Segment:
Heavy-duty pickup truck segment, designed for towing, hauling, and off-road capability.
Competitors:
Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD.
Truck Features:
Robust chassis, powerful engine options, substantial towing and payload capacities, and a reputation for durability.
Value:
Essential resource for owners and technicians to maintain, diagnose, and repair the Dodge Ram 2500 Series effectively and economically.
Engine:
All gasoline and diesel engine variants, including diagnostics, overhaul, and component testing.
Transmission:
Manual and automatic transmission systems, including torque converters, clutches, internal components, and electronic controls.
Drivetrain:
Four-wheel drive (4WD) systems, transfer cases, front and rear differentials, axle shafts, and driveshafts.
Brakes:
Antilock Braking System (ABS), front and rear brake systems (disc and drum), parking brake, hydraulic lines, and master cylinder.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, steering knuckles, and alignment specifications.
Steering:
Power steering system, steering gear, steering column, tie rods, and steering wheel components.
Electrical:
Complete electrical system, including battery, charging system, starter, ignition system, lighting, horn, power accessories, and wiring diagrams.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, including refrigerant service, blower motor, heater core, and A/C compressor.
Body:
Exterior and interior body panels, doors, hood, tailgate, bumpers, glass, trim, seats, and upholstery.
Chassis:
Frame construction, body mounts, and underbody components.
Fuel:
Fuel tank, fuel pump, fuel filter, fuel lines, and fuel injection system (for gasoline engines).
Exhaust:
Exhaust manifold, catalytic converter, mufflers, exhaust pipes, and emissions control systems.
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, belt inspections, and tune-ups.
Troubleshooting:
Systematic diagnostic procedures, fault code interpretation, and symptom-based troubleshooting guides.
Repair:
Detailed step-by-step repair instructions for all major vehicle components and systems, including disassembly and reassembly.
Diagnostics:
Engine diagnostics, ABS diagnostics, and other electronic system diagnostics using scan tools and specific test procedures.
Specifications:
Torque specifications, clearances, fluid capacities, resistance values, and other critical technical data.
Wiring Diagrams:
Comprehensive and detailed electrical wiring diagrams for all vehicle systems.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures.
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds.
Gasoline Engine Options:
5.2L Magnum V8 (318 cu in), 5.9L Magnum V8 (360 cu in)
Diesel Engine Option:
5.9L Cummins Turbo Diesel I6
5.2L V8 Horsepower:
~230 hp @ 4,000 rpm
5.2L V8 Torque:
~300 lb-ft @ 2,400 rpm
5.9L V8 Horsepower:
~245-250 hp @ 4,000 rpm
5.9L V8 Torque:
~330-335 lb-ft @ 3,200 rpm
5.9L Cummins Horsepower:
~215-235 hp @ 2,500 rpm (depending on year and configuration)
5.9L Cummins Torque:
~420-460 lb-ft @ 1,600 rpm (depending on year and configuration)
Gasoline Injection:
Sequential Electronic Fuel Injection (SEFI)
Diesel Injection:
Rotary Injection Pump (VE) or Bosch VP44 Injection Pump (later models), Direct Injection
5.9L Cummins:
ISB (International Series B)
Manual Transmission:
5-speed NV3500 or 6-speed NV4500 (depending on engine and configuration)
Automatic Transmission:
4-speed 46RE, 47RE (for V8 gasoline) or 48RE (for Cummins diesel)
Transfer Case:
New Process Gear (NP) 241 or 271 (manual or electronic shift, depending on configuration)
Automatic Transmission Fluid:
Chrysler ATF+3 (or equivalent, check manual for specific variants)
Manual Transmission Fluid:
API GL-3 or GL-4 gear oil, viscosity typically 75W-90 (check manual for specific fill)
Transfer Case Fluid:
ATF+3 (check manual for specific fill)
Body Styles:
Regular Cab, Club Cab (Extended Cab), Quad Cab (later models)
Bed Lengths:
6.3 ft (short bed), 8.0 ft (long bed)
Curb Weight Range:
~5,000 - 7,000 lbs (depending on configuration and drivetrain)
Gross Vehicle Weight Rating Gvwr:
Typically 8,800 lbs to 9,500 lbs (depending on model variant)
Towing Capacity:
Up to 13,000 lbs or more (depending on configuration, engine, and axle ratio)
Payload Capacity:
Up to 5,000 lbs or more (depending on configuration)
Oil Change Interval:
Typically 3,000-5,000 miles for gasoline engines, 5,000-7,500 miles for Cummins diesel (check manual for specific recommendations based on driving conditions).
Transmission Fluid Change:
Every 30,000-50,000 miles for automatic transmissions, depending on towing and load conditions (check manual).
Coolant Flush:
Every 30,000 miles or 2 years for gasoline engines; 50,000 miles or 5 years for Cummins diesel (using correct coolant type).
Air Filter Replacement:
15,000-30,000 miles or as needed based on driving environment.
Fuel Filter Replacement:
15,000-30,000 miles for gasoline; 10,000-15,000 miles for Cummins diesel (critical for diesel fuel system health).
Engine Oil Type Gasoline:
SAE 10W-30 or 10W-40 API SJ, SL (refer to manual for precise viscosity and API rating).
Engine Oil Type Diesel:
API CG-4 or CH-4, SAE 15W-40 (check manual for specific Cummins oil recommendations).
Coolant Type:
Mopar Antifreeze/Coolant (5/100), or equivalent HOAT (Hybrid Organic Acid Technology) coolant.
Diesel Vp44 Pump:
Known for potential failure due to fuel contamination or electrical issues, especially on later models of this generation. Manual covers diagnosis and replacement.
Transmission Hard Shifts:
May occur with automatic transmissions due to solenoid issues or fluid degradation. Manual provides diagnostic steps.
Front End Components:
Wear on ball joints, tie rods, and control arm bushings common with heavy use and towing. Manual details inspection and replacement.
Electrical Gremlins:
Intermittent electrical issues can occur; comprehensive wiring diagrams in the manual are essential for diagnosis.
Dodge Truck Legacy:
Dodge has a long history of producing rugged and capable trucks, with the Ram line establishing itself as a major player in the market.
Second Gen Ram:
The 1994-2001 generation, often called the 'second generation Ram', introduced a bold, aggressive styling that significantly boosted sales and brand image. This period saw the introduction and refinement of the Cummins turbodiesel option in heavy-duty trucks.
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan, USA (primary assembly locations)
Production Period:
1994-2001 (for the second generation platform, this manual covers 1998-2001)
