Dodge Ram Truck 1996 1997 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Model Generation: Second Generation (BR/BE) Codes Platform Code: BR/BE 👋 Introduction Market Position Segment: Full-size Pickup Truck Target Audience: DIY mechanics, professional automotive technicians, fleet managers, Dodge Ram owners seeking in-depth knowledge. Competitive Analysis Key Competitors: Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra (introduced later), Nissan Titan (introduced later). Key Features Vehicle Strengths: Robust construction, powerful engine options, towing and hauling capabilities, distinctive styling for the era. Manual Value Proposition: Provides essential, manufacturer-level technical information for accurate maintenance, troubleshooting, and repair, saving time and money. 📋 Manual Details Coverage Areas Covered Years: 1996, 1997 Covered Models: All Dodge Ram Truck models (e.g., 1500, 2500, 3500) Covered Trims: All trim levels Page Count Estimated Pages: Varies by specific manual edition, typically 1000+ pages for comprehensive workshop manuals. Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download File Format File Type: PDF Searchable Text: Yes (typically, depends on scan quality) Printable: Yes Print Quality Quality: High-resolution scans ensuring clarity of text and diagrams. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper: N/A (Digital PDF format) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, starting and charging systems, engine management (ECU/PCM). Transmission Systems: Manual transmission, automatic transmission (e.g., 46RE, 47RE), clutch system, transfer case (4WD models). Drivetrain Systems: Front axle, rear axle, driveshafts, CV joints, differentials. Suspension Systems: Front suspension (e.g., independent front suspension with torsion bars on some models, solid front axle on others), rear suspension (leaf springs), steering linkage, steering gear, power steering. Braking Systems: Front disc brakes, rear drum or disc brakes, parking brake, ABS (Anti-lock Braking System). Electrical Systems: Battery, charging system, starting system, lighting, instrumentation, body control modules, power distribution, wiring diagrams. HVAC Systems: Heating, Ventilation, and Air Conditioning (HVAC) system operation, diagnosis, and repair. Body Systems: Body panels, doors, windows, seats, interior trim, exterior trim, bumpers, tailgate/tailgate assist. Procedures Included Maintenance Procedures: Scheduled maintenance checks, oil changes, filter replacements, fluid level checks and top-offs, tire rotation, spark plug replacement, brake pad inspection. Troubleshooting Procedures: Diagnostic procedures for various symptoms, fault code interpretation (OBD-I/OBD-II depending on specific engine/year), component testing. Repair Procedures: Detailed step-by-step repair instructions for all major systems, including engine teardown and reassembly, transmission overhaul, suspension component replacement, brake caliper rebuild. Component Removal Installation: Procedures for removing and installing major components like alternators, starters, water pumps, radiators, AC compressors, fuel pumps. Torque Specifications: Essential torque values for critical fasteners and components across all systems. Wiring Diagrams: Comprehensive electrical wiring schematics for all vehicle circuits. Technical Depth Depth: Comprehensive Workshop Manual: Covers everything from routine maintenance and diagnostics to complete engine and transmission overhauls, electrical system troubleshooting, and bodywork repairs. Diagnostic Capabilities: Detailed diagnostic flowcharts, symptom-based troubleshooting guides, and component testing procedures. Special Tools: Identifies and describes specific tools required for certain repair procedures. ⚙️ Engine Specifications Primary Engine Engine Options 1996 1997: 5.2L (318 cu in) Magnum V8, 5.9L (360 cu in) Magnum V8, 8.0L (488 cu in) Magnum V10, 5.9L (359 cu in) Cummins Turbo Diesel (in 2500/3500 models). Performance 5 2L Horsepower 5 2L: Approx. 220-230 hp Torque 5 2L: Approx. 295-300 lb-ft Performance 5 9L V8 Horsepower 5 9L V8: Approx. 230-245 hp Torque 5 9L V8: Approx. 325-330 lb-ft Performance 8 0L V10 Horsepower 8 0L V10: Approx. 300 hp Torque 8 0L V10: Approx. 450 lb-ft Performance 5 9L Cummins Horsepower 5 9L Cummins: Approx. 180-215 hp (depending on year/version) Torque 5 9L Cummins: Approx. 420-460 lb-ft (depending on year/version) Fuel System Fuel Delivery Gasoline: Electronic Multi-Point Fuel Injection (MPI) Fuel Type Gasoline: Unleaded gasoline (Octane rating as per vehicle specification) Fuel Delivery Diesel: Inline Injection Pump (VE or VP series Bosch rotary) Fuel Type Diesel: Diesel Fuel 🔧 Transmission Standard Transmission Standard Transmission: 5-Speed Manual (NV4500, Getrag G360) Optional Transmission Optional Transmission: 4-Speed Automatic (46RE, 47RE) Features Automatic Automatic Features: Electronic controls, overdrive, torque converter lock-up. Features Manual Manual Features: Heavy-duty design, particularly the NV4500. 📐 Dimensions Exterior Dimensions Wheelbase Options: Various wheelbases depending on cab configuration (e.g., Regular Cab, Club Cab) and bed length (e.g., 6.5 ft, 8 ft). Overall Length Approx: Varies significantly with configuration, e.g., ~230 inches to ~260 inches. Width Excluding Mirrors Approx: Approx. 79.1 inches Height Approx: Approx. 74.8 - 77.6 inches (varies with configuration) Cargo Dimensions Bed Lengths: 6.5 ft (78.7 inches), 8 ft (95.7 inches) Weights Gvwr Range: Ranges from 6,000 lbs to 10,000+ lbs depending on chassis and configuration. Curb Weight Approx: Varies significantly, typically 4,500 lbs to 6,500+ lbs. 🛡️ Safety Features Ratings NHTSA Rollover Resistance: Typically rated for rollover resistance, specific score varies by configuration and testing year. Active Features Active Safety: Available ABS (Anti-lock Braking System) on all four wheels. Some models may have traction control....
