Dodge Ram 1996 Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Year: 1996 Series: Second Generation (BR/BE) Codes Platform Code: BR/BE 👋 Introduction Market Position Segment: Full-size pickup truck Target Audience: Professional automotive technicians, dealership service departments, DIY mechanics seeking in-depth repair knowledge. Competitive Analysis Competitors: Ford F-Series, Chevrolet Silverado/GMC Sierra. Key Features Manual Value Proposition: Provides critical, often proprietary, information necessary for accurate diagnosis and repair of the 1996 Dodge Ram, enabling efficient and correct maintenance. Vehicle Design Philosophy: Built for heavy-duty use, towing, and hauling, emphasizing robustness and functionality. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service and repair information for the 1996 Dodge Ram. Specific Systems Covered: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Fuel System, Exhaust System, Cooling System, Electrical System, Climate Control, Body and Frame, Interior, Emissions Control, Troubleshooting, Specifications, Torque Values, Maintenance. Page Count Estimated Page Count: Extensive, typically 1000+ pages for full factory service manuals. Manual Type Type: Factory Authorized Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed diagnosis, repair, and overhaul procedures for all engine variants, including disassembly, assembly, component testing, and specifications. Engine Performance: Ignition system timing and diagnosis, fuel injection system operation and troubleshooting, emission control system diagnosis. Transmission Manual: Service and repair for NV3500 and NV4500 manual transmissions, including clutch service, gear train inspection, and rebuild procedures. Transmission Automatic: Service and repair for 46RE and 47RE automatic transmissions, including hydraulic control, torque converter, and rebuild procedures. Drivetrain: Front and rear axle service, differential overhaul, driveshaft and U-joint repair, four-wheel-drive system operation and service. Suspension Front: Twin I-beam independent front suspension diagnosis and repair, ball joint replacement, shock absorber service, spring replacement. Suspension Rear: Leaf spring suspension service, shackle inspection and replacement, shock absorber service. Steering: Power steering system diagnosis and repair, steering gear overhaul, steering linkage inspection and replacement. Brakes Front: Disc brake rotor and pad replacement, caliper service, brake line inspection and repair. Brakes Rear: Drum brake shoe adjustment and replacement, wheel cylinder service, brake drum inspection. Brake System General: ABS system diagnosis (if equipped), master cylinder and brake booster service, hydraulic system bleeding. Fuel System: Fuel pump diagnosis and replacement, fuel injector service, fuel tank inspection and service, fuel filter replacement. Exhaust System: Muffler, catalytic converter, and exhaust pipe replacement, hanger and gasket service. Cooling System: Radiator and coolant hose replacement, water pump service, thermostat replacement, cooling fan diagnosis. Electrical System General: Battery and charging system testing and repair, starter motor service, alternator service. Lighting System: Headlight, taillight, and interior lighting diagnosis and bulb replacement. Instrument Panel: Gauges, warning lights, and indicator functions diagnosis and repair. Climate Control HVAC: Air conditioning system service, heater core replacement, blower motor diagnosis, climate control panel repair. Body And Frame: Door, hood, and tailgate adjustment and repair, window regulator service, body panel alignment, frame inspection. Interior Trim: Seat removal and installation, dashboard trim panel repair, headliner service. Emissions Control: Detailed information on emission control devices, diagnosis of related fault codes, and repair procedures. Procedures Included Scheduled Maintenance: Detailed maintenance schedules for various mileage and time intervals, including fluid changes, filter replacements, and inspections. Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon drivability issues, electrical faults, and mechanical problems, often presented in flowcharts. Repair Procedures: Step-by-step instructions for virtually all repair operations, from minor adjustments to complete component overhauls. Diagnostic Trouble Codes DTCs: Explanation of OBD-II codes (for vehicles so equipped), their meanings, and diagnostic paths. Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems, crucial for diagnosing electrical faults. Schematics: Vacuum diagrams, hydraulic schematics, and power flow diagrams for complex systems. Component Replacement: Detailed instructions for removing, installing, and adjusting all major and minor components. Special Tools: Identification and usage instructions for specialized tools required for specific repair procedures. Technical Depth Depth: Factory-level diagnostic and repair procedures suitable for professional technicians, including detailed specifications and tolerances. Diagnostic Focus: In-depth diagnostic strategies, symptom analysis, and pinpoint testing procedures for accurate fault identification. Rebuild Procedures: Complete overhaul instructions for engines, transmissions, and other major mechanical components, including clearances and assembly sequences. 📊 Manual Specifications File Format Format: Searchable PDF Quality: High-resolution scans, clear text and diagrams. Printability: Printable pages for on-the-job reference. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Base Engine: 5.2L (318 cu in) Magnum V8 Engine Code: EGR (for 5.2L) Optional Engines Gasoline V8: 5.9L (360 cu in) Magnum V8 Diesel Inline 6: 5.9L (359 cu in) Cummins Turbo Diesel (B-Series) Performance 5.2L Horsepower: Approx. 230 hp @ 4,000 RPM 5.2L Torque: Approx. 295 lb-ft @ 2,400 RPM 5.9L Magnum V8 Horsepower: Approx. 245 hp @ 4,000 RPM 5.9L Magnum V8 Torque: Approx. 335 lb-ft @ 3,200 RPM 5.9L Cummins Horsepower: Approx. 180 hp @ 2,500 RPM 5.9L Cummins Torque:...

