Dodge Ram 2500 1996 1997 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Dodge Model: Ram 2500 Model Generation: Second Generation (BR/BE) Model Years Covered: 1996, 1997 Codes Vehicle Platform Code: BR/BE 👋 Introduction Market Position Vehicle Segment:...

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类型: Truck

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标签: 1996 1997 Cars Dodge Misc Ram 2500 Truck

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram 2500

Model Generation:

Second Generation (BR/BE)

Model Years Covered:

1996, 1997

Codes

Vehicle Platform Code:

BR/BE

👋 Introduction

Market Position

Vehicle Segment:

Heavy-duty pickup truck, designed for towing, hauling, and demanding work applications.

Competitive Analysis

Primary Competitors:

Ford F-250 Super Duty, Chevrolet Silverado 2500HD, GMC Sierra 2500HD.

Key Features

Durability And Capability:

Known for robust construction, powerful engine options, and significant towing and payload capacities.

Utility:

Designed for work and commercial use, offering practical features and a focus on functionality.

Manual Value Proposition

Target Audience:

DIY mechanics, professional technicians, fleet owners, and enthusiasts seeking detailed repair and maintenance information.

Benefit:

Empowers users to perform accurate diagnostics, efficient repairs, and proper maintenance, saving time and money.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual

Language:

English

Format:

PDF (Digital Download)

Page Count

Page Count:

Manual Type

Download Method:

Instant Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full coverage including disassembly, assembly, inspection, and repair of all engine components.

Engine Management:

Diagnosis and repair of fuel injection, ignition, emission control systems, and powertrain control modules (PCMs).

Transmission Automatic:

Repair and overhaul procedures for automatic transmissions, including torque converter, valve body, and planetary gear sets.

Transmission Manual:

Repair and overhaul procedures for manual transmissions, including clutch, gearbox, and drive shaft components.

Drivetrain:

Front and rear axle service, differential repair, driveshaft balancing, and universal joint replacement.

Suspension:

Front and rear suspension component diagnosis, replacement, and alignment specifications (incl. coil springs, leaf springs, shock absorbers, control arms, ball joints, tie rod ends).

Steering:

Power steering system repair, steering gear box adjustment and replacement, and steering column service.

Brakes:

Complete brake system diagnosis and repair, including ABS, disc and drum brake components, hydraulic lines, and parking brake.

Electrical System:

Wiring diagrams, troubleshooting electrical faults, starter, alternator, battery, lighting, and accessory circuits.

Body Interior:

Body panel repair, interior trim removal and installation, door and window mechanisms, and seat adjustment systems.

Heating Ventilation Air Conditioning HVAC:

Diagnosis and repair of HVAC system components, refrigerant handling, and climate control operation.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, and pipe replacement and repair.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, and inspections.

Troubleshooting Diagnostics:

Systematic fault finding for common and complex vehicle issues with diagnostic trouble codes (DTCs) and symptom-based troubleshooting.

Component Repair Rebuild:

Detailed step-by-step instructions for disassembling, cleaning, inspecting, repairing, and reassembling major vehicle components.

Replacement Procedures:

Guidelines for replacing wear items, damaged parts, and upgrades.

Wiring Diagrams:

Comprehensive, detailed electrical schematics for all vehicle circuits.

Torque Specifications:

Precise torque values for all fasteners to ensure proper assembly and prevent damage.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair procedures.

Technical Depth

Depth Level:

Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, and advanced electrical diagnostics.

📊 Manual Specifications

File Format

File Format:

Searchability:

Searchable text for quick information retrieval.

Print Quality

Print Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Option 1:

8.0L (488ci) Magnum V10 OHV

Engine Option 2:

5.2L (318ci) Magnum V8 OHV

Engine Option 3:

5.9L (360ci) Magnum V8 OHV

Engine Option 4:

5.9L (359ci) Cummins Turbo Diesel I6 OHV

Performance

V10 Horsepower:

Approx. 300-310 hp @ 4000 rpm

V10 Torque:

Approx. 450-455 lb-ft @ 2400 rpm

Cummins Horsepower:

Approx. 180-215 hp @ 2500 rpm (depending on variant)

Cummins Torque:

Approx. 420-460 lb-ft @ 1600 rpm (depending on variant)

Fuel System

Fuel Delivery Gasoline:

Multi-point fuel injection (MPI)

Fuel Delivery Diesel:

Direct injection, Bosch rotary injection pump (VE or P7100 depending on specific Cummins model/year variant)

Cooling System

Engine Coolant Capacity:

Refer to manual for specific engine fill amounts (typically 14-18 quarts with 50/50 mix).

