Segment:
Heavy-Duty Pickup Truck
Target Audience:
Owners, professional mechanics, DIY enthusiasts, fleet operators.
Competitors:
Ford F-250/F-350 Super Duty, Chevrolet Silverado 2500HD/3500HD, GMC Sierra 2500HD/3500HD.
Engine Options:
Renowned for its robust V8 gasoline engines and the legendary Cummins Turbo Diesel.
Durability:
Built for heavy-duty work, emphasizing strength, towing capacity, and longevity.
Offering Value:
Provided a compelling blend of capability and value in the heavy-duty truck market.
Coverage Type:
Comprehensive Service and Repair
Type:
Software (Digital Manual)
Format:
Digital Software (likely PDF, executable, or specialized viewer)
File Format:
Digital Software (Likely Proprietary or PDF-based)
Searchability:
Typically high searchability within the software for keywords and topics.
Update Frequency:
Not applicable for a specific model year manual, as it reflects factory specifications for that period.
Engine Mechanical:
Detailed diagnostics, disassembly, assembly, and repair for all engine variants including V8 Magnum and Cummins Turbo Diesel.
Engine Electrical:
Ignition system, fuel injection system (MPI), emissions control, starter, alternator, and related wiring diagrams.
Transmission Manual:
Service and repair procedures for NV4500 (5-speed manual) and Getrag 5-speed manual transmissions.
Transmission Automatic:
Service and repair procedures for 47RH (4-speed automatic with lock-up converter) and 48RE (4-speed automatic) transmissions.
Drivetrain:
Front and rear axle service, differential repair, transfer case (NV241 HD/DHD), driveshaft maintenance, and U-joint replacement.
Suspension Steering:
Front and rear suspension component service (leaf springs, shock absorbers, ball joints, steering linkage), steering gear repair, and alignment specifications.
Brakes:
Front disc brake service (including ABS), rear drum brake service, parking brake system, hydraulic system, and component replacement.
Electrical Body:
Lighting systems, power windows, door locks, mirrors, wipers, horns, interior and exterior trim, and related electrical components.
HVAC:
Air conditioning system service, heater core replacement, climate control operation, and component diagnostics.
Body Chassis:
Frame inspection and repair, body panel removal and installation, cab mounting, bumper service, and exterior hardware.
Fuel System:
Fuel tank and pump service, fuel filter replacement, fuel lines, and diesel injection system specifics.
Preventive Maintenance:
Scheduled maintenance intervals, fluid checks and changes, filter replacements, lubrication, and inspections.
Diagnostic Troubleshooting:
Systematic diagnostic flowcharts, symptom-based troubleshooting guides, and common problem identification for all major systems.
Component Replacement:
Step-by-step instructions for replacing virtually all serviceable components, from spark plugs to engine assemblies.
Rebuild Procedures:
Detailed instructions for rebuilding engines, transmissions, differentials, and other major mechanical units.
Electrical Diagnostics:
Wiring diagrams, connector pinouts, diagnostic trouble code (DTC) interpretation, and component testing procedures.
Torque Specifications:
Comprehensive list of all critical torque specifications for fasteners across all vehicle systems.
Special Tools:
Identification and usage of specialized tools required for specific repair and maintenance procedures.
Depth:
Factory-level detail, covering everything from basic fluid changes to complete engine and transmission overhauls.
Diagnostic Accuracy:
High accuracy due to official licensing, providing reliable diagnostic trees and repair information.
Component Diagrams:
Detailed exploded views and diagrams for all major component assemblies.
Wiring Schematics:
Complete and accurate wiring diagrams for all electrical systems, essential for troubleshooting.
Wheelbase Regular Cab:
134.7 inches
Wheelbase Club Cab:
160.8 inches
Bed Length Standard:
8.0 feet
Bed Length Optional:
6.5 feet (less common for 2500)
Gvwr Gas:
8,800 - 9,000 lbs (approx.)
Gvwr Diesel:
9,500 - 10,000 lbs (approx.)
Payload Capacity:
Varies by configuration, typically 2,000 - 4,000 lbs.
Towing Capacity:
Varies by configuration, can exceed 10,000 lbs with proper equipment.
Oil Change Gas:
Every 3,000 - 6,000 miles or 6 months (depending on oil type and driving conditions)
Oil Change Diesel:
Every 7,500 - 15,000 miles or 12 months (using appropriate diesel oil)
Transmission Fluid Change Auto:
Every 30,000 - 60,000 miles (ATF+4 or equivalent)
Transmission Fluid Change Manual:
Every 60,000 - 100,000 miles (appropriate manual transmission fluid, e.g., GL-4 or GL-5)
Coolant Flush:
Every 30,000 - 60,000 miles or 2-4 years
Engine Oil Gas Spec:
API SG/SH/SJ; SAE 5W-30, 10W-30, or 10W-40 (check manual for specific recommendations based on temperature)
Engine Oil Diesel Spec:
API CI-4/CH-4/CG-4/CF (or ACEA E3/E5); SAE 15W-40 (most common) or 5W-40 synthetic
Automatic Transmission Fluid:
ATF+4 (Mopar specification) or equivalent Dexron III/Mercon
Manual Transmission Fluid Nv4500:
GL-3 or GL-4 (specific recommendation is critical for the NV4500 to avoid premature wear of synchros; avoid GL-5 unless specified by transmission manufacturer)
Gear Oil Spec:
API GL-5; SAE 75W-90 or 80W-90
Nv4500 5Th Gear Nut:
Potential for the 5th gear nut to loosen, leading to gear damage. Manual covers inspection and proper torque/staking.
Diesel Injector Pump:
Early VE pumps could be prone to failure; later P7100 are generally very robust. Manual covers diagnostics.
Automatic Transmission Cooler Lines:
Potential for corrosion and leaks in cooler lines, especially in rust-belt regions. Manual covers inspection and replacement.
Cab Mounts Bushings:
Wear and tear on cab mounting bushings can lead to rattling or a soft ride. Manual covers replacement.
Brake Wear:
Heavy-duty use can accelerate brake wear; manual provides inspection intervals and repair procedures.
Dodge Truck Legacy:
Dodge has a long history of producing rugged and capable trucks, particularly its Ram line, known for durability and towing prowess.
Second Generation Ram:
The 1994-2001 (second generation) Ram introduced a distinctive, aggressive styling and significant mechanical upgrades, including the introduction of the Cummins Turbo Diesel as a factory option for the half-ton and heavy-duty models.
Manufacturing Location:
St. Louis, Missouri, USA; Saltillo, Mexico
Production Years For Gen:
1994-2001