1996 Dodge Ram Truck 1500-3500 Workshop Service Reapir Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Year: 1996 Sub Models: 1500, 2500, 3500 Codes Chassis Code: BR/BE 👋 Introduction Market Position Positioning: The definitive DIY and professional mechanic's guide for the 1996 Dodge Ram, a highly popular and robust full-size pickup truck. Competitive Analysis Comparison: This workshop manual offers a level of detail comparable to or exceeding factory service manuals, providing essential information for maintaining and repairing these workhorses. Key Features Manual Benefits: Empowers owners and technicians with in-depth knowledge for diagnostics, repair, and maintenance, saving time and money. Technical Accuracy: Presents accurate technical data, diagrams, and procedures essential for the correct servicing of the vehicle. 📋 Manual Details Coverage Areas Coverage: Complete Service and Repair Coverage for 1996 Dodge Ram Trucks (1500, 2500, 3500 Series) Page Count Estimated Pages: Over 1500 (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, assembly, disassembly, cylinder head, block, pistons, connecting rods, crankshaft, camshaft, timing gear/chain/belt, lubrication system, cooling system. Engine Performance: Fuel injection system (MPI), ignition system, emission control systems, turbocharging (if applicable), diagnosis and testing. Transmission Manual: Service and repair of NV3500, NV4500 manual transmissions, clutch system, drive axles. Transmission Automatic: Service and repair of 46RE, 47RE automatic transmissions, torque converter, transmission control system. Brakes: Front and rear brake systems (disc/drum), anti-lock braking system (ABS), hydraulic system, parking brake. Suspension: Front and rear suspension (independent front suspension on 1500, solid front axle on 2500/3500), springs, shocks, steering linkage, alignment. Steering: Power steering system, steering column, steering gear/rack, troubleshooting. Electrical System: Battery, charging system, starting system, lighting, instrumentation, power distribution, fuses, relays. Body And Chassis: Body construction, interior trim, exterior trim, doors, windows, seats, bumpers, frame structure, collision repair basics. HVAC: Heating, ventilation, and air conditioning (HVAC) system diagnosis and repair. Comfort Convenience: Power windows, power locks, mirrors, seat adjustment, cruise control. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication, tune-ups. Troubleshooting: Diagnostic procedures, symptom-based troubleshooting charts, electrical schematics for fault finding. Repair: Step-by-step repair instructions for all major mechanical and electrical components. Disassembly Assembly: Detailed procedures for disassembling and reassembling components for repair or replacement. Specifications Torque: Torque specifications for all critical fasteners. Technical Depth Depth: Comprehensive: Covers basic maintenance, routine service, advanced diagnostics, and complete engine/transmission rebuilds. 📊 Manual Specifications File Format Digital Format Details: High-resolution digital document, likely searchable text-based PDF for ease of navigation and keyword searching. Print Quality Print Quality Recommendation: Printable on standard office printers; optimized for clarity of diagrams and text. Binding Type Binding Type: N/A (Downloadable) Paper Type Paper Type: N/A (Downloadable) ⚙️ Engine Specifications Primary Engine Engine Options: 5.2L Magnum V8 (318 ci), 5.9L Magnum V8 (360 ci), 3.9L Magnum V6 (239 ci), 8.0L Magnum V10 (488 ci - 2500/3500), 5.9L Cummins Turbo Diesel (359 ci - 2500/3500 HD). Performance Horsepower Torque 5 2L: Approx. 230 hp @ 4800 rpm / 300 lb-ft @ 3200 rpm (Varies slightly by model year and application). Horsepower Torque 5 9L: Approx. 245 hp @ 4400 rpm / 330 lb-ft @ 3200 rpm (Varies slightly by model year and application). Horsepower Torque 8 0L V10: Approx. 300 hp @ 4400 rpm / 450 lb-ft @ 3200 rpm. Horsepower Torque 5 9L Cummins: Approx. 215 hp @ 2600 rpm / 420 lb-ft @ 1600 rpm. Fuel System Fuel Injection: Sequential Multi-Port Fuel Injection (MPI) for gasoline engines; Direct Injection for Cummins Diesel. Cooling System Cooling Type: Pressurized, liquid-cooled system with electric cooling fan or viscous fan clutch. Lubrication System Oil Capacity 5 2L: 6 US quarts (5.7 Liters) with filter (check manual for exact capacity). Oil Capacity 5 9L V8: 7 US quarts (6.6 Liters) with filter (check manual for exact capacity). Oil Capacity Cummins: 11 US quarts (10.4 Liters) with filter (check manual for exact capacity). 🔧 Transmission Standard Standard Transmission 1500: NV3500 5-speed manual (typically on 5.2L models). Optional Optional Transmission Gas: 46RE 4-speed automatic, 47RE 4-speed automatic (heavy-duty). Optional Transmission Diesel: NV4500 5-speed manual (heavy-duty), 47RE 4-speed automatic (heavy-duty). Features 4Wd Transfer Case: New Process NP231 (part-time, 2-speed) or NP241 (part-time, 2-speed with more robust options for HD models). Fluid Specifications Automatic Transmission Fluid: ATF+3 (Chrysler material number 05010162AA) or equivalent specification. Manual Transmission Fluid Nv3500: GM Synchromesh Transmission Fluid or Mopar Manual Transmission Lubricant (GL-3 specification). Manual Transmission Fluid Nv4500: Synchromesh Transmission Fluid or Mopar Manual Transmission Lubricant (GL-3 specification). 📐 Dimensions Exterior Wheelbase Options: 134.7 inches (Standard Bed), 164.7 inches (Long Bed), 179.7 inches (Mega Cab - late 90s variant, less common in '96). Body Styles: Regular Cab, Club Cab (Extended Cab), Chassis Cab. Cargo Bed Lengths: 6.5 ft (Standard), 8 ft (Long Bed). Weights Gvwr Range: 6,000 lbs...
