Dodge Ram 2500 1995 Workshop Service Manual for Repair
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🏷️ Basic Information Identification Make: Dodge Model: Ram 2500 Year: 1995 Codes Platform: BR/BE Ram Pickup 👋 Introduction Market Position Market Segment: Heavy-duty pickup truck, positioned for commercial use, towing, and hauling applications. Competitive Analysis Competitors: Ford F-250/F-350 Super Duty, Chevrolet Silverado 2500/3500, GMC Sierra 2500/3500. Key Features Vehicle Attributes: Robust chassis, powerful engine options, significant towing and payload capacity, durable construction. Manual Value Proposition Benefit To Owner: Enables owners to perform accurate diagnostics, repairs, and maintenance, reducing reliance on expensive dealership services and ensuring longevity of the vehicle. 📋 Manual Details Coverage Areas Systems Covered: Engine, Transmission (Manual & Automatic), Drivetrain, Suspension, Steering, Brakes, HVAC, Electrical Systems, Body & Frame, Fuel System, Cooling System, Exhaust System, Emissions Control, Diagnostics, Troubleshooting, Wiring Diagrams, Specifications. Troubleshooting Charts: Includes detailed troubleshooting flowcharts for common drivability and electrical issues. Page Count Total Pages: 1754 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Complete overhaul, diagnostics, repair procedures for all engine variants, including cooling, lubrication, fuel delivery, ignition, and emission control systems. Transmission Systems: Detailed repair and overhaul for manual transmissions (e.g., NV4500) and automatic transmissions (e.g., 46RH, 47RH), including torque converter and transfer case (NV241). Drivetrain And Suspension: Front and rear axle repair, differential service, driveshaft maintenance, U-joints, suspension components (leaf springs, shocks), steering system (power steering pump, steering gear). Brake Systems: Front and rear brake system service, including disc and drum brake components, hydraulic system, parking brake, and ABS troubleshooting (if equipped). Electrical Systems: Comprehensive coverage of starting, charging, lighting, ignition, instrument cluster, power windows, power locks, and other electrical accessories, including detailed wiring diagrams. HVAC And Body: Air conditioning system service, heater core replacement, body panel repair, door mechanisms, interior trim, and exterior lighting. Procedures Included Routine Maintenance: Oil change intervals, filter replacements, tire rotation, fluid checks and changes, belt inspection and replacement, spark plug replacement, air filter service. Diagnostic Procedures: Step-by-step troubleshooting guides for common drivability issues, electrical faults, and mechanical problems. Includes diagnostic trouble codes (DTCs) for OBD-I and early OBD-II systems. Repair And Rebuild: Detailed instructions for component removal, installation, and complete rebuilding of major systems like engines, transmissions, differentials, and brake assemblies. Special Tools: Identification and usage of specialized tools required for specific repair procedures, ensuring accuracy and efficiency. Alignment And Wheel Service: Specifications and procedures for front-end alignment, wheel bearing service, and tire pressure recommendations. Body And Interior Repair: Instructions for body panel removal and installation, interior trim component replacement, and glass replacement. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission overhauls, suitable for professional technicians and experienced DIY enthusiasts. Wiring Diagrams: Comprehensive, often full-page, wiring diagrams for all electrical systems, color-coded for clarity. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable, enabling quick access to specific information. Organization: Structured by system, with chapters dedicated to specific repair procedures, specifications, and diagnostic information. Print Quality Quality: Digital reproduction quality; content clarity dependent on source scan. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Option 1: 5.9L (360 cu in) Magnum V8 (LA series) Engine Code 1: 360 Magnum Displacement 1: 5.9 Liters (360 cubic inches) Configuration 1: V8 Horsepower 1: Approx. 230-245 HP (varies by specific tuning) Torque 1: Approx. 320-335 lb-ft (varies by specific tuning) Fuel System 1: Sequential Multi-Port Fuel Injection (MPI) Bore Stroke 1: 4.02 in x 3.58 in (5.9L Magnum) Optional Engine Engine Option 2: 5.2L (318 cu in) Magnum V8 (LA series) Engine Code 2: 318 Magnum Displacement 2: 5.2 Liters (318 cubic inches) Configuration 2: V8 Horsepower 2: Approx. 220-230 HP (varies by specific tuning) Torque 2: Approx. 290-300 lb-ft (varies by specific tuning) Fuel System 2: Sequential Multi-Port Fuel Injection (MPI) Engine Option 3: 8.0L (488 cu in) Magnum V10 (VIPER derived) Engine Code 3: 8.0L V10 Displacement 3: 8.0 Liters (488 cubic inches) Configuration 3: V10 Horsepower 3: Approx. 300 HP Torque 3: Approx. 450 lb-ft Fuel System 3: Sequential Multi-Port Fuel Injection (MPI) Engine Option 4: 5.9L (359 cu in) Cummins Turbo Diesel I6 Engine Code 4: Cummins 6BT Displacement 4: 5.9 Liters (359 cubic inches) Configuration 4: Inline 6-Cylinder Turbo Diesel Horsepower 4: Approx. 160-175 HP (depending on specific turbo and tuning) Torque 4: Approx. 400-420 lb-ft (depending on specific turbo and tuning) Fuel System 4: Inline Injection Pump (Bosch VE, early models), Bosch P7100 (later models) Bore Stroke 4: 4.02 in x 4.72 in (5.9L Cummins) Performance Fuel Type: Gasoline (MPI), Diesel (Turbo Diesel) Fuel System Ignition System: Distributor-based with coil packs for gasoline engines. 🔧 Transmission Standard Transmission Option 1: 5-Speed Manual Transmission (NV4500) Optional Transmission Option 2: 4-Speed Automatic Transmission (46RH / 47RH) Features Transfer Case: New Process NP241 (part-time, 2-speed, 4WD)...
