Dodge Ram 2500 Series 1998-2001 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram 2500 Series Model Line: Ram Pickup Chassis Code: DR Platform (Second Generation Ram) Codes Product Code: Workshop Service Repair Manual PDF Download 👋 Introduction Market Position Segment: Heavy-duty pickup truck segment, designed for towing, hauling, and off-road capability. Competitive Analysis Competitors: Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD. Key Features Truck Features: Robust chassis, powerful engine options, substantial towing and payload capacities, and a reputation for durability. Manual Value Proposition Value: Essential resource for owners and technicians to maintain, diagnose, and repair the Dodge Ram 2500 Series effectively and economically. 📋 Manual Details Coverage Areas Years Covered: 1998, 1999, 2000, 2001 Page Count Estimated Pages: 3000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download File Format Details: Searchable PDF for easy navigation and keyword access. Print Quality: High-resolution, printable pages suitable for workshop use. Binding Type: N/A (Digital PDF Download) Paper Type: N/A (Digital PDF Download) 📖 Manual Coverage Systems Covered Engine: All gasoline and diesel engine variants, including diagnostics, overhaul, and component testing. Transmission: Manual and automatic transmission systems, including torque converters, clutches, internal components, and electronic controls. Drivetrain: Four-wheel drive (4WD) systems, transfer cases, front and rear differentials, axle shafts, and driveshafts. Brakes: Antilock Braking System (ABS), front and rear brake systems (disc and drum), parking brake, hydraulic lines, and master cylinder. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, steering knuckles, and alignment specifications. Steering: Power steering system, steering gear, steering column, tie rods, and steering wheel components. Electrical: Complete electrical system, including battery, charging system, starter, ignition system, lighting, horn, power accessories, and wiring diagrams. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, including refrigerant service, blower motor, heater core, and A/C compressor. Body: Exterior and interior body panels, doors, hood, tailgate, bumpers, glass, trim, seats, and upholstery. Chassis: Frame construction, body mounts, and underbody components. Fuel: Fuel tank, fuel pump, fuel filter, fuel lines, and fuel injection system (for gasoline engines). Exhaust: Exhaust manifold, catalytic converter, mufflers, exhaust pipes, and emissions control systems. Procedures Included Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, belt inspections, and tune-ups. Troubleshooting: Systematic diagnostic procedures, fault code interpretation, and symptom-based troubleshooting guides. Repair: Detailed step-by-step repair instructions for all major vehicle components and systems, including disassembly and reassembly. Diagnostics: Engine diagnostics, ABS diagnostics, and other electronic system diagnostics using scan tools and specific test procedures. Specifications: Torque specifications, clearances, fluid capacities, resistance values, and other critical technical data. Wiring Diagrams: Comprehensive and detailed electrical wiring diagrams for all vehicle systems. Special Tools: Identification and usage instructions for specialized tools required for specific repair procedures. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds. ⚙️ Engine Specifications Primary Engine Gasoline Engine Options: 5.2L Magnum V8 (318 cu in), 5.9L Magnum V8 (360 cu in) Diesel Engine Option: 5.9L Cummins Turbo Diesel I6 Performance 5.2L V8 Horsepower: ~230 hp @ 4,000 rpm 5.2L V8 Torque: ~300 lb-ft @ 2,400 rpm 5.9L V8 Horsepower: ~245-250 hp @ 4,000 rpm 5.9L V8 Torque: ~330-335 lb-ft @ 3,200 rpm 5.9L Cummins Horsepower: ~215-235 hp @ 2,500 rpm (depending on year and configuration) 5.9L Cummins Torque: ~420-460 lb-ft @ 1,600 rpm (depending on year and configuration) Fuel System Gasoline Injection: Sequential Electronic Fuel Injection (SEFI) Diesel Injection: Rotary Injection Pump (VE) or Bosch VP44 Injection Pump (later models), Direct Injection Engine Codes 5.2L V8: 318 5.9L V8: 360 5.9L Cummins: ISB (International Series B) 🔧 Transmission Standard Manual Transmission: 5-speed NV3500 or 6-speed NV4500 (depending on engine and configuration) Optional Automatic Transmission: 4-speed 46RE, 47RE (for V8 gasoline) or 48RE (for Cummins diesel) Features Transfer Case: New Process Gear (NP) 241 or 271 (manual or electronic shift, depending on configuration) Fluid Specifications Automatic Transmission Fluid: Chrysler ATF+3 (or equivalent, check manual for specific variants) Manual Transmission Fluid: API GL-3 or GL-4 gear oil, viscosity typically 75W-90 (check manual for specific fill) Transfer Case Fluid: ATF+3 (check manual for specific fill) 📐 Dimensions Exterior Body Styles: Regular Cab, Club Cab (Extended Cab), Quad Cab (later models) Bed Lengths: 6.3 ft (short bed), 8.0 ft (long bed) Weights Curb Weight Range: ~5,000 - 7,000 lbs (depending on configuration and drivetrain) Gross Vehicle Weight Rating Gvwr: Typically 8,800 lbs to 9,500 lbs (depending on model variant) Towing Capacity: Up to 13,000 lbs or more (depending on configuration, engine, and axle ratio) Payload Capacity: Up to 5,000 lbs or more (depending on configuration) 🛡️ Safety Features Ratings Frontal Crash Test Rating NHTSA: 4-star rating for driver and passenger in frontal impact (typical for the era, specific results may vary by year) Active Features ABS: Standard on most 2500 models, four-wheel disc brakes often standard on higher trims and later years. Passive Features Airbags: Driver and...
