Primary Focus:
Mechanical, electrical, and bodywork repairs and maintenance.
Body Styles Covered:
Likely includes Regular Cab, Club Cab (Extended Cab).
Drivetrain Configurations Covered:
2WD (Rear-Wheel Drive) and 4WD (Four-Wheel Drive).
Estimated Page Count:
Likely between 800-1500 pages, typical for comprehensive service manuals of this era.
Type:
Service and Repair Workshop Manual
Intended Audience:
Professional Mechanics, DIY Enthusiasts.
Format:
Print (Paperback or Spiral-bound - typical for original manuals)
Engine Systems:
Engine mechanicals (including disassembly, inspection, assembly), fuel system (injection, pumps, injectors), ignition system, cooling system, lubrication system, emission control systems.
Transmission Drivetrain:
Manual transmission, automatic transmission (e.g., A500, A518), transfer case (for 4WD), drive shafts, axles, differential.
Brakes:
Front disc brakes, rear drum brakes (standard for many configurations), ABS system (if equipped), brake hydraulics, parking brake.
Suspension Steering:
Front suspension (e.g., Independent Front Suspension - IFS with torsion bars for some models, or solid front axle for specific configurations), rear suspension (leaf springs), steering system (power steering, steering gear), wheel alignment.
Electrical Electronic:
Battery, charging system (alternator), starting system, ignition system, lighting (headlights, taillights, interior), instrument cluster, power accessories (windows, locks, mirrors), wiper system, horn, fuse box, relays, wiring diagrams (crucial detail).
Body Chassis:
Body panel repair, doors, hood, tailgate, interior trim, seat removal, frame repair, rust prevention and repair, glass replacement, weatherstripping.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, refrigerant handling (with safety precautions).
Fuel Tank Exhaust:
Fuel tank removal and installation, fuel lines, exhaust system components.
Maintenance:
Routine maintenance, fluid changes (oil, coolant, transmission, brake), filter replacements, lubrication, inspection points.
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting guides, common fault diagnosis.
Repair:
Step-by-step repair instructions for all major components and systems, including engine rebuild, transmission overhaul, suspension component replacement, brake caliper service.
Installation:
Installation procedures for common replacement parts and accessories (e.g., alternators, starters, water pumps, alternators).
Specifications Tolerances:
Detailed torque specifications for fasteners, engine bearing clearances, piston ring end gap, valve lash adjustments (if applicable).
Depth:
Comprehensive, covering from basic maintenance to full engine and transmission overhauls, including electrical system diagnostics.
Diagnostic Tools Required:
Information on standard mechanic's tools, specialized tools (e.g., bearing pullers, ring compressors), and diagnostic equipment (e.g., multimeter, scan tool if OBD-I diagnostics are detailed).
Engine Options 1:
5.2L Magnum V8 (318 cu in)
Engine Options 2:
5.9L Magnum V8 (360 cu in)
Engine Options 3:
3.9L Magnum V6 (239 cu in) - less common in 1500 models, more in 1500 variations or lower trims.
Engine Options 4:
5.9L Cummins Turbo Diesel I6 (likely reserved for 2500/3500 models, but manual might cover engine basics).
Horsepower 5.2L:
Approximately 230 hp @ 4400 rpm
Torque 5.2L:
Approximately 310 lb-ft @ 3200 rpm
Horsepower 5.9L:
Approximately 245 hp @ 4400 rpm
Torque 5.9L:
Approximately 335 lb-ft @ 3200 rpm
Fuel Injection Type:
Multi-point Fuel Injection (MPI).
Engine Family:
Chrysler Magnum V-engine series.
Spark Plugs:
Refer to manual for specific gap and torque (e.g., Champion Copper).
Oil Change Interval Gas:
Approximately 3,000-7,500 miles or 6 months, depending on driving conditions (severe vs. normal). Manual will specify exact intervals and recommended oil viscosity.
Service Intervals Coolant
Coolant Flush Interval:
Approximately 30,000 miles or 2 years. Manual will specify coolant type.
Engine Oil Viscosity:
Likely SAE 5W-30 or 10W-30 for gasoline engines, depending on ambient temperature. Manual will confirm.
Coolant Type:
Ethylene Glycol based coolant, likely Mopar OAT (Organic Additive Technology) or HOAT (Hybrid Organic Additive Technology) depending on the specific formulation for 1995. Refer to manual for correct type and mixture.
Brake Fluid Type:
DOT 3 brake fluid.
Common Wear Items:
Ball joints, tie rod ends, wheel bearings, brake pads/rotors, radiator, water pump, TPS (Throttle Position Sensor), lift pump (for diesel, less common in 1500), fuel injectors.
Potential Electrical Gremlins:
Corrosion in connectors, failing relays, intermittent sensor issues. Wiring diagrams are critical for diagnosis.
Rust Prone Areas:
Rocker panels, cab corners, rear fender lips, frame rails (especially in rust-belt regions).