Dodge Ram 3500 1995 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram 3500 Year: 1995 Codes Chassis Code: 2nd Generation Ram (BR/BE) 👋 Introduction Market Position Vehicle Segment: Heavy-duty pickup truck Target Audience: Commercial users, fleet owners, serious DIY mechanics, owners seeking in-depth maintenance and repair knowledge. Competitive Analysis Competitors 1995: Ford F-Series Super Duty, Chevrolet Silverado HD Key Features Vehicle Durability: Known for robust construction and heavy-duty capabilities, designed for towing and hauling. Manual Utility: Provides the necessary technical information to maintain and repair the vehicle to manufacturer specifications, crucial for longevity and performance. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: PDF Page Count Estimated Page Count: Extensive (typically 1000+ pages for comprehensive workshop manuals of this era) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel, ignition, emission control, engine management, turbocharging (if applicable) Transmission Drivetrain: Manual transmission, automatic transmission, transfer case, driveshafts, axles, differentials Brakes: Hydraulic brake system, parking brake, ABS (if equipped) Suspension Steering: Front suspension, rear suspension, steering gear, power steering system Electrical Electronics: Battery, charging system, starting system, lighting, instruments, body electrical, power distribution, engine control modules (ECM/PCM), powertrain control modules (PCM) Body Chassis: Body construction, exterior trim, interior trim, HVAC system, doors, windows, seats, frame, bumpers Diagnostics Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based diagnostics, wiring diagrams, connector pinouts Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes Repair Overhaul: Engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement, starter motor replacement, alternator replacement Diagnostics: Troubleshooting engine performance issues, diagnosing electrical faults, identifying causes of braking problems Specifications Tolerances: Torque specifications for fasteners, engine bearing clearances, valve lash settings, brake pad thickness, alignment specifications Technical Depth Depth: Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers detailed component removal, disassembly, inspection, repair, reassembly, and installation. 📊 Manual Specifications File Format PDF Quality: Likely scanned from original print, quality can vary but should be legible. Searchable text functionality is highly desirable. Print Quality Original Print Quality: Professional, designed for workshop use with clear diagrams and text. Binding Type Original Binding: Typically bound for durability, often with spiral or section-sewn binding for lay-flat use. Paper Type Original Paper Type: Durable paper stock suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Options 1995: 5.2L (318 cu in) Magnum V8, 5.9L (360 cu in) Magnum V8, 5.9L (359 cu in) Cummins Turbo Diesel I6 Performance 5.2L Magnum V8 Horsepower: Approx. 230 hp @ 4000 rpm 5.2L Magnum V8 Torque: Approx. 295 lb-ft @ 3200 rpm 5.9L Magnum V8 Horsepower: Approx. 245 hp @ 4000 rpm 5.9L Magnum V8 Torque: Approx. 330 lb-ft @ 3200 rpm 5.9L Cummins Turbo Diesel Horsepower: Approx. 160 hp @ 2500 rpm 5.9L Cummins Turbo Diesel Torque: Approx. 400 lb-ft @ 1600 rpm Fuel System Gasoline Engines Fuel Delivery: Electronic Fuel Injection (EFI) Diesel Engine Fuel Delivery: Inline Injection Pump (VE or P7100 depending on specific build) 🔧 Transmission Standard Standard Transmission Gas: 5-Speed Manual (NV4500) Optional Optional Transmission Gas: 4-Speed Automatic (47RH) Transmission Diesel: 5-Speed Manual (NV4500), 4-Speed Automatic (47RH) Features 47Rh Transmission Features: Electronically controlled, overdrive Nv4500 Transmission Features: Heavy-duty, robust design with granny gear 📐 Dimensions Exterior Wheelbase Options: Various (e.g., 130.2" for regular cab, 154.7" for club cab) Body Styles: Regular Cab, Club Cab Weights Gvwr Range: 8,800 - 10,000+ lbs (depending on configuration) Curb Weight: Varies significantly by configuration (e.g., 5000-7000+ lbs) 🛡️ Safety Features Ratings NHTSA Ratings 1995: Information for 1995 heavy-duty trucks is less standardized than passenger cars. Focus is on structural integrity and load capacity. Active Features Active Safety Features: Rear-wheel Anti-lock Brakes (RWAL) standard on most models, 4-wheel ABS optional/standard on higher trims or specific configurations. Passive Features Passive Safety Features: High-strength steel frame, reinforced cab structure, three-point seat belts 💡 Technology Features Infotainment Infotainment System 1995: Basic AM/FM radio with cassette player, optional CD player available on higher trims. Driver Assistance Driver Assistance Features: Limited by era; focus on ABS and potentially cruise control. No advanced electronic driver aids. Connectivity Connectivity Options: None (pre-smartphone era, basic power outlets) 🔧 Maintenance Service Intervals Oil Change Interval Gas: Typically every 3,000-5,000 miles or 3-6 months (refer to manual for specific conditions) Oil Change Interval Diesel: Typically every 3,000-7,500 miles or 6 months (diesel specific oil and filter) Transmission Fluid Change: Automatic: 30,000-60,000 miles. Manual: Inspect periodically, change as needed or at higher mileage intervals (e.g., 100,000 miles). Fluid Specifications Engine Oil Gas: API SG or SH, SAE 10W-30 or 10W-40 (check manual for ambient temperature recommendations) Engine Oil Diesel: API CG-4 or CH-4, SAE 15W-40 (diesel specific) Coolant: Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water. Mopar OAT or HOAT recommended. Transmission Fluid Auto: ATF+3 (Chrysler spec) or equivalent Transmission Fluid Manual: NV4500 requires specific manual transmission fluid (e.g., Dexron II/III or...