The definitive DIY and professional mechanic's guide for the 1996 Dodge Ram, a highly popular and robust full-size pickup truck.
Competitive Analysis
Comparison:
This workshop manual offers a level of detail comparable to or exceeding factory service manuals, providing essential information for maintaining and repairing these workhorses.
Key Features
Manual Benefits:
Empowers owners and technicians with in-depth knowledge for diagnostics, repair, and maintenance, saving time and money.
Technical Accuracy:
Presents accurate technical data, diagrams, and procedures essential for the correct servicing of the vehicle.
📋 Manual Details
Coverage Areas
Coverage:
Complete Service and Repair Coverage for 1996 Dodge Ram Trucks (1500, 2500, 3500 Series)
Page Count
Estimated Pages:
Over 1500 (typical for comprehensive workshop manuals of this era)
Synchromesh Transmission Fluid or Mopar Manual Transmission Lubricant (GL-3 specification).
📐 Dimensions
Exterior
Wheelbase Options:
134.7 inches (Standard Bed), 164.7 inches (Long Bed), 179.7 inches (Mega Cab - late 90s variant, less common in '96).
Body Styles:
Regular Cab, Club Cab (Extended Cab), Chassis Cab.
Cargo
Bed Lengths:
6.5 ft (Standard), 8 ft (Long Bed).
Weights
Gvwr Range:
6,000 lbs to 11,500 lbs (depending on model and configuration).
🛡️ Safety Features
Ratings
NHTSA Ratings:
Varies by specific configuration and year, typically focused on frontal impacts. Safety standards of the era.
Active Features
Active Safety:
Optional Anti-lock Braking System (ABS) on rear wheels or all four wheels.
Passive Features
Passive Safety:
Front airbags (driver and passenger), three-point seat belts, reinforced passenger cage.
Lighting
Headlight Type:
Composite headlights.
💡 Technology Features
Infotainment
Infotainment System:
Factory-installed AM/FM stereo radio with cassette player. Optional CD player. Basic analog gauge cluster.
Driver Assistance
Driver Assistance Features:
Limited by modern standards. Primarily ABS, cruise control. No electronic stability control or advanced driver aids.
Connectivity
Connectivity Features:
Basic electrical systems. No factory integrated Bluetooth or USB connectivity. Aftermarket solutions common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000 miles or 3 months under normal driving conditions; 7,500 miles or 6 months under severe conditions (refer to manual for specific engine).
Transmission Fluid Change:
Automatic: 30,000 - 60,000 miles; Manual: 60,000 - 100,000 miles (refer to manual).
Spark Plug Replacement:
Magnum engines often used platinum-tipped plugs with longer intervals, around 60,000 - 100,000 miles (refer to manual).
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 or 10W-30 API certified for gasoline engines; SAE 15W-40 API CH-4 for Cummins Diesel (check manual for exact viscosity based on climate).
Coolant Specification:
Chrysler specific green ethylene glycol coolant or equivalent Mopar HOAT coolant.
Brake Fluid Specification:
DOT 3 brake fluid.
Known Issues
Common Problems Gas Engines:
Intake manifold gasket leaks (especially on older Magnum V8s), distributorless ignition system (DIS) coil pack issues, occasional fuel injector problems.
Common Problems Diesel Engines:
Lift pump failure, injector line issues, potential for cracking exhaust manifolds on early Cummins. Transmission temperature issues on automatics under heavy load.
Common Problems Suspension Steering:
Wear in ball joints and tie rod ends, especially on trucks used for heavy work. Power steering pump leaks.
Common Problems Electrical:
Corrosion on grounds, failure of body control modules or instrument cluster components over time.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing durable and capable trucks, with the Ram nameplate signifying power and utility.
Model Evolution
Third Generation Ram:
The 1996 model year is part of the second generation of Dodge Ram trucks (BR/BE platform), introduced in 1994, which featured a significant redesign including a more aerodynamic and distinctive 'big rig' styling.
Production
Manufacturing Location:
St. Louis Assembly, Missouri, USA; Saltillo Engine Plant, Coahuila, Mexico.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
The Dodge Ram, particularly models equipped with the Cummins diesel engine, consistently received praise for its towing capacity, durability, and powertrain performance in its class.
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