New Process Gear (NP) 241 or 271 (manual or electronic shift, depending on configuration)
Fluid Specifications
Automatic Transmission Fluid:
Chrysler ATF+3 (or equivalent, check manual for specific variants)
Manual Transmission Fluid:
API GL-3 or GL-4 gear oil, viscosity typically 75W-90 (check manual for specific fill)
Transfer Case Fluid:
ATF+3 (check manual for specific fill)
📐 Dimensions
Exterior
Body Styles:
Regular Cab, Club Cab (Extended Cab), Quad Cab (later models)
Bed Lengths:
6.3 ft (short bed), 8.0 ft (long bed)
Weights
Curb Weight Range:
~5,000 - 7,000 lbs (depending on configuration and drivetrain)
Gross Vehicle Weight Rating Gvwr:
Typically 8,800 lbs to 9,500 lbs (depending on model variant)
Towing Capacity:
Up to 13,000 lbs or more (depending on configuration, engine, and axle ratio)
Payload Capacity:
Up to 5,000 lbs or more (depending on configuration)
🛡️ Safety Features
Ratings
Frontal Crash Test Rating NHTSA:
4-star rating for driver and passenger in frontal impact (typical for the era, specific results may vary by year)
Active Features
ABS:
Standard on most 2500 models, four-wheel disc brakes often standard on higher trims and later years.
Passive Features
Airbags:
Driver and passenger front airbags.
Seatbelts:
Three-point seatbelts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette and CD player options, speaker configurations varied by trim.
Driver Assistance
Cruise Control:
Available as an option.
Connectivity
Trailer Wiring:
Provision for trailer brake controller and trailer lighting harness typically available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-5,000 miles for gasoline engines, 5,000-7,500 miles for Cummins diesel (check manual for specific recommendations based on driving conditions).
Transmission Fluid Change:
Every 30,000-50,000 miles for automatic transmissions, depending on towing and load conditions (check manual).
Coolant Flush:
Every 30,000 miles or 2 years for gasoline engines; 50,000 miles or 5 years for Cummins diesel (using correct coolant type).
Air Filter Replacement:
15,000-30,000 miles or as needed based on driving environment.
Fuel Filter Replacement:
15,000-30,000 miles for gasoline; 10,000-15,000 miles for Cummins diesel (critical for diesel fuel system health).
Fluid Specifications
Engine Oil Type Gasoline:
SAE 10W-30 or 10W-40 API SJ, SL (refer to manual for precise viscosity and API rating).
Engine Oil Type Diesel:
API CG-4 or CH-4, SAE 15W-40 (check manual for specific Cummins oil recommendations).
Known for potential failure due to fuel contamination or electrical issues, especially on later models of this generation. Manual covers diagnosis and replacement.
Transmission Hard Shifts:
May occur with automatic transmissions due to solenoid issues or fluid degradation. Manual provides diagnostic steps.
Front End Components:
Wear on ball joints, tie rods, and control arm bushings common with heavy use and towing. Manual details inspection and replacement.
Electrical Gremlins:
Intermittent electrical issues can occur; comprehensive wiring diagrams in the manual are essential for diagnosis.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing rugged and capable trucks, with the Ram line establishing itself as a major player in the market.
Model Evolution
Second Gen Ram:
The 1994-2001 generation, often called the 'second generation Ram', introduced a bold, aggressive styling that significantly boosted sales and brand image. This period saw the introduction and refinement of the Cummins turbodiesel option in heavy-duty trucks.
Production
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan, USA (primary assembly locations)
Production Period:
1994-2001 (for the second generation platform, this manual covers 1998-2001)
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
While specific awards for the 1998-2001 Ram 2500 are not widely publicized, the Ram lineup consistently received praise for its design and capability during this era.