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Dodge Ram 2500 Series 1996 1997 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 2500 Series Year: 1997 Codes Chassis Code: BR/BE 👋 Introduction Market Position Segment: Heavy-duty pickup truck Competitive Analysis Competitors: Ford F-250 Super Duty, Chevrolet Silverado 2500 Key Features Durability: Renowned for its robust construction and towing/hauling capabilities Powertrain Options: Offered with potent V8 gasoline and inline-6 diesel engines for demanding applications Capability: Designed for work, towing, and off-road use 📋 Manual Details Coverage Areas Models Covered: Dodge Ram 2500 Series (all trims and configurations) Page Count Estimated Page Count: 1000+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, engine control systems (ECM/PCM) Transmission: Manual transmission (NV4500), Automatic transmission (46RE, 47RE) diagnostics, repair, overhaul, fluid service Drivetrain: Four-wheel drive system (transfer case, front axle, rear axle), driveshafts, U-joints Brakes: Front disc brakes, rear drum brakes (standard), ABS system diagnostics and repair Suspension: Front suspension (leaf springs), rear suspension (leaf springs), steering system, alignment specifications Electrical: 12-volt electrical system, battery, charging system, starting system, lighting, instrument cluster, power accessories, wiring diagrams HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system operation and service Body: Exterior body panels, interior trim, doors, glass, bumpers, chassis and frame Procedures Included Maintenance: Routine maintenance procedures, lubrication points, filter replacement, fluid changes Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based troubleshooting Repair: Step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, brake component replacement, suspension work Specifications: Torque specifications, clearances, tolerances, alignment angles, diagnostic data Technical Depth Depth: Comprehensive, covering from basic maintenance to advanced diagnostics and complete overhauls 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text Print Quality Resolution: High-resolution, suitable for printing Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code 1: 5.9L Magnum V8 (360 cu in) Engine Code 2: 5.2L Magnum V8 (318 cu in) Engine Code 3: 8.0L Magnum V10 (488 cu in) Engine Code 4: 5.9L Cummins Turbo Diesel (I6) Performance V8 360 Hp: 230 hp @ 4000 rpm (approx.) V8 360 Torque: 330 lb-ft @ 3200 rpm (approx.) Cummins Hp: 180 hp @ 2500 rpm (approx.) Cummins Torque: 420 lb-ft @ 1600 rpm (approx.) Fuel System V8 Fuel System: Multi-port Fuel Injection (MPI) Diesel Fuel System: Bosch Rotary Injection Pump, Indirect Injection 🔧 Transmission Standard Standard Transmission Gas: 5-Speed Manual (NV4500) Standard Transmission Diesel: 5-Speed Manual (NV4500) Optional Optional Transmission Gas: 4-Speed Automatic (46RE) Optional Transmission Diesel: 4-Speed Automatic (47RE) Features Overdrive: All transmissions feature overdrive gearing for highway efficiency Transfer Case: Part-time 4WD system with floor-mounted shifter or electronic shift-on-the-fly (ESOF) 📐 Dimensions Exterior Wheelbase Regular Cab: 134.7 inches Wheelbase Extended Cab: 160.5 inches Weights Gvwr Gas: 8,800 - 9,500 lbs (approx.) Gvwr Diesel: 9,000 - 9,500 lbs (approx.) Towing Capacity Max: Up to 13,000 lbs (when properly equipped) Payload Capacity Max: Up to 4,000 lbs (when properly equipped) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: Not directly rated for this generation, but inherently stable due to heavy-duty chassis. Active Features ABS: Anti-lock Braking System (ABS) available on all wheels Passive Features Airbags: Driver and passenger airbags Seatbelts: Three-point front seat belts 💡 Technology Features Infotainment Audio System: AM/FM radio with cassette player and optional CD player Speakers: 4 or 6 speaker configurations Driver Assistance Cruise Control: Standard or optional cruise control Connectivity Auxiliary Input: Not standard; aftermarket solutions available 🔧 Maintenance Service Intervals Oil Change Interval Gas: Every 3,000 - 5,000 miles or 6 months (depending on severe/normal use) Oil Change Interval Diesel: Every 7,500 miles or 6 months (using quality diesel-specific oil) Transmission Fluid Change: Every 30,000 - 60,000 miles (refer to manual for specific fluid type and interval) Fluid Specifications Engine Oil Spec Gas: API SG/SH rated, SAE 10W-30 or 10W-40 (consult manual for specific viscosity based on temperature) Engine Oil Spec Diesel: API CH-4 or CI-4 rated, SAE 15W-40 (for Cummins 5.9L) Coolant Type: Ethylene Glycol based, Mopar HOAT (Hybrid Organic Acid Technology) or equivalent Known Issues Diesel Injection Pump: Potential wear on the Bosch rotary injection pump seals Rust: Common rust issues on fenders, rocker panels, and cab corners, especially in salt-belt regions Transmission Clutch: NV4500 clutch wear, potential 5th gear nut issue if not updated Heater Core: Premature heater core failure leading to coolant leaks inside the cabin 📚 Vehicle History Brand Heritage Dodge Trucks: Dodge has a long-standing reputation for producing durable and capable trucks. Model Evolution Third Generation Ram: This generation (1994-2001) marked a significant redesign with a bolder, more aerodynamic styling and improved chassis. Production Manufacturing Plant: Saltillo, Mexico; Warren, Michigan, USA 🏆 Awards & Recognition Recognitions Cummins Diesel Reputation: The 5.9L Cummins Turbo Diesel engine is highly regarded for its durability and longevity....
