1990 Dodge Ram Truck W150 W250 W350 D150 D250 D350 AD100 AD150 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Year: 1990 Chassis Codes: W150, W250, W350, D150, D250, D350, AD100, AD150 Generation Generation Name: Second Generation (1972-1993, with significant updates in 1981 for the 'New' generation and subsequent refinements) 👋 Introduction Market Position Market Segment: Heavy-duty pickup truck, designed for work, towing, and general utility. Competed against Ford F-Series, Chevrolet C/K Series, and GMC Sierra. Target Audience: Owners who perform their own maintenance and repairs, small business owners using trucks for work, fleet maintenance operations, restoration enthusiasts. Key Features Vehicle Attributes: Robust chassis, strong towing and payload capacities, variety of gasoline and diesel engine options, available in 2WD and 4WD configurations, choice of cab styles (regular, extended) and bed lengths. Competitive Analysis Market Rivals: Ford F-Series (F-150, F-250, F-350), Chevrolet C/K Series (C10, C20, C30), GMC Sierra (K1500, K2500, K3500), and their associated platform variants. 📋 Manual Details Coverage Coverage Areas: W150, W250, W350 (4x4), D150, D250, D350 (2WD), AD100, AD150 (likely special order/fleet configurations), including diesel engine variants. Page Count Estimated Page Count: Likely over 1000 pages (typical for a comprehensive factory service manual for this era) Manual Type Manual Type: Service and Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Systems: Engine (gasoline and diesel), Fuel System, Cooling System, Lubrication System, Exhaust System, Ignition System, Starting System, Charging System, Clutch, Manual Transmission, Automatic Transmission, Transfer Case (for 4x4 models), Drive Axles, Suspension (front and rear), Steering System, Brakes (hydraulic, ABS if equipped), Electrical System (wiring diagrams, components, lighting, instruments), HVAC (Heating, Ventilation, Air Conditioning), Body and Frame, Interior Components, Restraint Systems (seat belts), Speed Control, Vehicle Theft Security, Wipers and Washers, Audio/Video Systems, Navigation/Telecommunication, Emission Control Systems. Engine Systems Detail: Includes complete overhaul procedures, timing adjustments, valve adjustments, piston and connecting rod torque sequences, crankshaft and camshaft specifications, cylinder head torque specifications, oil pump operation, and lubrication system flow charts. Electrical Systems Detail: Comprehensive wiring diagrams for all vehicle circuits, fuse and fusible link identification, relay locations, component testing procedures, charging system diagnosis, starter system troubleshooting, and lighting system repairs. Suspension Steering Detail: Front and rear suspension component replacement (ball joints, tie rod ends, control arm bushings, shock absorbers), wheel alignment specifications, power steering system diagnosis and repair, steering gear and pump service. Brake Systems Detail: Front disc brake caliper and rotor replacement, rear drum brake shoe and hardware replacement, brake bleeding procedures, master cylinder and brake booster service, ABS system diagnosis and component testing (if equipped). HVAC Detail: Refrigerant handling (R-12 for this era), compressor, condenser, evaporator service, blower motor replacement, heater core diagnosis, control panel operation and repair, diagnostic procedures for cooling and heating performance. Fuel System Detail: Fuel tank removal and installation, fuel pump testing and replacement, fuel filter replacement, fuel line inspection and repair, fuel pressure testing, EFI system component diagnosis (sensors, injectors, ECU). Cooling System Detail: Radiator and coolant hose replacement, thermostat testing and replacement, water pump service, fan clutch diagnosis, cooling system pressure testing, coolant capacity specifications. Instrument Cluster Detail: Gauge testing and repair (speedometer, tachometer, fuel, temperature, oil pressure), warning lamp diagnostics, indicator light function, and instrument cluster removal/installation. Procedures Included Procedures: Routine maintenance, scheduled maintenance, lubrication, fluid changes, tune-ups, diagnostic procedures, troubleshooting guides, repair procedures for all major systems, component removal and installation, assembly and disassembly, specifications for adjustments and torques, wiring harness repair, body panel replacement, HVAC system service, emission control component testing and repair. Troubleshooting Methodology: Systematic diagnostic flowcharts for common problems, symptom-based troubleshooting, using diagnostic codes (if applicable), electrical continuity testing, pressure testing, and component resistance checks. Diagnostic Tools: Discussion on basic diagnostic tools like multimeters, fuel pressure gauges, vacuum gauges, and timing lights. For diesel, specialized pump and injector testing equipment. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission overhauls, complex electrical diagnostics, and detailed body repair. Includes exploded views, diagrams, and schematics. Precision Measurements: Includes detailed torque specifications for critical fasteners, bearing clearances, piston ring gap, valve seat recession, and other precision measurements required for proper assembly and performance. Rebuild Manuals: Procedures for complete engine and transmission rebuilds, including detailed schematics of internal components and clearances. 📊 Manual Specifications File Attributes File Format: PDF Searchability: Likely text-searchable PDF, allowing users to quickly find specific topics or components. Print Attributes Printable: Yes, without restriction Delivery Delivery Method: Digital Download Binding Type Binding: Digital (Downloadable PDF) Paper Type Paper Quality Analog: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Gas Engine Options Gasoline: 3.9L (239 ci) Magnum V6, 5.2L (318 ci) Magnum V8, 5.9L (360 ci) Magnum V8. (Note: The 'Magnum' designation for these engines became more prominent in later years, but these displacements were available.) Primary Engine Diesel Engine Options Diesel: 5.9L (360 ci) Cummins Turbo Diesel I6 (often denoted as 6BT). Performance Gas Typical Horsepower...

