Dodge Ram 2500 1996 1997 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 2500 Year: 1996-1997 Codes Chassis Code: BR/BE Platform: Third Generation Dodge Ram 👋 Introduction Market Position Segment: Heavy-duty pickup truck. Target Audience: Truck owners, DIY mechanics, professional automotive technicians. Competitive Analysis Competitors: Ford F-250/F-350 Super Duty, Chevrolet Silverado 2500/3500, GMC Sierra 2500/3500. Key Features Vehicle Strengths: Robust construction, powerful engine options (especially Cummins diesel), towing and hauling capability, comfortable interior for its class. Manual Value Proposition: Provides expert-level guidance to maintain, diagnose, and repair the vehicle, saving time and money on service. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for 1996-1997 Dodge Ram 2500 trucks. Secondary Coverage: Includes diagnostics, troubleshooting, maintenance, and overhaul procedures. Page Count Estimated Pages: 1000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: 5.2L Magnum V8 (318 ci), 5.9L Magnum V8 (360 ci), 8.0L Magnum V10 (488 ci), 5.9L Cummins Turbo Diesel I6 (359 ci). Transmission: NV3500 5-speed Manual, NV4500 5-speed Manual, 47RH 4-speed Automatic, 48RE 4-speed Automatic. Drivetrain: Front axle ( Dana 44, Dana 60), Rear axle (Chrysler 9.25, Dana 70HD), 4WD transfer case (New Process NP231, NP241). Suspension: Front: Independent Front Suspension (IFS) with torsion bars; Rear: Leaf springs. Brakes: Front disc brakes (Vented rotors), Rear drum brakes (with optional rear disc brakes on some models). Electrical: Starting and charging system, lighting, ignition system (distributorless ignition system on some engines), instrument cluster, power accessories, trailer wiring. HVAC: Air conditioning system, heater core, blower motor, controls. Body: Body panel removal and installation, door mechanisms, interior trim, glass, bumpers, tailgate. Diagnostics: On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), wiring diagrams, component testing. Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, lubrication, tire rotations, spark plug replacement, belt replacement. Repair: Engine rebuilds, transmission overhauls, brake system repairs, suspension component replacement, steering system repairs, exhaust system repairs. Overhaul: Complete engine overhaul procedures, transmission rebuilding, differential service. Troubleshooting: Step-by-step troubleshooting guides for common and uncommon issues, diagnostic flowcharts. Installation: Component replacement procedures for all major systems. Technical Depth Depth: Detailed diagnostic procedures, torque specifications, clearances, wiring diagrams, component removal and installation, overhaul procedures, specifications. 📊 Manual Specifications File Format PDF Quality: High resolution, searchable text. Printability: Printable pages for easy reference in a workshop environment. Binding Type Binding: N/A (PDF format) Paper Type Paper: N/A (PDF format) ⚙️ Engine Specifications Primary Engine Engine 1 Type: 5.2L (318 ci) Magnum V8 Engine 1 Bore X Stroke: 3.91 in x 3.58 in (99.3 mm x 90.9 mm) Engine 1 Compression Ratio: 8.7:1 Engine 1 Horsepower: 230 hp @ 4,400 rpm (approx.) Engine 1 Torque: 295 lb-ft @ 2,400 rpm (approx.) Engine 2 Type: 5.9L (360 ci) Magnum V8 Engine 2 Bore X Stroke: 4.00 in x 3.58 in (101.6 mm x 90.9 mm) Engine 2 Compression Ratio: 8.7:1 Engine 2 Horsepower: 245 hp @ 4,000 rpm (approx.) Engine 2 Torque: 335 lb-ft @ 3,200 rpm (approx.) Engine 3 Type: 8.0L (488 ci) Magnum V10 Engine 3 Bore X Stroke: 4.00 in x 3.88 in (101.6 mm x 98.4 mm) Engine 3 Compression Ratio: 8.4:1 Engine 3 Horsepower: 300 hp @ 4,000 rpm (approx.) Engine 3 Torque: 450 lb-ft @ 2,400 rpm (approx.) Engine 4 Type: 5.9L (359 ci) Cummins Turbo Diesel I6 Engine 4 Bore X Stroke: 4.02 in x 4.72 in (102 mm x 120 mm) Engine 4 Compression Ratio: 17.3:1 Engine 4 Horsepower: 190 hp @ 2,500 rpm (approx.) Engine 4 Torque: 420 lb-ft @ 1,600 rpm (approx.) Fuel System Gasoline Engines: Multi-point Fuel Injection (MPI). Diesel Engine: Bosch VE Rotary Injection Pump (VE44). 🔧 Transmission Standard Transmission 1 Type: NV3500 5-Speed Manual (standard on some gas models). Transmission 2 Type: 47RH 4-Speed Automatic (standard on some diesel models). Optional Transmission 3 Type: NV4500 5-Speed Manual (optional on some gas and diesel models). Transmission 4 Type: 48RE 4-Speed Automatic (optional on some diesel models, successor to 47RH). Features Transmission Fluid Type Auto: ATF+3 (Chrysler specification) or equivalent. Transmission Fluid Type Manual: Manual Transmission Fluid (MTF), SAE 75W-90 or 80W-90 GL-5. 📐 Dimensions Exterior Wheelbase Std: 134.0 inches (3404 mm) Wheelbase Long: 154.5 inches (3924 mm) (Quad Cab) Length Std Bed: 231.7 inches (5885 mm) Length Long Bed: 251.7 inches (6393 mm) (Quad Cab) Width: 79.4 inches (2017 mm) Height: 77.4 inches (1966 mm) Weights Curb Weight Gas: 5,000 - 6,000 lbs (approx.) Curb Weight Diesel: 5,500 - 6,500 lbs (approx.) Gvwr: 8,800 - 9,500 lbs (depending on configuration) Payload Capacity: 2,000 - 3,500 lbs (depending on configuration) Towing Capacity: Up to 12,000 lbs (depending on configuration and hitch type) Wheel Bolt Pattern: 8x6.5 (8x165.1 mm) Tire Size Std: P265/75R16 (varies by trim and configuration) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 3/5 stars (typical for the era, specific data varies by configuration)...