Front suspension, rear suspension, steering gear, power steering system
Electrical Electronics:
Battery, charging system, starting system, lighting, instruments, body electrical, power distribution, engine control modules (ECM/PCM), powertrain control modules (PCM)
Torque specifications for fasteners, engine bearing clearances, valve lash settings, brake pad thickness, alignment specifications
Technical Depth
Depth:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers detailed component removal, disassembly, inspection, repair, reassembly, and installation.
📊 Manual Specifications
File Format
PDF Quality:
Likely scanned from original print, quality can vary but should be legible. Searchable text functionality is highly desirable.
Print Quality
Original Print Quality:
Professional, designed for workshop use with clear diagrams and text.
Binding Type
Original Binding:
Typically bound for durability, often with spiral or section-sewn binding for lay-flat use.
Paper Type
Original Paper Type:
Durable paper stock suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Options 1995:
5.2L (318 cu in) Magnum V8, 5.9L (360 cu in) Magnum V8, 5.9L (359 cu in) Cummins Turbo Diesel I6
Performance
5.2L Magnum V8 Horsepower:
Approx. 230 hp @ 4000 rpm
5.2L Magnum V8 Torque:
Approx. 295 lb-ft @ 3200 rpm
5.9L Magnum V8 Horsepower:
Approx. 245 hp @ 4000 rpm
5.9L Magnum V8 Torque:
Approx. 330 lb-ft @ 3200 rpm
5.9L Cummins Turbo Diesel Horsepower:
Approx. 160 hp @ 2500 rpm
5.9L Cummins Turbo Diesel Torque:
Approx. 400 lb-ft @ 1600 rpm
Fuel System
Gasoline Engines Fuel Delivery:
Electronic Fuel Injection (EFI)
Diesel Engine Fuel Delivery:
Inline Injection Pump (VE or P7100 depending on specific build)
🔧 Transmission
Standard
Standard Transmission Gas:
5-Speed Manual (NV4500)
Optional
Optional Transmission Gas:
4-Speed Automatic (47RH)
Transmission Diesel:
5-Speed Manual (NV4500), 4-Speed Automatic (47RH)
Features
47Rh Transmission Features:
Electronically controlled, overdrive
Nv4500 Transmission Features:
Heavy-duty, robust design with granny gear
📐 Dimensions
Exterior
Wheelbase Options:
Various (e.g., 130.2" for regular cab, 154.7" for club cab)
Body Styles:
Regular Cab, Club Cab
Weights
Gvwr Range:
8,800 - 10,000+ lbs (depending on configuration)
Curb Weight:
Varies significantly by configuration (e.g., 5000-7000+ lbs)
🛡️ Safety Features
Ratings
NHTSA Ratings 1995:
Information for 1995 heavy-duty trucks is less standardized than passenger cars. Focus is on structural integrity and load capacity.
Active Features
Active Safety Features:
Rear-wheel Anti-lock Brakes (RWAL) standard on most models, 4-wheel ABS optional/standard on higher trims or specific configurations.
Basic AM/FM radio with cassette player, optional CD player available on higher trims.
Driver Assistance
Driver Assistance Features:
Limited by era; focus on ABS and potentially cruise control. No advanced electronic driver aids.
Connectivity
Connectivity Options:
None (pre-smartphone era, basic power outlets)
🔧 Maintenance
Service Intervals
Oil Change Interval Gas:
Typically every 3,000-5,000 miles or 3-6 months (refer to manual for specific conditions)
Oil Change Interval Diesel:
Typically every 3,000-7,500 miles or 6 months (diesel specific oil and filter)
Transmission Fluid Change:
Automatic: 30,000-60,000 miles. Manual: Inspect periodically, change as needed or at higher mileage intervals (e.g., 100,000 miles).
Fluid Specifications
Engine Oil Gas:
API SG or SH, SAE 10W-30 or 10W-40 (check manual for ambient temperature recommendations)
Engine Oil Diesel:
API CG-4 or CH-4, SAE 15W-40 (diesel specific)
Coolant:
Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water. Mopar OAT or HOAT recommended.
Transmission Fluid Auto:
ATF+3 (Chrysler spec) or equivalent
Transmission Fluid Manual:
NV4500 requires specific manual transmission fluid (e.g., Dexron II/III or equivalent approved by Dodge, or a dedicated synthetic manual transmission fluid).
Differential Fluid:
API GL-5, SAE 80W-90 or 75W-140 (depending on application and temperature). Limited-slip differentials require friction modifier.
Known Issues
Common Issues Gas Engines:
Plenum gasket leaks (4.7L V8 not applicable in 1995 but mention for context of later models if relevant to general perception), distributor issues, minor oil leaks.
Common Issues Diesel Engines:
Injector pump issues (VE), potential for head gasket failure under extreme load if not properly maintained, clutch wear (manual transmission).
Common Issues Transmission:
NV4500: 5th gear nut issue (recall often addressed), potential for clutch wear. 47RH: Torque converter lock-up issues, solenoid failures.
Common Issues Suspension Steering:
Ball joint wear, tie rod end wear, steering box looseness, leaf spring fatigue.
📚 Vehicle History
Brand Heritage
Dodge Truck History:
Dodge has a long-standing reputation for building rugged and capable trucks, dating back to the 1930s.
Model Evolution
2Nd Gen Ram Introduction:
The 2nd generation Ram (1994-2001) marked a significant redesign with a more aerodynamic and aggressive styling, becoming a major success.
Production
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan; St. Louis, Missouri
🏆 Awards & Recognition
Recognitions
Truck Of The Year Awards:
The Dodge Ram series received numerous 'Truck of the Year' awards from various automotive publications during this generation, highlighting its competitive standing.
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