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1996 Dodge Dakota Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Dakota Year: 1996 Codes Platform: NS 👋 Introduction Market Position Segment: Compact Pickup Truck Target Audience: DIY mechanics, independent repair shops, truck owners Competitive Analysis Competitors 1996: Ford Ranger, Chevrolet S-10, Toyota Tacoma, Nissan Hardbody Key Features Unique Selling Point: Robust truck offering with a range of engine options, known for its V8 power in a compact package Manual Advantage: Provides in-depth, factory-level repair information essential for proper maintenance and repair 📋 Manual Details Coverage Areas Engine: 2.5L I4, 3.9L V6, 5.2L V8 Transmission: 4-speed Automatic (A500/42RE, A518/46RE), 5-speed Manual Drivetrain: Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD) Body Style: Regular Cab, Club Cab Suspension: Front: Independent Torsion Bar, Rear: Solid Axle with Leaf Springs Brakes: Front: Disc, Rear: Drum Electrical: All 1996 Dakota models Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, internal components, cylinder heads, crankshaft, pistons, rings, bearings Engine Performance: Fuel delivery, ignition system, cooling system, lubrication, exhaust system Fuel System: Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, evaporative emission control (EVAP) Ignition System: Spark plugs, ignition coils, distributor (if applicable), ignition control module (ICM) Cooling System: Radiator, water pump, thermostat, coolant hoses, cooling fan Lubrication System: Oil pump, oil pan, oil filter, oil passages Exhaust System: Exhaust manifolds, catalytic converter, muffler, exhaust pipes Transmission Automatic: Internal components, valve body, torque converter, clutch packs, seals, fluid service Transmission Manual: Clutch, gearbox, shift linkage, fluid service Drivetrain Components: Driveshafts, universal joints, axle shafts, differential (rear) Suspension Front: Torsion bars, control arms, ball joints, steering knuckles, sway bar Suspension Rear: Leaf springs, shock absorbers, axle housing Steering System: Steering gear, power steering pump, steering column, tie rods Brake System: Master cylinder, brake lines, calipers, brake pads, wheel cylinders, brake shoes, parking brake Electrical System: Battery, charging system (alternator), starting system (starter), lighting, fuses, relays, wiring diagrams Body And Frame: Body panels, chassis components, doors, glass, interior trim, upholstery HVAC System: Air conditioning, heating, ventilation, blower motor, controls Safety Systems: Airbags (if equipped), seat belts, body structure integrity Procedures Included Preventive Maintenance: Oil changes, filter replacements, fluid checks and flushes, belt inspections, tire rotations Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based diagnosis Repair Procedures: Step-by-step instructions for component removal, installation, and repair Component Rebuild: Detailed instructions for rebuilding major components like engines and transmissions Electrical Diagnostics: Interpreting wiring diagrams, testing circuits, diagnosing electrical faults Wheel Alignment: Specifications and procedures for front and rear wheel alignment Brake Service: Brake pad replacement, rotor resurfacing/replacement, caliper overhaul, bleeding procedures HVAC Service: Refrigerant charging, component replacement, leak detection Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission overhauls Diagnostic Tools: Information on diagnostic trouble codes (DTCs), scan tool usage, and specialized tools Specifications: Torque specifications, clearance measurements, fluid capacities, electrical tolerances 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable (OCR processed) Print Quality Quality: High-resolution scans, clear diagrams and text Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1: 2.5L Magnum Inline-4 (JTEC) Engine 2: 3.9L Magnum V6 (JTEC) Engine 3: 5.2L Magnum V8 (JTEC) Performance 2 5L Displacement 2 5L: 2492 cc (152 cu in) Horsepower 2 5L: 122 hp @ 4800 rpm Torque 2 5L: 137 lb-ft @ 3200 rpm Performance 3 9L Displacement 3 9L: 3906 cc (238 cu in) Horsepower 3 9L: 175 hp @ 4800 rpm Torque 3 9L: 225 lb-ft @ 3200 rpm Performance 5 2L Displacement 5 2L: 5211 cc (318 cu in) Horsepower 5 2L: 220 hp @ 4400 rpm Torque 5 2L: 295 lb-ft @ 3200 rpm Fuel System Fuel Delivery: Multi-port Electronic Fuel Injection (MPI) Fuel Type: Unleaded gasoline Engine Management ECM: JTEC (Jeep Truck Engine Controller) 🔧 Transmission Standard Transmission Standard: 5-speed manual (NV3500) Optional Transmission Optional 1: 4-speed automatic (A500/42RE) - RWD Transmission Optional 2: 4-speed automatic (A518/46RE) - Heavy Duty/V8 Features Automatic Features: Overdrive gear, electronically controlled Fluid Specifications Manual Transmission Fluid: ATF+4 or equivalent (check manual for specific type and capacity) Automatic Transmission Fluid: ATF+4 or equivalent (check manual for specific type and capacity) 📐 Dimensions Exterior Wheelbase: 111.9 inches (Regular Cab), 124.9 inches (Club Cab) Length: Varies by bed length (e.g., approx. 197.0 inches for standard bed) Width: Approx. 71.7 inches Height: Approx. 65.0 inches Cargo Bed Lengths: Short Bed (approx. 70.5 inches), Long Bed (approx. 83.5 inches) Weights Curb Weight: Varies by configuration (approx. 3500-4500 lbs) Towing Capacity: Up to 7000 lbs (with appropriate engine and equipment) 🛡️ Safety Features Ratings NHTSA Driver Side Front Impact: Not rated (vehicles from this era often lacked standardized testing) NHTSA Passenger Side Front Impact: Not rated Active Features ABS: Available on...
