Target Audience:
DIY mechanics, professional technicians, fleet maintenance personnel, owners seeking in-depth knowledge.
Competitor Manuals:
Haynes, Chilton (often less detailed than factory manuals)
Comprehensiveness:
Considered the most thorough resource for this generation of Dodge Ram trucks.
User Experience:
Includes step-by-step instructions and exploded views for clarity.
Vehicle Generations Covered:
Primarily Second Generation (1994-2001) for Ram 1500, 2500, 3500. May include overlap into early Third Generation depending on specific edition.
Estimated Page Count:
1000+
Manual Type:
Factory Service Manual / Workshop Manual / Repair Manual
Format:
Likely digital (PDF) or possibly a comprehensive printed volume.
Engine:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, emissions control, engine diagnostics.
Transmission Drivetrain:
Manual transmission (NV3500, NV4500, NV5600), Automatic transmission (46RE, 47RE, 48RE), transfer case, driveline, axles, differentials.
Brakes:
Front and rear brake systems (disc and drum), parking brake, ABS (Anti-lock Braking System).
Suspension Steering:
Front and rear suspension components (leaf springs, coil springs, shock absorbers, control arms), steering system, power steering.
Electrical Electronics:
Battery, charging system, starting system, lighting, instrument cluster, wiring diagrams, Body Control Module (BCM), Powertrain Control Module (PCM) diagnostics.
Body Chassis:
Body structure, interior trim, exterior trim, doors, windows, seats, HVAC system, chassis frame, exhaust system.
Maintenance Routine:
Oil changes, fluid checks, filter replacements, tire rotations, lubrication points.
Diagnostics Troubleshooting:
Fault code interpretation, symptom-based troubleshooting charts, diagnostic procedures for all major systems.
Repair Overhaul:
Engine rebuild procedures, transmission overhaul, brake caliper replacement, suspension component replacement, electrical component repair.
Component Disassembly Assembly:
Detailed instructions for removing and installing virtually every component on the vehicle.
Depth Of Information:
Comprehensive. Covers basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications.
Detail Level:
Step-by-step instructions, exploded views, torque specifications, wiring diagrams, diagnostic flowcharts.
File Format Digital:
PDF (Searchable text, bookmark navigation, printable pages recommended)
Print Quality Printed:
High-resolution scans or professionally printed pages
Binding Type Printed:
Spiral bound or perfect bound for lay-flat usability
Paper Type Printed:
Durable, coated paper stock suitable for workshop environments
Engine Options:
3.9L V6 Magnum, 5.2L V8 Magnum, 5.9L V8 Magnum, 5.9L Cummins Turbo Diesel, 8.0L V10 Magnum
3.9L V6 Horsepower:
Approx. 175 hp @ 4800 rpm
3.9L V6 Torque:
Approx. 230 lb-ft @ 3200 rpm
5.2L V8 Horsepower:
Approx. 220 hp @ 4800 rpm
5.2L V8 Torque:
Approx. 295 lb-ft @ 3200 rpm
5.9L V8 Horsepower:
Approx. 245 hp @ 4000 rpm
5.9L V8 Torque:
Approx. 335 lb-ft @ 3200 rpm
5.9L Cummins Turbo Diesel Horsepower:
Approx. 160-215 hp (varies by year/tune)
5.9L Cummins Turbo Diesel Torque:
Approx. 400-440 lb-ft (varies by year/tune)
8.0L V10 Horsepower:
Approx. 300 hp @ 4000 rpm
8.0L V10 Torque:
Approx. 450 lb-ft @ 3200 rpm
Fuel System Type:
Multi-point fuel injection (MPI) for gasoline engines; Direct injection with rotary injection pump for Cummins diesel.
Required Fuel Octane:
87 Octane Recommended for Gasoline Engines
Diesel Fuel Spec:
ULSD (Ultra-Low Sulfur Diesel) recommended for later models, standard diesel for earlier.