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Type: Truck

Sku: 389847

Collections: ALL Dodge

Availability: In stock

Tags: 1996 Cars Dodge Misc Ram Truck

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Year:

Series:

Second Generation (BR/BE)

Codes

Platform Code:

BR/BE

👋 Introduction

Market Position

Segment:

Full-size pickup truck

Target Audience:

Professional automotive technicians, dealership service departments, DIY mechanics seeking in-depth repair knowledge.

Competitive Analysis

Competitors:

Ford F-Series, Chevrolet Silverado/GMC Sierra.

Key Features

Manual Value Proposition:

Provides critical, often proprietary, information necessary for accurate diagnosis and repair of the 1996 Dodge Ram, enabling efficient and correct maintenance.

Vehicle Design Philosophy:

Built for heavy-duty use, towing, and hauling, emphasizing robustness and functionality.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive service and repair information for the 1996 Dodge Ram.

Specific Systems Covered:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Fuel System, Exhaust System, Cooling System, Electrical System, Climate Control, Body and Frame, Interior, Emissions Control, Troubleshooting, Specifications, Torque Values, Maintenance.

Page Count

Estimated Page Count:

Extensive, typically 1000+ pages for full factory service manuals.

Manual Type

Type:

Factory Authorized Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed diagnosis, repair, and overhaul procedures for all engine variants, including disassembly, assembly, component testing, and specifications.

Engine Performance:

Ignition system timing and diagnosis, fuel injection system operation and troubleshooting, emission control system diagnosis.

Transmission Manual:

Service and repair for NV3500 and NV4500 manual transmissions, including clutch service, gear train inspection, and rebuild procedures.

Transmission Automatic:

Service and repair for 46RE and 47RE automatic transmissions, including hydraulic control, torque converter, and rebuild procedures.

Drivetrain:

Front and rear axle service, differential overhaul, driveshaft and U-joint repair, four-wheel-drive system operation and service.

Suspension Front:

Twin I-beam independent front suspension diagnosis and repair, ball joint replacement, shock absorber service, spring replacement.

Suspension Rear:

Leaf spring suspension service, shackle inspection and replacement, shock absorber service.

Steering:

Power steering system diagnosis and repair, steering gear overhaul, steering linkage inspection and replacement.

Brakes Front:

Disc brake rotor and pad replacement, caliper service, brake line inspection and repair.

Brakes Rear:

Drum brake shoe adjustment and replacement, wheel cylinder service, brake drum inspection.

Brake System General:

ABS system diagnosis (if equipped), master cylinder and brake booster service, hydraulic system bleeding.

Fuel System:

Fuel pump diagnosis and replacement, fuel injector service, fuel tank inspection and service, fuel filter replacement.

Exhaust System:

Muffler, catalytic converter, and exhaust pipe replacement, hanger and gasket service.