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1996 Dodge Dakota Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Dakota
Year:
1996
Codes
Platform:
NS
👋 Introduction
Market Position
Segment:
Compact Pickup Truck
Target Audience:
DIY mechanics, independent repair shops, truck owners
Competitive Analysis
Competitors 1996:
Ford Ranger, Chevrolet S-10, Toyota Tacoma, Nissan Hardbody
Key Features
Unique Selling Point:
Robust truck offering with a range of engine options, known for its V8 power in a compact package
Manual Advantage:
Provides in-depth, factory-level repair information essential for proper maintenance and repair
📋 Manual Details
Coverage Areas
Engine:
2.5L I4, 3.9L V6, 5.2L V8
Transmission:
4-speed Automatic (A500/42RE, A518/46RE), 5-speed Manual
Drivetrain:
Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD)
Body Style:
Regular Cab, Club Cab
Suspension:
Front: Independent Torsion Bar, Rear: Solid Axle with Leaf Springs
Brakes:
Front: Disc, Rear: Drum
Electrical:
All 1996 Dakota models
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, internal components, cylinder heads, crankshaft, pistons, rings, bearings
Engine Performance:
Fuel delivery, ignition system, cooling system, lubrication, exhaust system
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, evaporative emission control (EVAP)
Ignition System:
Spark plugs, ignition coils, distributor (if applicable), ignition control module (ICM)
Cooling System:
Radiator, water pump, thermostat, coolant hoses, cooling fan
Lubrication System:
Oil pump, oil pan, oil filter, oil passages
Exhaust System:
Exhaust manifolds, catalytic converter, muffler, exhaust pipes
Transmission Automatic:
Internal components, valve body, torque converter, clutch packs, seals, fluid service
Transmission Manual:
Clutch, gearbox, shift linkage, fluid service
Drivetrain Components:
Driveshafts, universal joints, axle shafts, differential (rear)
Suspension Front:
Torsion bars, control arms, ball joints, steering knuckles, sway bar
Suspension Rear:
Leaf springs, shock absorbers, axle housing
Steering System:
Steering gear, power steering pump, steering column, tie rods
Brake System:
Master cylinder, brake lines, calipers, brake pads, wheel cylinders, brake shoes, parking brake
Electrical System:
Battery, charging system (alternator), starting system (starter), lighting, fuses, relays, wiring diagrams
Body And Frame:
Body panels, chassis components, doors, glass, interior trim, upholstery
HVAC System:
Air conditioning, heating, ventilation, blower motor, controls
Safety Systems:
Airbags (if equipped), seat belts, body structure integrity
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements, fluid checks and flushes, belt inspections, tire rotations
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based diagnosis
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair
Component Rebuild:
Detailed instructions for rebuilding major components like engines and transmissions
Electrical Diagnostics:
Interpreting wiring diagrams, testing circuits, diagnosing electrical faults
Wheel Alignment:
Specifications and procedures for front and rear wheel alignment
Brake Service:
Brake pad replacement, rotor resurfacing/replacement, caliper overhaul, bleeding procedures
HVAC Service:
Refrigerant charging, component replacement, leak detection
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission overhauls
Diagnostic Tools:
Information on diagnostic trouble codes (DTCs), scan tool usage, and specialized tools
Specifications:
Torque specifications, clearance measurements, fluid capacities, electrical tolerances
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable (OCR processed)
Print Quality
Quality:
High-resolution scans, clear diagrams and text
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1:
2.5L Magnum Inline-4 (JTEC)
Engine 2:
3.9L Magnum V6 (JTEC)
Engine 3:
5.2L Magnum V8 (JTEC)
Performance 2 5L
Displacement 2 5L:
2492 cc (152 cu in)
Horsepower 2 5L:
122 hp @ 4800 rpm
Torque 2 5L:
137 lb-ft @ 3200 rpm
Performance 3 9L
Displacement 3 9L:
3906 cc (238 cu in)
Horsepower 3 9L:
175 hp @ 4800 rpm
Torque 3 9L:
225 lb-ft @ 3200 rpm
Performance 5 2L
Displacement 5 2L:
5211 cc (318 cu in)
Horsepower 5 2L:
220 hp @ 4400 rpm
Torque 5 2L:
295 lb-ft @ 3200 rpm
Fuel System
Fuel Delivery:
Multi-port Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Engine Management
ECM:
JTEC (Jeep Truck Engine Controller)
🔧 Transmission
Standard
Transmission Standard:
5-speed manual (NV3500)
Optional
Transmission Optional 1:
4-speed automatic (A500/42RE) - RWD
Transmission Optional 2:
4-speed automatic (A518/46RE) - Heavy Duty/V8
Features
Automatic Features:
Overdrive gear, electronically controlled
Fluid Specifications
Manual Transmission Fluid:
ATF+4 or equivalent (check manual for specific type and capacity)
Automatic Transmission Fluid:
ATF+4 or equivalent (check manual for specific type and capacity)
📐 Dimensions
Exterior
Wheelbase:
111.9 inches (Regular Cab), 124.9 inches (Club Cab)
Length:
Varies by bed length (e.g., approx. 197.0 inches for standard bed)
Width:
Approx. 71.7 inches
Height:
Approx. 65.0 inches
Cargo
Bed Lengths:
Short Bed (approx. 70.5 inches), Long Bed (approx. 83.5 inches)
Weights
Curb Weight:
Varies by configuration (approx. 3500-4500 lbs)
Towing Capacity:
Up to 7000 lbs (with appropriate engine and equipment)
🛡️ Safety Features
Ratings
NHTSA Driver Side Front Impact:
Not rated (vehicles from this era often lacked standardized testing)
NHTSA Passenger Side Front Impact:
Not rated
Active Features
ABS:
Available on some models
Passive Features
Airbags:
Driver-side airbag standard
Seatbelts:
Three-point front seatbelts, lap belts for rear passengers (Club Cab)
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette player, optional CD player
Speaker Configuration:
Standard 2-speaker, optional 4-speaker or 6-speaker systems
Driver Assistance
Cruise Control:
Available on most trims
Connectivity
Interior Features:
Power windows and locks available on higher trims
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 miles or 3 months (severe duty), 7,500 miles or 6 months (normal duty) - consult manual for specifics
Air Filter Replacement:
Every 15,000 miles or 12 months
Spark Plug Replacement V8:
Approx. 60,000 miles
Transmission Fluid Change:
Every 30,000-60,000 miles, depending on usage (consult manual)
Fluid Specifications
Engine Oil Spec:
API SG or SH, SAE 10W-30 or 10W-40 (check manual for specific engine and temperature ranges)
Coolant Spec:
Mopar Antifreeze/Coolant (50/50 mix with distilled water)
Brake Fluid Spec:
DOT 3
Power Steering Fluid Spec:
ATF+4 or equivalent (check manual)
Known Issues
Common Issue 1:
Head gasket leaks (especially on 5.2L V8)
Common Issue 2:
Rust and corrosion, particularly on rear wheel wells and frame rails
Common Issue 3:
EGR valve issues causing rough idle or stalling
Common Issue 4:
Cracked exhaust manifolds on V8 engines
Common Issue 5:
Transmission solenoid issues (42RE/46RE)
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing reliable and capable trucks, dating back to the 1930s.
Model Evolution
First Generation Start:
1997 (Second Generation)
1996 Model Year Context:
The 1996 model is part of the first generation of the Dodge Dakota, introduced in 1986. It received a significant refresh in 1991.
Production
Manufacturing Location:
Warren Truck Assembly Plant, Warren, Michigan, USA
🏆 Awards & Recognition
Recognitions
Popular Mechanics Editors Choice:
The 1996 Dodge Dakota was recognized by some automotive publications for its value and capability in its segment.
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