Enables owners to perform accurate diagnostics, repairs, and maintenance, reducing reliance on expensive dealership services and ensuring longevity of the vehicle.
Includes detailed troubleshooting flowcharts for common drivability and electrical issues.
Page Count
Total Pages:
1754
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Complete overhaul, diagnostics, repair procedures for all engine variants, including cooling, lubrication, fuel delivery, ignition, and emission control systems.
Transmission Systems:
Detailed repair and overhaul for manual transmissions (e.g., NV4500) and automatic transmissions (e.g., 46RH, 47RH), including torque converter and transfer case (NV241).
Drivetrain And Suspension:
Front and rear axle repair, differential service, driveshaft maintenance, U-joints, suspension components (leaf springs, shocks), steering system (power steering pump, steering gear).
Brake Systems:
Front and rear brake system service, including disc and drum brake components, hydraulic system, parking brake, and ABS troubleshooting (if equipped).
Electrical Systems:
Comprehensive coverage of starting, charging, lighting, ignition, instrument cluster, power windows, power locks, and other electrical accessories, including detailed wiring diagrams.
HVAC And Body:
Air conditioning system service, heater core replacement, body panel repair, door mechanisms, interior trim, and exterior lighting.
Procedures Included
Routine Maintenance:
Oil change intervals, filter replacements, tire rotation, fluid checks and changes, belt inspection and replacement, spark plug replacement, air filter service.
Diagnostic Procedures:
Step-by-step troubleshooting guides for common drivability issues, electrical faults, and mechanical problems. Includes diagnostic trouble codes (DTCs) for OBD-I and early OBD-II systems.
Repair And Rebuild:
Detailed instructions for component removal, installation, and complete rebuilding of major systems like engines, transmissions, differentials, and brake assemblies.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures, ensuring accuracy and efficiency.
Alignment And Wheel Service:
Specifications and procedures for front-end alignment, wheel bearing service, and tire pressure recommendations.
Body And Interior Repair:
Instructions for body panel removal and installation, interior trim component replacement, and glass replacement.
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine and transmission overhauls, suitable for professional technicians and experienced DIY enthusiasts.
Wiring Diagrams:
Comprehensive, often full-page, wiring diagrams for all electrical systems, color-coded for clarity.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable, enabling quick access to specific information.
Organization:
Structured by system, with chapters dedicated to specific repair procedures, specifications, and diagnostic information.
Print Quality
Quality:
Digital reproduction quality; content clarity dependent on source scan.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Option 1:
5.9L (360 cu in) Magnum V8 (LA series)
Engine Code 1:
360 Magnum
Displacement 1:
5.9 Liters (360 cubic inches)
Configuration 1:
V8
Horsepower 1:
Approx. 230-245 HP (varies by specific tuning)
Torque 1:
Approx. 320-335 lb-ft (varies by specific tuning)
Fuel System 1:
Sequential Multi-Port Fuel Injection (MPI)
Bore Stroke 1:
4.02 in x 3.58 in (5.9L Magnum)
Optional Engine
Engine Option 2:
5.2L (318 cu in) Magnum V8 (LA series)
Engine Code 2:
318 Magnum
Displacement 2:
5.2 Liters (318 cubic inches)
Configuration 2:
V8
Horsepower 2:
Approx. 220-230 HP (varies by specific tuning)
Torque 2:
Approx. 290-300 lb-ft (varies by specific tuning)
Fuel System 2:
Sequential Multi-Port Fuel Injection (MPI)
Engine Option 3:
8.0L (488 cu in) Magnum V10 (VIPER derived)
Engine Code 3:
8.0L V10
Displacement 3:
8.0 Liters (488 cubic inches)
Configuration 3:
V10
Horsepower 3:
Approx. 300 HP
Torque 3:
Approx. 450 lb-ft
Fuel System 3:
Sequential Multi-Port Fuel Injection (MPI)
Engine Option 4:
5.9L (359 cu in) Cummins Turbo Diesel I6
Engine Code 4:
Cummins 6BT
Displacement 4:
5.9 Liters (359 cubic inches)
Configuration 4:
Inline 6-Cylinder Turbo Diesel
Horsepower 4:
Approx. 160-175 HP (depending on specific turbo and tuning)
Torque 4:
Approx. 400-420 lb-ft (depending on specific turbo and tuning)
Fuel System 4:
Inline Injection Pump (Bosch VE, early models), Bosch P7100 (later models)
Bore Stroke 4:
4.02 in x 4.72 in (5.9L Cummins)
Performance
Fuel Type:
Gasoline (MPI), Diesel (Turbo Diesel)
Fuel System
Ignition System:
Distributor-based with coil packs for gasoline engines.