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Stichworte: 1996 1997 Cars Dodge Misc Ram 2500 Truck

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Beschreibung

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram 2500

Year:

1996-1997

Codes

Chassis Code:

BR/BE

Platform:

Third Generation Dodge Ram

👋 Introduction

Market Position

Segment:

Heavy-duty pickup truck.

Target Audience:

Truck owners, DIY mechanics, professional automotive technicians.

Competitive Analysis

Competitors:

Ford F-250/F-350 Super Duty, Chevrolet Silverado 2500/3500, GMC Sierra 2500/3500.

Key Features

Vehicle Strengths:

Robust construction, powerful engine options (especially Cummins diesel), towing and hauling capability, comfortable interior for its class.

Manual Value Proposition:

Provides expert-level guidance to maintain, diagnose, and repair the vehicle, saving time and money on service.

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service and repair for 1996-1997 Dodge Ram 2500 trucks.

Secondary Coverage:

Includes diagnostics, troubleshooting, maintenance, and overhaul procedures.

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

5.2L Magnum V8 (318 ci), 5.9L Magnum V8 (360 ci), 8.0L Magnum V10 (488 ci), 5.9L Cummins Turbo Diesel I6 (359 ci).

Transmission:

NV3500 5-speed Manual, NV4500 5-speed Manual, 47RH 4-speed Automatic, 48RE 4-speed Automatic.

Drivetrain:

Front axle ( Dana 44, Dana 60), Rear axle (Chrysler 9.25, Dana 70HD), 4WD transfer case (New Process NP231, NP241).

Suspension:

Front: Independent Front Suspension (IFS) with torsion bars; Rear: Leaf springs.

Brakes:

Front disc brakes (Vented rotors), Rear drum brakes (with optional rear disc brakes on some models).