🔧 Transmission

Standard

Transmission Option 1:

4-speed Automatic (46RH/47RH/48RE depending on engine)

Optional

Transmission Option 2:

5-speed Manual (NV4500 for diesel, Getrag 5-speed for gasoline)

Features

Transmission Fluid Automatic:

ATF+3 or ATF+4 (refer to manual for specific fill requirements)

Transmission Fluid Manual:

GL-4 or GL-5 gear oil (specific viscosity recommended in manual, e.g., 75W-90).

Transfer Case:

Part-time 4WD system with manual or electronic shift-on-the-fly engagement.

📐 Dimensions

Exterior

Wheelbase:

Varies by cab and bed configuration (e.g., 134.7 inches for Regular Cab Short Bed, 164.7 inches for Crew Cab Long Bed).

Overall Length:

Varies by configuration (e.g., 216.5 inches for Regular Cab Short Bed, 246.5 inches for Crew Cab Long Bed).

Width:

Approx. 79.1 inches (excluding mirrors).

Height:

Approx. 75.7 inches (depending on configuration).

Weights

Curb Weight:

Varies significantly by configuration and engine, typically ranging from 5,500 lbs to over 7,000 lbs.

Gross Vehicle Weight Rating Gvwr:

Ranges from approximately 8,800 lbs to 10,000 lbs or more depending on configuration.

Cargo

Bed Length Options:

6.3 feet (standard bed) and 8.0 feet (long bed).

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Test:

Refer to specific NHTSA reports for detailed ratings. Trucks of this era generally focused on robust construction.

Active Features

ABS Brakes:

Standard on many models, with specific calibration for heavy-duty use.

Passive Features

Airbags:

Driver and passenger airbags (standard on most trims).

Seatbelts:

Three-point seatbelts in front and rear seating positions.

💡 Technology Features

Infotainment

Radio System:

AM/FM stereo, optional cassette or CD player, basic speaker configurations.

Driver Assistance

Cruise Control:

Available on most trims.

Connectivity

Power Accessories:

Power windows, power door locks (availability varies by trim level).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles or 6 months, depending on engine type (gas vs. diesel) and driving conditions (refer to manual for exact recommendations).

Transmission Fluid Change:

Every 30,000-60,000 miles for automatic transmissions, or as specified by service bulletin. Manual transmission fluid inspection typically every 30,000 miles.

Coolant Flush:

Every 30,000-100,000 miles or 2-5 years, depending on coolant type (e.g., conventional vs. HOAT).

Fuel Filter Replacement Gasoline:

Every 30,000 miles.

Fuel Filter Replacement Diesel:

Every 15,000-30,000 miles (critical for Cummins engines).

Fluid Specifications

Engine Oil Viscosity Gasoline:

5W-30 or 10W-30 (refer to manual for specific engine and ambient temperature).

Engine Oil Viscosity Diesel:

15W-40 API CI-4 or CH-4 (or equivalent) for Cummins.

Brake Fluid Type:

DOT 3.

Known Issues

Cummins Injection Pump Problems:

Early models with VE pumps can experience wear; P7100 is generally more robust but requires specialized knowledge.

Transmission Hard Shifting Automatic:

Can be caused by worn valve bodies or low fluid pressure.

Suspension Wear:

Ball joints, tie rod ends, and bushings can wear prematurely due to heavy loads.

Radiator And Hoses:

Aging components can lead to coolant leaks or overheating.

Rust And Corrosion:

Common in older trucks, particularly in areas exposed to road salt.

📚 Vehicle History

Brand Heritage

Dodge Truck Legacy:

Dodge has a long history of producing durable and capable trucks, establishing a strong reputation in the work and commercial vehicle market.

Model Evolution

Second Generation Launch:

The second generation Ram trucks (BR/BE platform) were introduced in 1994, representing a significant redesign with a distinctive 'big rig' styling.

Year Specific Updates 1996:

Introduction of the 8.0L V10 Magnum engine option, increased towing capacities.

Year Specific Updates 1997:

Minor refinements, potential updates to transmissions or electronic systems.

Production

Manufacturing Locations:

Primarily Saltillo, Mexico, and Warren, Michigan, USA.

🏆 Awards & Recognition

Recognitions

Diesel Engine Reputation:

The 5.9L Cummins turbodiesel is highly regarded for its durability, longevity, and aftermarket performance potential, often considered one of the best diesel engines of its era.

Towing And Hauling Awards:

Ram trucks of this period consistently received praise for their robust chassis and towing capabilities in automotive publications.