust on rocker panels, cab corners, and wheel wells, especially in areas with salt exposure.

Radiator And Cooling System:

Occasional leaks from radiator tanks or hoses, water pump seal failures.

ABS Sensor Failure:

ABS wheel speed sensor failure can trigger ABS warning lights.

📚 Vehicle History

Dodge Truck Legacy:

Dodge has a long history of building robust and capable trucks, particularly for work and towing applications, dating back to the 1930s.

Third Generation Ram:

This era (1994-2001) marked a significant redesign for the Ram pickup, introducing the distinctive 'Big Rig' styling with its prominent grille and forward-leaning cab. The 3500 model emphasized heavy-duty capabilities, with robust chassis, suspension, and powertrain options.

Powertrain Development:

The 5.9L Cummins diesel engine gained significant popularity during this period for its durability and torque. The V10 gas engine was introduced to compete with Ford's large V10 offerings. The manual transmission (NV4500) was a favored option for heavy towing and off-road use.

Manufacturing Plant:

Primarily produced at the Warren Truck Assembly Plant in Warren, Michigan.

🏆 Awards & Recognition

Cummins Reputation:

The 5.9L Cummins Turbo Diesel engine has a legendary reputation for durability, reliability, and longevity, making these trucks highly sought after by diesel enthusiasts and commercial users.

Overall Truck Capability:

Consistently recognized for its robust construction and towing/hauling capabilities within the heavy-duty segment of its time.