Cooling System:

Radiator and coolant hose replacement, water pump service, thermostat replacement, cooling fan diagnosis.

Electrical System General:

Battery and charging system testing and repair, starter motor service, alternator service.

Lighting System:

Headlight, taillight, and interior lighting diagnosis and bulb replacement.

Instrument Panel:

Gauges, warning lights, and indicator functions diagnosis and repair.

Climate Control HVAC:

Air conditioning system service, heater core replacement, blower motor diagnosis, climate control panel repair.

Body And Frame:

Door, hood, and tailgate adjustment and repair, window regulator service, body panel alignment, frame inspection.

Interior Trim:

Seat removal and installation, dashboard trim panel repair, headliner service.

Emissions Control:

Detailed information on emission control devices, diagnosis of related fault codes, and repair procedures.

Procedures Included

Scheduled Maintenance:

Detailed maintenance schedules for various mileage and time intervals, including fluid changes, filter replacements, and inspections.

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon drivability issues, electrical faults, and mechanical problems, often presented in flowcharts.

Repair Procedures:

Step-by-step instructions for virtually all repair operations, from minor adjustments to complete component overhauls.

Diagnostic Trouble Codes DTCs:

Explanation of OBD-II codes (for vehicles so equipped), their meanings, and diagnostic paths.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, crucial for diagnosing electrical faults.

Schematics:

Vacuum diagrams, hydraulic schematics, and power flow diagrams for complex systems.

Component Replacement:

Detailed instructions for removing, installing, and adjusting all major and minor components.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair procedures.

Technical Depth

Depth:

Factory-level diagnostic and repair procedures suitable for professional technicians, including detailed specifications and tolerances.

Diagnostic Focus:

In-depth diagnostic strategies, symptom analysis, and pinpoint testing procedures for accurate fault identification.

Rebuild Procedures:

Complete overhaul instructions for engines, transmissions, and other major mechanical components, including clearances and assembly sequences.

📊 Manual Specifications

File Format

Format:

Searchable PDF

Quality:

High-resolution scans, clear text and diagrams.

Printability:

Printable pages for on-the-job reference.

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Base Engine:

5.2L (318 cu in) Magnum V8

Engine Code:

EGR (for 5.2L)

Optional Engines

Gasoline V8:

5.9L (360 cu in) Magnum V8

Diesel Inline 6:

5.9L (359 cu in) Cummins Turbo Diesel (B-Series)

Performance

5.2L Horsepower:

Approx. 230 hp @ 4,000 RPM

5.2L Torque:

Approx. 295 lb-ft @ 2,400 RPM

5.9L Magnum V8 Horsepower:

Approx. 245 hp @ 4,000 RPM

5.9L Magnum V8 Torque:

Approx. 335 lb-ft @ 3,200 RPM

5.9L Cummins Horsepower:

Approx. 180 hp @ 2,500 RPM

5.9L Cummins Torque:

Approx. 420 lb-ft @ 1,600 RPM

Fuel System

Fuel Delivery Gasoline:

Multi-point Fuel Injection (MPI)

Fuel Type Gasoline:

Unleaded Regular (87 Octane recommended)

Fuel System Diesel:

Direct Injection with Bosch VE Injection Pump

Fuel Type Diesel:

Diesel Fuel

Engine Design

Configuration V8:

Overhead Valve (OHV), Pushrod V8

Configuration Diesel:

Inline 6-Cylinder, Overhead Valve (OHV), Pushrod

Cooling System

Coolant Type:

Ethylene Glycol based coolant (50/50 mix with distilled water)

Oil Specifications

5.2L And 5.9L V8 Oil Type:

SAE 5W-30 or 10W-30 (depending on ambient temperature), API Service SG or SH

5.9L Cummins Oil Type:

SAE 15W-40 Heavy Duty Diesel Engine Oil, API Service CG-4 or CH-4

🔧 Transmission

Standard Transmission

Type:

5-Speed Manual (NV3500)

Optional Transmission

Type:

4-Speed Automatic (46RE)

Heavy Duty Automatic:

