🏷️ Basic Information

Make:

Dodge

Model:

Ram Truck

Model Generation:

Second Generation (BR/BE)

Model Years Covered:

1996, 1997

Engine Codes:

3.9L Magnum V6 (10-4), 5.2L Magnum V8 (15-8), 5.9L Magnum V8 (19-8), 8.0L Magnum V10 (20-B), 5.9L Cummins Turbo Diesel (19-D)

👋 Introduction

Vehicle Segment:

Full-size pickup truck, known for its ruggedness and towing capability.

Key Competitors:

Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra (introduced later).

Engine Options:

Diverse powertrain lineup including the economical 3.9L V6, powerful 5.2L and 5.9L V8s, the torque-rich 8.0L V10, and the legendary 5.9L Cummins turbodiesel.

Body Styles:

Available in regular cab, club cab (extended cab), and crew cab configurations; various bed lengths (e.g., 6.5 ft, 8 ft).

Drivetrain Options:

Rear-wheel drive (RWD) and four-wheel drive (4WD) available.

📋 Manual Details

Manual Type:

Complete Workshop Service Repair Manual

Language:

English

Format:

Downloadable Digital Format (likely PDF)

Page Count:

Estimated to be extensive, typically over 1500 pages for a complete workshop manual of this era.

Manual Completeness:

This is a 'Complete Workshop Service Repair Manual', indicating it covers all aspects of vehicle maintenance, diagnosis, and repair for the specified models and years.

📖 Manual Coverage

Engine Mechanical:

Engine overhaul, assembly, disassembly, lubrication, cooling system, fuel system, ignition system, exhaust system, starting system, charging system.

Engine Control Systems:

Engine control module (ECM) diagnostics, sensor identification and function, actuator testing, emissions control systems (OBD-II).

Transmission Manual:

Disassembly, assembly, adjustment, and repair of manual transmissions (e.g., NV3500, NV4500).

Transmission Automatic:

Diagnosis, service, and overhaul of automatic transmissions (e.g., 42RE, 46RE, 47RE).

Drivetrain:

Front and rear axle service, differential overhaul, driveshaft and U-joint service, transfer case service (4WD models).

Suspension:

Front and rear suspension component diagnosis, replacement, alignment specifications, shock absorber and strut service.

Steering:

Power steering system service, steering gear diagnosis and repair, steering column service.

Brakes:

Front and rear brake system diagnosis and repair (disc and drum), ABS system service and bleeding, parking brake service.

Electrical System:

Wiring diagrams, fuse and relay locations, lighting system service, battery and charging system troubleshooting, instrument cluster service.

Body And Chassis:

Body panel removal and installation, door and window service, interior trim removal, chassis component service, frame inspection.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system diagnosis, refrigerant handling, component replacement.

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, belt and hose inspections, spark plug replacement, brake pad replacement.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides, pinpoint tests for electrical issues.

Repair:

Step-by-step instructions for component removal, installation, and adjustment for all major vehicle systems.

Diagnostics:

OBD-II diagnostic codes, component testing procedures, use of diagnostic scan tools.

Specifications:

Torque specifications, fluid capacities, clearances, pressure readings, electrical values.

Engine Timing:

Procedures for setting ignition timing on gasoline engines and injection pump timing on diesel engines.

Wheel Alignment:

Front and rear wheel alignment specifications and adjustment procedures.

Depth Of Coverage:

Comprehensive, covering everything from basic preventative maintenance to complete engine and transmission overhauls. Includes detailed diagnostic procedures for complex electrical and mechanical systems.

Diagrams And Illustrations:

Includes exploded views, wiring diagrams, schematic diagrams, and detailed illustrations to aid in repair and diagnosis.

Diesel Specific Coverage:

Detailed sections on the 5.9L Cummins Turbo Diesel, including fuel system, turbocharger, exhaust gas recirculation (EGR) if equipped, and specific engine diagnostic procedures.

Wiring Diagrams:

Comprehensive electrical system wiring diagrams for all major circuits, including engine control, lighting, accessories, and HVAC.

📊 Manual Specifications

Digital Format:

Downloadable, accessible on computers, tablets, and smartphones. Often searchable PDF.

Digital Quality:

High-resolution scans or digital originals, ensuring legibility of text and clarity of diagrams.

Digital Binding:

Not applicable for digital format; organized into chapters and sections for easy navigation.

Digital Paper Type:

Not applicable for digital format; content is presented digitally.

⚙️ Engine Specifications

3.9L Magnum V6:

Displacement: 3.9L (239 cu in), Configuration: OHV V6, Horsepower: ~175-180 hp, Torque: ~230-235 lb-ft, Fuel System: Multi-point Fuel Injection (MPFI).

5.2L Magnum V8:

Displacement: 5.2L (318 cu in), Configuration: OHV V8, Horsepower: ~220-230 hp, Torque: ~295-300 lb-ft, Fuel System: Multi-point Fuel Injection (MPFI).

5.9L Magnum V8:

Displacement: 5.9L (360 cu in), Configuration: OHV V8, Horsepower: ~235-245 hp, Torque: ~330-345 lb-ft, Fuel System: Multi-point Fuel Injection (MPFI).

8.0L Magnum V10:

Displacement: 8.0L (488 cu in), Configuration: OHV V10, Horsepower: ~300-310 hp, Torque: ~450-455 lb-ft, Fuel System: Multi-point Fuel Injection (MPFI).

