Market Segment:
Heavy-duty pickup truck.
Target Audience:
Owners and professional mechanics of Dodge Ram 2500 Series trucks from 1996-1997.
Key Competitors:
Ford F-250, Chevrolet Silverado 2500, GMC Sierra 2500.
Manual Value:
Provides essential knowledge for maintaining, diagnosing, and repairing these robust trucks, saving time and money.
Vehicle Strengths:
Renowned for their heavy-duty capability, powerful engine options, and rugged construction.
Engine Mechanical:
Complete overhaul, diagnostics, repair, and maintenance for all gasoline and diesel engines.
Engine Electrical:
Ignition system, fuel injection, sensors, actuators, wiring diagrams, ECU troubleshooting.
Transmission Manual:
Service and repair of NV3500, NV4500 manual transmissions.
Transmission Automatic:
Service and repair of 46RE, 47RE automatic transmissions, including torque converter.
Drivetrain:
Four-wheel drive system (NV241, NV243), transfer case, differentials, axle shafts, U-joints.
Suspension:
Front and rear suspension components, springs, shocks, bushings, alignment procedures.
Steering:
Power steering system, steering gear, linkages, power steering pump.
Brakes:
Front and rear brake systems (disc/drum), ABS, hydraulic system, parking brake.
Electrical System:
Battery, charging system, starting system, lighting, accessories, fuses, relays.
HVAC:
Heating, ventilation, and air conditioning system service and repair.
Body And Frame:
Body panel repair, chassis structural analysis, door mechanisms, glass replacement.
Interior:
Seat removal/installation, dashboard components, trim panels, interior electronics.
Emissions Control:
Catalytic converter, EGR system, evaporative emission control, diagnostic trouble codes (DTCs).
Routine Maintenance:
Oil changes, filter replacements, fluid checks, tire rotation, spark plug replacement.
Troubleshooting:
Diagnostic procedures for all major systems, symptom-based fault finding.
Repair Procedures:
Step-by-step instructions for component removal, replacement, and adjustment.
Overhaul Procedures:
Detailed instructions for complete engine and transmission rebuilds.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Specification Charts:
Torque specifications, clearances, fluid capacities, component dimensions.
Special Tools:
Identification and usage of specialized tools required for specific repairs.
Depth:
Comprehensive. Covers everything from basic maintenance to full engine and transmission rebuilds and advanced diagnostics.
Gasoline Options:
8.0L Magnum V10 (300-310 hp, 450-470 lb-ft torque), 5.9L Magnum V8 (220-245 hp, 330-345 lb-ft torque).
Diesel Option:
5.9L 12-valve Cummins Turbo Diesel (180-215 hp, 420-440 lb-ft torque).
Fuel Type:
Gasoline and Diesel.
Gasoline Injection:
Multi-point fuel injection (MPI) for V8 and V10 engines.
Diesel Injection:
Inline injection pump for 5.9L Cummins.
Standard Transmission Type:
NV3500 5-speed manual (typically on lighter duty models/engines), NV4500 5-speed manual (heavy duty).
Optional Transmission Type:
46RE 4-speed automatic, 47RE 4-speed automatic (with overdrive).
Overdrive:
Present on 47RE automatic transmission.
Transfer Case:
Part-time 4WD (NV241DHD, NV243DHD) and potentially full-time 4WD options.
Wheelbase:
Varies by configuration (e.g., 134.9 inches for standard cab, 164.9 inches for long bed).
Body Styles:
Regular Cab, Club Cab (Extended Cab).
Bed Lengths:
6.3 ft (short), 8.0 ft (long).
Gvwr:
Ranges from approximately 8,510 lbs to 10,000 lbs depending on configuration and axle.
Oil Change Gasoline:
Typically every 3,000-5,000 miles or 6 months, depending on driving conditions.
Oil Change Diesel:
Typically every 5,000-7,500 miles or 6 months for the 5.9L Cummins.
Transmission Fluid Change:
Consult manual, but generally around 30,000-50,000 miles for automatics and manuals, depending on load and usage.
Engine Oil Gasoline:
API SG or SH, SAE 10W-30 or 10W-40 recommended (check manual for specific weight).
Engine Oil Diesel:
API CD, CE, CF-4, CG-4, CH-4 or Cummins CES 20071/20076 rated oil, SAE 15W-40 recommended.
Transmission Fluid Automatic:
ATF+3 or ATF+4 (Mopar spec)
Transmission Fluid Manual:
Refer to manual for specific manual transmission fluid (MTF) or gear oil type, e.g., SAE 75W-90 or 75W-140.
Coolant:
Chrysler OAT (Organic Additive Technology) or HOAT (Hybrid OAT) coolant, typically orange or Mopar's specific color.
V10 Engine:
Spark plug blow-out (proper torque is crucial), potential for valve spring issues in early models.
Cummins Engine:
Generally very reliable; potential for fuel supply issues or injector wear over very high mileage, overheating if cooling system is neglected.
Automatic Transmission:
47RE can develop torque converter shudder or clutch pack wear; proper cooling is essential.
Front Suspension:
Wear in ball joints, tie rod ends, and control arm bushings common due to heavy-duty use.
Body Rust:
Can be an issue in areas with road salt exposure, particularly around wheel wells and rocker panels.