Standard Transmission 1500:
5-Speed Manual (NV3500)
Standard Transmission 2500 3500:
5-Speed Manual (NV4500), 6-Speed Manual (NV5600 - later years)
Optional Transmission Gasoline:
4-Speed Automatic (46RE, 47RE)
Optional Transmission Diesel:
4-Speed Automatic (47RE, 48RE - later years)
Transmission Fluid Type Automatic:
ATF+4 (or equivalent)
Transmission Fluid Type Manual:
MS-9224 for NV3500, MS-9060 for NV4500/NV5600 (refer to specific manual for exact spec)
Wheelbase Options:
Various: Regular Cab (134.7"), Extended Cab (134.7", 160.5"), Crew Cab (145.7" - early years)
Bed Length Options:
6.0 ft, 8.0 ft
Gross Vehicle Weight Ratings:
Varies significantly by model and configuration (e.g., 6300 lbs for 1500, 8800-10200 lbs for 2500/3500)
Curb Weight Examples:
Approx. 4500-6000 lbs depending on configuration
NHTSA Crash Test Ratings:
Generally fair to good for its era; details vary by model year and configuration. Frontal impact was a focus.
Anti Lock Brakes:
Standard on most 2500/3500, optional on 1500 depending on year and trim. Rear-wheel ABS and 4-wheel ABS available.
Airbags:
Driver airbag standard; passenger airbag optional on early models, standard on later ones.
Seat Belts:
All seating positions equipped with lap and shoulder belts.
Infotainment System Era:
Basic for the era; factory radio with cassette/CD player, AM/FM tuner. Optional premium audio systems available.
Connectivity Options:
Limited; some models may have had dealer-installed options for CD changers or early satellite radio.
Driver Assistance Features:
Minimal by modern standards; primarily focused on active safety like ABS. Cruise control standard on most trims.
Engine Oil Change Interval:
Every 3,000 miles (severe service) or 6,000 miles (normal service) for gasoline; 5,000-7,500 miles for diesel.
Engine Oil Filter Replacement:
Replace with every oil change.
Air Filter Replacement Interval:
Inspect every 12,000 miles, replace as needed (typically 24,000-36,000 miles).
Transmission Fluid Change Interval:
Automatic: Every 30,000-60,000 miles; Manual: Check condition periodically, replace as per manual (often 60,000-100,000 miles).
Engine Oil Spec Gasoline:
API SG or higher, SAE 10W-30 or 5W-30 (depending on temperature and specific engine, consult manual).
Engine Oil Spec Diesel:
API CI-4 or CH-4, SAE 15W-40 (or 5W-40 synthetic for cold weather) for Cummins 5.9L.
Coolant Type:
Ethylene Glycol based coolant, typically Mopar OAT (Organic Additive Technology) or HOAT (Hybrid Organic Additive Technology) compatible, 50/50 mix with distilled water.
Common Issues Gasoline Engines:
Intake manifold gasket leaks, exhaust manifold cracks (especially on V8s), distributor issues, fuel pump failures.
Common Issues Cummins Diesel:
Lift pump failures (stock), injector line issues, potential for rear main seal leaks, governor spring issues on older models, exhaust manifold gasket leaks.
Common Issues Transmissions:
Automatic transmission valve body issues, overdrive unit problems, manual transmission clutch wear.
Common Issues Suspension Steering:
Worn ball joints, tie rod ends, steering gear wear, leaf spring fatigue on heavy-duty models.
Common Issues Electrical:
Instrument cluster failures (especially odometer), headlight switch issues, power window motor failures.
Dodge Truck Legacy:
Dodge has a long-standing reputation for building robust and capable trucks.
Second Generation Ram Introduction:
Introduced for the 1994 model year, a significant redesign from the previous generation, featuring a more aerodynamic and distinctive 'cathedral grille' design.
Key Updates During Generation:
Introduction of Quad Cab, expanded engine options (including the 8.0L V10 and updated Cummins 5.9L), revised interiors, and updated transmissions.
Production Period:
1994-2001 (Second Generation)
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan; St. Louis, Missouri (assembly plants varied)
Truck Of The Year Awards:
The Ram lineup, particularly with the Cummins diesel option, received numerous accolades for towing and hauling capabilities throughout the second generation.
Cummins Engine Reputation:
The 5.9L Cummins Turbo Diesel is legendary for its durability and longevity, often cited as a key selling point.