5.9L Cummins Turbo Diesel:

Displacement: 5.9L (359 cu in), Configuration: OHV Inline-6 Turbo Diesel, Horsepower: ~180-215 hp (depending on calibration), Torque: ~400-440 lb-ft (depending on calibration), Fuel System: Bosch VE Rotary Injection Pump or Bosch VP44 Injection Pump (later 1997 models), Aspiration: Turbocharged.

Cooling System:

Pressurized liquid cooling system with fan clutch and/or electric fan.

Fuel Delivery:

Electric fuel pump, fuel filter, and multi-point fuel injection (MPFI) for gasoline engines. Direct injection for diesel.

Fuel Type:

Unleaded gasoline (87 octane or higher recommended for V8s/V10) for gasoline engines; Diesel fuel for Cummins engine.

🔧 Transmission

Manual Transmission Options:

NV3500 (5-speed) typically with 3.9L and 5.2L V8. NV4500 (5-speed heavy duty) often paired with 5.9L V8 and 5.9L Cummins.

Automatic Transmission Options:

42RE (3-speed with overdrive) for 3.9L and 5.2L engines. 46RE (4-speed with overdrive) for 5.2L and 5.9L engines. 47RE (4-speed with overdrive, heavier duty) for 5.9L V8, 8.0L V10, and 5.9L Cummins.

Transfer Case Options:

New Process (NP) 231 (light duty 2WD/4WD) and NP241 (heavy duty 2WD/4WD) available for 4WD models.

📐 Dimensions

Wheelbase Options:

134.7 inches (standard cab, short bed), 142.4 inches (club cab, short bed), 151.2 inches (regular cab, long bed), 162.0 inches (club cab, long bed).

Bed Length Options:

6.5 feet (short bed), 8.0 feet (long bed).

Curb Weight Range:

Approximately 4,500 to 6,000 lbs, depending on configuration and engine.

Gross Vehicle Weight Rating Range:

Approximately 6,000 lbs (1500 series) to 8,800 lbs (2500/3500 series).

🛡️ Safety Features

NHTSA Frontal Impact Rating:

Varied by year and configuration, generally considered average for its class and era. Specific ratings should be verified for individual model years.

ABS:

Anti-lock Braking System (ABS) available on most models, typically standard on 4WD and higher trims.

Airbags:

Driver and passenger airbags standard.

Seatbelts:

Three-point inertia reel seatbelts for front occupants, lap belts for rear occupants in extended cabs.

💡 Technology Features

Audio System:

Factory AM/FM radio with cassette tape player and optional CD player. Basic speaker configurations.

Cruise Control:

Electronic cruise control standard on most trims.

Trailer Towing Features:

Factory trailer brake controller wiring harness often available. Towing mirrors optional.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-7,500 miles or 3-6 months, depending on driving conditions and oil type. Check manual for specific recommendations.

Transmission Fluid Change:

Automatic transmissions: typically every 30,000-60,000 miles. Manual transmissions: typically every 60,000-100,000 miles. Check manual for specific intervals and fluid types.

Coolant Flush:

Every 30,000-60,000 miles or 2-4 years, depending on coolant type.

Spark Plug Replacement:

Varies by plug type (copper, platinum, iridium), typically 30,000-100,000 miles. Consult manual or plug manufacturer.

Engine Oil Type:

Gasoline engines: SAE 5W-30 or 10W-30 (check owner's manual for ambient temperature suitability). Cummins Diesel: SAE 15W-40 (API CI-4 or CJ-4).

Transmission Fluid Automatic:

Chrysler ATF+4 (or equivalent spec from era like ATF+3) for 42RE, 46RE, 47RE.

Transmission Fluid Manual:

GL-4 or GL-5 gear oil for NV3500/NV4500, viscosity will vary based on temperature (e.g., 75W-90).

Coolant Type:

Ethylene glycol-based antifreeze/coolant (green type), typically 50/50 mix with distilled water.

Common Issues Gasoline:

Cracked exhaust manifolds (especially 5.2L/5.9L V8s), plenum gasket leaks (intake manifold), radiator leaks, ball joint wear, intermittent ABS light due to wheel speed sensor or tone ring issues, distributor cap and rotor wear.

Common Issues Diesel:

Lift pump failure (especially early VP44 equipped models), injector issues, turbocharger wear, overheating on older models due to radiator capacity, grid heater failure.

Common Issues Transmission:

Overdrive planetary gear failure in 46RE/47RE, torque converter shudder, manual clutch wear.

Electrical Gremlins:

Can experience various electrical gremlins due to aging wiring harnesses, grounds, and body control modules. Wiper motor issues, headlight switch problems.

📚 Vehicle History

Dodge Truck Legacy:

Dodge has a long history of producing durable and capable trucks, with the Ram nameplate evolving into a distinct brand. The Ram trucks were known for their distinctive "sweeping crosshair" grille design during this period.

Second Generation Ram Introduction:

The second generation Ram (BR/BE) was introduced for the 1994 model year, representing a significant redesign with a more aerodynamic and sculpted body, a modernized interior, and a wider range of engine and transmission options, including the highly popular Cummins turbodiesel.

Manufacturing Location:

Primarily manufactured in Warren, Michigan, USA.

Market Impact:

The second-generation Ram trucks were very successful, challenging established leaders like Ford and Chevrolet, and significantly boosting Dodge's market share in the full-size pickup segment.

🏆 Awards & Recognition

Truck Of The Year Awards:

While specific awards for the 1996-1997 models might be harder to pinpoint, the second-generation Ram platform generally received positive reviews and recognition for its powerful engines (especially the Cummins) and robust construction.

Consumer Reports Ratings:

Consumer Reports historically rated these trucks as average to below average in reliability for certain model years and configurations due to some of the common issues listed above. However, their durability and capability were often praised.