4-Speed Automatic (47RE) - Often paired with Diesel and larger V8 engines

Heavy Duty Manual:

6-Speed Manual (NV4500) - Primarily with Diesel engines

Fluid Specifications Automatic

Fluid Type:

ATF+3 (or equivalent Mopar specification)

Fluid Specifications Manual

Fluid Type:

Manual Transmission Fluid (MTF), specific viscosity as per manual (e.g., 75W-90 GL-5)

Features

Transfer Case 4Wd:

New Process NP231 (part-time) or NP241 (full-time) transfer cases

📐 Dimensions

Exterior

Wheelbase Regular Cab:

118.7 inches (3015 mm)

Wheelbase Extended Cab:

134.7 inches (3421 mm)

Bed Lengths:

6.5 ft (standard), 8 ft (long bed)

Weights

Gvwr Range:

Approximately 6,000 - 8,800 lbs (depending on configuration)

Curb Weight Range:

Approximately 4,500 - 5,500 lbs (depending on configuration)

Towing Capacity

Max Towing Capacity:

Up to 7,500 lbs (with proper equipment and engine configuration)

Max Payload Capacity:

Up to 2,500 lbs (depending on configuration)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

Varies by configuration, generally rated for its class but susceptible to rollover due to high center of gravity.

Active Features

Anti-lock Braking System (ABS) available on rear wheels or four wheels, depending on model and options.

Passive Features

Airbags:

Driver's side airbag standard.

Seat Belts:

Three-point front seat belts, lap belts for rear passengers.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player. Optional CD player and premium sound systems.

Display:

Basic instrument cluster with analog gauges.

Driver Assistance

Cruise Control:

Available on most trims.

Towing Features:

Trailer brake controller pre-wiring often available. Heavy-duty cooling and suspension options for towing.

Connectivity

Original Connectivity:

Limited to basic radio and potential external power outlets.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 - 5,000 miles or 3-6 months, depending on driving conditions and oil used (refer to manual for specifics).

Air Filter Replacement:

Every 12,000 - 15,000 miles or as needed based on inspection.

Spark Plug Replacement:

Approx. 30,000 - 60,000 miles for gasoline engines, depending on plug type.

Transmission Fluid Service:

Automatic: Every 30,000 - 60,000 miles. Manual: Every 60,000 - 100,000 miles.

Fluid Specifications

Coolant Capacity:

Approx. 14-17 quarts (depending on engine and radiator size)

Engine Oil Capacity:

5.2L: 5 quarts; 5.9L V8: 5 quarts; 5.9L Cummins: 12 quarts (with filter)

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

ATF+3 or Mopar Power Steering Fluid

Known Issues

Common Issues Gasoline:

Intake manifold gasket leaks, oil filter adapter seal leaks, exhaust manifold cracks, distributor rotor and cap wear, fuel pump issues.

Common Issues Diesel:

Lift pump failures, injector pump timing issues, vacuum pump leaks, overheating (especially under load), minor electrical gremlins.

Common Issues General:

Radiator and heater core failures, AC system leaks, front suspension component wear (ball joints, tie rods), rust issues in certain climates, aging wiring harness connectors.

📚 Vehicle History

Brand Heritage

Dodge Truck Legacy:

Dodge has a long history of producing rugged and capable trucks, dating back to the 1930s.

Model Evolution

Second Generation Launch:

The second generation Ram (BR/BE) was introduced for the 1994 model year, marking a significant redesign with a distinctive 'bullet' grille and improved aerodynamics.

1996 Updates:

Minor updates typically include trim changes, new option packages, and potential feature refinements. The core mechanicals and design remained consistent with the early second generation.

Production

Manufacturing Locations:

Primarily assembled in Warren, Michigan, and Saltillo, Mexico.

🏆 Awards & Recognition

Recognitions

Segment Popularity:

The Dodge Ram was consistently one of the top-selling full-size pickup trucks in North America during its production run, indicating strong market acceptance.

Powertrain Recognition:

The Cummins Turbo Diesel option became highly regarded for its durability and torque, earning a reputation for longevity and performance in demanding applications.