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Dodge Ram 2500 Series 1996 1997 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram 2500 Series
Year:
1997
Codes
Chassis Code:
BR/BE
👋 Introduction
Market Position
Segment:
Heavy-duty pickup truck
Competitive Analysis
Competitors:
Ford F-250 Super Duty, Chevrolet Silverado 2500
Key Features
Durability:
Renowned for its robust construction and towing/hauling capabilities
Powertrain Options:
Offered with potent V8 gasoline and inline-6 diesel engines for demanding applications
Capability:
Designed for work, towing, and off-road use
📋 Manual Details
Coverage Areas
Models Covered:
Dodge Ram 2500 Series (all trims and configurations)
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, engine control systems (ECM/PCM)
Transmission:
Manual transmission (NV4500), Automatic transmission (46RE, 47RE) diagnostics, repair, overhaul, fluid service
Drivetrain:
Four-wheel drive system (transfer case, front axle, rear axle), driveshafts, U-joints
Brakes:
Front disc brakes, rear drum brakes (standard), ABS system diagnostics and repair
Suspension:
Front suspension (leaf springs), rear suspension (leaf springs), steering system, alignment specifications
Electrical:
12-volt electrical system, battery, charging system, starting system, lighting, instrument cluster, power accessories, wiring diagrams
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system operation and service
Body:
Exterior body panels, interior trim, doors, glass, bumpers, chassis and frame
Procedures Included
Maintenance:
Routine maintenance procedures, lubrication points, filter replacement, fluid changes
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based troubleshooting
Repair:
Step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, brake component replacement, suspension work
Specifications:
Torque specifications, clearances, tolerances, alignment angles, diagnostic data
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to advanced diagnostics and complete overhauls
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text
Print Quality
Resolution:
High-resolution, suitable for printing
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
5.9L Magnum V8 (360 cu in)
Engine Code 2:
5.2L Magnum V8 (318 cu in)
Engine Code 3:
8.0L Magnum V10 (488 cu in)
Engine Code 4:
5.9L Cummins Turbo Diesel (I6)
Performance
V8 360 Hp:
230 hp @ 4000 rpm (approx.)
V8 360 Torque:
330 lb-ft @ 3200 rpm (approx.)
Cummins Hp:
180 hp @ 2500 rpm (approx.)
Cummins Torque:
420 lb-ft @ 1600 rpm (approx.)
Fuel System
V8 Fuel System:
Multi-port Fuel Injection (MPI)
Diesel Fuel System:
Bosch Rotary Injection Pump, Indirect Injection
🔧 Transmission
Standard
Standard Transmission Gas:
5-Speed Manual (NV4500)
Standard Transmission Diesel:
5-Speed Manual (NV4500)
Optional
Optional Transmission Gas:
4-Speed Automatic (46RE)
Optional Transmission Diesel:
4-Speed Automatic (47RE)
Features
Overdrive:
All transmissions feature overdrive gearing for highway efficiency
Transfer Case:
Part-time 4WD system with floor-mounted shifter or electronic shift-on-the-fly (ESOF)
📐 Dimensions
Exterior
Wheelbase Regular Cab:
134.7 inches
Wheelbase Extended Cab:
160.5 inches
Weights
Gvwr Gas:
8,800 - 9,500 lbs (approx.)
Gvwr Diesel:
9,000 - 9,500 lbs (approx.)
Towing Capacity Max:
Up to 13,000 lbs (when properly equipped)
Payload Capacity Max:
Up to 4,000 lbs (when properly equipped)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
Not directly rated for this generation, but inherently stable due to heavy-duty chassis.
Active Features
ABS:
Anti-lock Braking System (ABS) available on all wheels
Passive Features
Airbags:
Driver and passenger airbags
Seatbelts:
Three-point front seat belts
💡 Technology Features
Infotainment
Audio System:
AM/FM radio with cassette player and optional CD player
Speakers:
4 or 6 speaker configurations
Driver Assistance
Cruise Control:
Standard or optional cruise control
Connectivity
Auxiliary Input:
Not standard; aftermarket solutions available
🔧 Maintenance
Service Intervals
Oil Change Interval Gas:
Every 3,000 - 5,000 miles or 6 months (depending on severe/normal use)
Oil Change Interval Diesel:
Every 7,500 miles or 6 months (using quality diesel-specific oil)
Transmission Fluid Change:
Every 30,000 - 60,000 miles (refer to manual for specific fluid type and interval)
Fluid Specifications
Engine Oil Spec Gas:
API SG/SH rated, SAE 10W-30 or 10W-40 (consult manual for specific viscosity based on temperature)
Engine Oil Spec Diesel:
API CH-4 or CI-4 rated, SAE 15W-40 (for Cummins 5.9L)
Coolant Type:
Ethylene Glycol based, Mopar HOAT (Hybrid Organic Acid Technology) or equivalent
Known Issues
Diesel Injection Pump:
Potential wear on the Bosch rotary injection pump seals
Rust:
Common rust issues on fenders, rocker panels, and cab corners, especially in salt-belt regions
Transmission Clutch:
NV4500 clutch wear, potential 5th gear nut issue if not updated
Heater Core:
Premature heater core failure leading to coolant leaks inside the cabin
📚 Vehicle History
Brand Heritage
Dodge Trucks:
Dodge has a long-standing reputation for producing durable and capable trucks.
Model Evolution
Third Generation Ram:
This generation (1994-2001) marked a significant redesign with a bolder, more aerodynamic styling and improved chassis.
Production
Manufacturing Plant:
Saltillo, Mexico; Warren, Michigan, USA
🏆 Awards & Recognition
Recognitions
Cummins Diesel Reputation:
The 5.9L Cummins Turbo Diesel engine is highly regarded for its durability and longevity.
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