🔧 Transmission
Standard
Transmission Option 1:
5-Speed Manual Transmission (NV4500)
Optional
Transmission Option 2:
4-Speed Automatic Transmission (46RH / 47RH)
Features
Transfer Case:
New Process NP241 (part-time, 2-speed, 4WD)
Overdrive Gears:
Standard on most transmissions, particularly the automatic and the 5-speed manual (5th gear).
Varies by cab and bed configuration (e.g., approx. 230-250 inches)
Height:
Varies by configuration (approx. 73-77 inches)
Width Without Mirrors:
Approx. 79.1 inches
Weights
Curb Weight:
Varies significantly by engine, drivetrain, and cab configuration (e.g., 5,500 - 7,500 lbs).
Gross Vehicle Weight Rating Gvw:
Typically around 8,800 lbs to 9,600 lbs, depending on configuration.
Towing Capacity:
Up to 14,000+ lbs with appropriate configuration (hitch, axle ratio, engine).
Payload Capacity:
Up to 4,000+ lbs, depending on configuration.
🛡️ Safety Features
Ratings
NHTSA Ratings:
Ratings for this era are generally not directly comparable to modern standards. Focus was on structural integrity and basic safety features.
Active Features
Braking System:
Power-assisted front disc brakes and rear drum brakes. Optional Anti-lock Braking System (ABS) on rear wheels or all wheels depending on configuration.
Passive Features
Seat Belts:
Three-point seat belts for front occupants. Lap belts for rear occupants.
Airbags:
Driver-side airbag standard.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette stereo. Optional CD player. Basic speaker configurations.
Driver Assistance
ABS:
Available Anti-lock Braking System (ABS), typically on rear wheels.
Connectivity
Cruise Control:
Optional electronic cruise control.
Gauges
Instrument Panel:
Standard analog gauges for speedometer, tachometer (optional), fuel, oil pressure, coolant temperature, and voltmeter.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-5,000 miles for gasoline engines, 5,000-7,500 miles for diesel engines, depending on oil type and driving conditions.
Transmission Fluid Change:
Automatic: 30,000-50,000 miles. Manual: Inspect periodically, change if signs of wear or contamination.
Coolant Flush:
Every 30,000-50,000 miles or 2-3 years.
Fluid Specifications
Engine Oil Gasoline:
API SG or SH, SAE 10W-30 or 10W-40 (check owner's manual for specific temperature ranges).
Engine Oil Diesel:
API CD or CE, SAE 15W-40 (preferred for Cummins).
Transmission Fluid Automatic:
Chrysler ATF+3 or equivalent.
Transmission Fluid Manual:
NV4500: GL-4 75W-90 gear oil.
Coolant:
Ethylene Glycol based antifreeze, 50/50 mix with distilled water.
Brake Fluid:
DOT 3.
Power Steering Fluid:
ATF+3 or equivalent.
Known Issues
Common Complaints Gasoline:
Intake manifold gasket leaks, distributor issues, power steering pump wear, potential for plenum gasket failure (on some V8s).
Common Complaints Diesel:
VP44 injection pump failures (later models, less common on '95), injector line leaks, front gear cover seal leaks, and potential for clutch wear on manual transmissions.
General Issues:
Rust on cab corners, bed sides, and frame; HVAC blower motor resistor failure; power window motor issues; dashboard cracks.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history in the pickup truck market, with the 'Ram' nameplate becoming synonymous with heavy-duty capability and reliability.
Model Evolution
Third Generation Ram:
The 1995 model year falls within the second generation of the Dodge Ram pickup (1994-2001), known for its significant redesign featuring a bolder grille and more aggressive styling.
Production
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan; St. Louis, Missouri.
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
While the 1995 model year itself may not have a specific 'Truck of the Year' award, the Dodge Ram platform consistently received praise for its bold styling and capability in the heavy-duty segment.