Electrical:

Starting and charging system, lighting, ignition system (distributorless ignition system on some engines), instrument cluster, power accessories, trailer wiring.

HVAC:

Air conditioning system, heater core, blower motor, controls.

Body:

Body panel removal and installation, door mechanisms, interior trim, glass, bumpers, tailgate.

Diagnostics:

On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), wiring diagrams, component testing.

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, lubrication, tire rotations, spark plug replacement, belt replacement.

Repair:

Engine rebuilds, transmission overhauls, brake system repairs, suspension component replacement, steering system repairs, exhaust system repairs.

Overhaul:

Complete engine overhaul procedures, transmission rebuilding, differential service.

Troubleshooting:

Step-by-step troubleshooting guides for common and uncommon issues, diagnostic flowcharts.

Installation:

Component replacement procedures for all major systems.

Technical Depth

Depth:

Detailed diagnostic procedures, torque specifications, clearances, wiring diagrams, component removal and installation, overhaul procedures, specifications.

📊 Manual Specifications

File Format

PDF Quality:

High resolution, searchable text.

Printability:

Printable pages for easy reference in a workshop environment.

Binding Type

Binding:

N/A (PDF format)

Paper Type

Paper:

N/A (PDF format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Type:

5.2L (318 ci) Magnum V8

Engine 1 Bore X Stroke:

3.91 in x 3.58 in (99.3 mm x 90.9 mm)

Engine 1 Compression Ratio:

8.7:1

Engine 1 Horsepower:

230 hp @ 4,400 rpm (approx.)

Engine 1 Torque:

295 lb-ft @ 2,400 rpm (approx.)

Engine 2 Type:

5.9L (360 ci) Magnum V8

Engine 2 Bore X Stroke:

4.00 in x 3.58 in (101.6 mm x 90.9 mm)

Engine 2 Compression Ratio:

8.7:1

Engine 2 Horsepower:

245 hp @ 4,000 rpm (approx.)

Engine 2 Torque:

335 lb-ft @ 3,200 rpm (approx.)

Engine 3 Type:

8.0L (488 ci) Magnum V10

Engine 3 Bore X Stroke:

4.00 in x 3.88 in (101.6 mm x 98.4 mm)

Engine 3 Compression Ratio:

8.4:1

Engine 3 Horsepower:

300 hp @ 4,000 rpm (approx.)

Engine 3 Torque:

450 lb-ft @ 2,400 rpm (approx.)

Engine 4 Type:

5.9L (359 ci) Cummins Turbo Diesel I6

Engine 4 Bore X Stroke:

4.02 in x 4.72 in (102 mm x 120 mm)

Engine 4 Compression Ratio:

17.3:1

Engine 4 Horsepower:

190 hp @ 2,500 rpm (approx.)

Engine 4 Torque:

420 lb-ft @ 1,600 rpm (approx.)

Fuel System

Gasoline Engines:

Multi-point Fuel Injection (MPI).

Diesel Engine:

Bosch VE Rotary Injection Pump (VE44).

🔧 Transmission

Standard

Transmission 1 Type:

NV3500 5-Speed Manual (standard on some gas models).

Transmission 2 Type:

47RH 4-Speed Automatic (standard on some diesel models).

Optional

Transmission 3 Type:

NV4500 5-Speed Manual (optional on some gas and diesel models).

Transmission 4 Type:

48RE 4-Speed Automatic (optional on some diesel models, successor to 47RH).

Features

Transmission Fluid Type Auto:

ATF+3 (Chrysler specification) or equivalent.

Transmission Fluid Type Manual:

Manual Transmission Fluid (MTF), SAE 75W-90 or 80W-90 GL-5.

📐 Dimensions

Exterior

Wheelbase Std:

134.0 inches (3404 mm)

Wheelbase Long:

154.5 inches (3924 mm) (Quad Cab)

Length Std Bed:

231.7 inches (5885 mm)

Length Long Bed:

251.7 inches (6393 mm) (Quad Cab)

Width:

79.4 inches (2017 mm)

Height:

77.4 inches (1966 mm)

Weights

Curb Weight Gas:

5,000 - 6,000 lbs (approx.)