Manual transmission, automatic transmission (e.g., 46RE, 47RE), clutch system, transfer case (4WD models).
Drivetrain Systems:
Front axle, rear axle, driveshafts, CV joints, differentials.
Suspension Systems:
Front suspension (e.g., independent front suspension with torsion bars on some models, solid front axle on others), rear suspension (leaf springs), steering linkage, steering gear, power steering.
Braking Systems:
Front disc brakes, rear drum or disc brakes, parking brake, ABS (Anti-lock Braking System).
Electrical Systems:
Battery, charging system, starting system, lighting, instrumentation, body control modules, power distribution, wiring diagrams.
HVAC Systems:
Heating, Ventilation, and Air Conditioning (HVAC) system operation, diagnosis, and repair.
Scheduled maintenance checks, oil changes, filter replacements, fluid level checks and top-offs, tire rotation, spark plug replacement, brake pad inspection.
Troubleshooting Procedures:
Diagnostic procedures for various symptoms, fault code interpretation (OBD-I/OBD-II depending on specific engine/year), component testing.
Repair Procedures:
Detailed step-by-step repair instructions for all major systems, including engine teardown and reassembly, transmission overhaul, suspension component replacement, brake caliper rebuild.
Component Removal Installation:
Procedures for removing and installing major components like alternators, starters, water pumps, radiators, AC compressors, fuel pumps.
Torque Specifications:
Essential torque values for critical fasteners and components across all systems.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all vehicle circuits.
Technical Depth
Depth:
Comprehensive Workshop Manual: Covers everything from routine maintenance and diagnostics to complete engine and transmission overhauls, electrical system troubleshooting, and bodywork repairs.
Diagnostic Capabilities:
Detailed diagnostic flowcharts, symptom-based troubleshooting guides, and component testing procedures.
Special Tools:
Identifies and describes specific tools required for certain repair procedures.
⚙️ Engine Specifications
Primary Engine
Engine Options 1996 1997:
5.2L (318 cu in) Magnum V8, 5.9L (360 cu in) Magnum V8, 8.0L (488 cu in) Magnum V10, 5.9L (359 cu in) Cummins Turbo Diesel (in 2500/3500 models).
Performance 5 2L
Horsepower 5 2L:
Approx. 220-230 hp
Torque 5 2L:
Approx. 295-300 lb-ft
Performance 5 9L V8
Horsepower 5 9L V8:
Approx. 230-245 hp
Torque 5 9L V8:
Approx. 325-330 lb-ft
Performance 8 0L V10
Horsepower 8 0L V10:
Approx. 300 hp
Torque 8 0L V10:
Approx. 450 lb-ft
Performance 5 9L Cummins
Horsepower 5 9L Cummins:
Approx. 180-215 hp (depending on year/version)
Torque 5 9L Cummins:
Approx. 420-460 lb-ft (depending on year/version)
Fuel System
Fuel Delivery Gasoline:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type Gasoline:
Unleaded gasoline (Octane rating as per vehicle specification)
Fuel Delivery Diesel:
Inline Injection Pump (VE or VP series Bosch rotary)
Lift pump failures, injector pump issues (VE/VP), potential for crankshaft thrust bearing wear (later models, but good to be aware), transmission issues (especially older NV4500 5th gear nut).
Known Issues General
Common Issues General:
Leaf spring sag, ball joint wear, steering linkage wear, rust (especially in northern climates), AC system performance issues, window regulator failures.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing durable and capable trucks dating back to the early 20th century.
Model Evolution
Second Gen Launch:
The second generation Ram Truck (BR/BE platform) was introduced for the 1994 model year, marking a significant redesign with its aggressive, forward-thrusting grille and bold styling.
Key Updates 1996 1997:
Minor updates and refinements were made during these years, including potential feature packaging changes and minor interior/exterior trim adjustments. Introduction of the V10 engine and improved diesel engines were key developments in this generation.
Production
Manufacturing Plants:
Primarily St. Louis Assembly Plant (Missouri, USA) and Warren Truck Assembly Plant (Michigan, USA) during this era.
🏆 Awards & Recognition
Recognitions
Truck Of The Year Awards:
While specific 1996-1997 models might not have received dedicated 'Truck of the Year' titles, the second-generation Ram platform was generally well-received for its styling and capability, contributing to Dodge's strong truck market presence.