Curb Weight Diesel:

5,500 - 6,500 lbs (approx.)

Gvwr:

8,800 - 9,500 lbs (depending on configuration)

Payload Capacity:

2,000 - 3,500 lbs (depending on configuration)

Towing Capacity:

Up to 12,000 lbs (depending on configuration and hitch type)

Wheel Bolt Pattern:

8x6.5 (8x165.1 mm)

Tire Size Std:

P265/75R16 (varies by trim and configuration)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3/5 stars (typical for the era, specific data varies by configuration)

Active Features

Standard Anti-lock Braking System (ABS) on all four wheels.

Passive Features

Airbags:

Driver and passenger airbags.

Seatbelts:

Three-point seatbelts with pretensioners.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM stereo with cassette player and optional CD player. Speaker configurations vary by trim.

Driver Assistance

Cruise Control:

Standard on most models.

Tow Haul Mode:

Available on some automatic transmissions to optimize shift points for towing.

Connectivity

Trailer Connector:

Standard trailer wiring connector for brake lights, turn signals, and auxiliary power.

🔧 Maintenance

Service Intervals

Oil Change Gas:

Every 3,000 miles or 3 months, whichever comes first.

Oil Change Diesel:

Every 7,500 miles or 6 months, whichever comes first.

Transmission Fluid Auto:

Every 30,000 miles or 24 months.

Transmission Fluid Manual:

Inspect every 15,000 miles, replace as needed or every 60,000 miles.

Coolant Flush:

Every 30,000 miles or 24 months.

Spark Plugs Gas:

Recommended replacement around 60,000 - 100,000 miles depending on type (copper vs. platinum).

Fuel Filter Diesel:

Replace every 15,000 miles or annually.

Fluid Specifications

Engine Oil Gas:

API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on temperature).

Engine Oil Diesel:

API CD, CE, CF-4, CG-4, CH-4, or ACEA E2 specification, SAE 15W-40 or 5W-40.

Coolant:

Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent, 50/50 mix with distilled water.

Brake Fluid:

DOT 3.

Known Issues

Diesel Injectors:

Early VP44 injection pump issues on later models of this generation (though less common on '96-'97). Injector line failures can also occur.

Automatic Transmission:

Overheating and solenoid issues in 47RH/48RE transmissions, especially under heavy load. Band adjustment is crucial.

Front Suspension:

Wear in ball joints, tie rod ends, and control arm bushings due to the weight and IFS design. Death wobble can occur if steering/suspension components are worn.

Radiator:

Cracked plastic end tanks on the radiator can lead to coolant leaks.

A C System:

Leaks in the A/C system, particularly at the compressor and fittings.

Body Rust:

Rust can affect cab corners, rocker panels, and rear fender wells, especially in areas with road salt.

📚 Vehicle History

Brand Heritage

Dodge Trucks:

Dodge has a long history of producing robust and capable trucks, with the Ram nameplate being synonymous with toughness.

Model Evolution

Third Gen Ram:

The 1994-2001 generation (nicknamed 'Second Gen' by enthusiasts, but technically the third generation Ram) marked a significant redesign with a more aggressive, 'big rig' inspired styling, improved aerodynamics, and updated powertrains. The 1996-1997 models fall into the early part of this generation.

Production

Manufacturing Plant:

Saltillo Truck Assembly Plant, Mexico; Warren Truck Assembly Plant, Michigan, USA.

Production Years:

1994-2001 (This generation).

🏆 Awards & Recognition

Recognitions

Truck Of The Year:

This generation of Ram trucks received numerous accolades, including Motor Trend's Truck of the Year award in 1994, setting a strong benchmark for the brand.

Ratings

Consumer Reports:

Generally rated as a capable and durable truck, though specific reliability ratings varied by powertrain and can be found in historical consumer reports.