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Sku: 207582

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Labels: 1990 AD100 AD150 Cars D Series D150 D250 D350 Dodge Ram Truck Truck W150 W250 W350

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram Truck

Year:

Chassis Codes:

W150, W250, W350, D150, D250, D350, AD100, AD150

Generation

Generation Name:

Second Generation (1972-1993, with significant updates in 1981 for the 'New' generation and subsequent refinements)

👋 Introduction

Market Position

Market Segment:

Heavy-duty pickup truck, designed for work, towing, and general utility. Competed against Ford F-Series, Chevrolet C/K Series, and GMC Sierra.

Target Audience:

Owners who perform their own maintenance and repairs, small business owners using trucks for work, fleet maintenance operations, restoration enthusiasts.

Key Features

Vehicle Attributes:

Robust chassis, strong towing and payload capacities, variety of gasoline and diesel engine options, available in 2WD and 4WD configurations, choice of cab styles (regular, extended) and bed lengths.

Competitive Analysis

Market Rivals:

Ford F-Series (F-150, F-250, F-350), Chevrolet C/K Series (C10, C20, C30), GMC Sierra (K1500, K2500, K3500), and their associated platform variants.

📋 Manual Details

Coverage

Coverage Areas:

W150, W250, W350 (4x4), D150, D250, D350 (2WD), AD100, AD150 (likely special order/fleet configurations), including diesel engine variants.

Page Count

Estimated Page Count:

Likely over 1000 pages (typical for a comprehensive factory service manual for this era)

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Systems:

Engine (gasoline and diesel), Fuel System, Cooling System, Lubrication System, Exhaust System, Ignition System, Starting System, Charging System, Clutch, Manual Transmission, Automatic Transmission, Transfer Case (for 4x4 models), Drive Axles, Suspension (front and rear), Steering System, Brakes (hydraulic, ABS if equipped), Electrical System (wiring diagrams, components, lighting, instruments), HVAC (Heating, Ventilation, Air Conditioning), Body and Frame, Interior Components, Restraint Systems (seat belts), Speed Control, Vehicle Theft Security, Wipers and Washers, Audio/Video Systems, Navigation/Telecommunication, Emission Control Systems.

Engine Systems Detail:

Includes complete overhaul procedures, timing adjustments, valve adjustments, piston and connecting rod torque sequences, crankshaft and camshaft specifications, cylinder head torque specifications, oil pump operation, and lubrication system flow charts.

Electrical Systems Detail:

Comprehensive wiring diagrams for all vehicle circuits, fuse and fusible link identification, relay locations, component testing procedures, charging system diagnosis, starter system troubleshooting, and lighting system repairs.

Suspension Steering Detail:

Front and rear suspension component replacement (ball joints, tie rod ends, control arm bushings, shock absorbers), wheel alignment specifications, power steering system diagnosis and repair, steering gear and pump service.

Brake Systems Detail:

Front disc brake caliper and rotor replacement, rear drum brake shoe and hardware replacement, brake bleeding procedures, master cylinder and brake booster service, ABS system diagnosis and component testing (if equipped).

HVAC Detail:

Refrigerant handling (R-12 for this era), compressor, condenser, evaporator service, blower motor replacement, heater core diagnosis, control panel operation and repair, diagnostic procedures for cooling and heating performance.

Fuel System Detail:

Fuel tank removal and installation, fuel pump testing and replacement, fuel filter replacement, fuel line inspection and repair, fuel pressure testing, EFI system component diagnosis (sensors, injectors, ECU).

Cooling System Detail:

Radiator and coolant hose replacement, thermostat testing and replacement, water pump service, fan clutch diagnosis, cooling system pressure testing, coolant capacity specifications.

Instrument Cluster Detail:

Gauge testing and repair (speedometer, tachometer, fuel, temperature, oil pressure), warning lamp diagnostics, indicator light function, and instrument cluster removal/installation.

Procedures Included

Procedures:

Routine maintenance, scheduled maintenance, lubrication, fluid changes, tune-ups, diagnostic procedures, troubleshooting guides, repair procedures for all major systems, component removal and installation, assembly and disassembly, specifications for adjustments and torques, wiring harness repair, body panel replacement, HVAC system service, emission control component testing and repair.

Troubleshooting Methodology:

Systematic diagnostic flowcharts for common problems, symptom-based troubleshooting, using diagnostic codes (if applicable), electrical continuity testing, pressure testing, and component resistance checks.

Diagnostic Tools:

Discussion on basic diagnostic tools like multimeters, fuel pressure gauges, vacuum gauges, and timing lights. For diesel, specialized pump and injector testing equipment.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission overhauls, complex electrical diagnostics, and detailed body repair. Includes exploded views, diagrams, and schematics.

Precision Measurements:

Includes detailed torque specifications for critical fasteners, bearing clearances, piston ring gap, valve seat recession, and other precision measurements required for proper assembly and performance.

Rebuild Manuals:

Procedures for complete engine and transmission rebuilds, including detailed schematics of internal components and clearances.

📊 Manual Specifications

File Attributes

File Format:

Searchability:

Likely text-searchable PDF, allowing users to quickly find specific topics or components.

Print Attributes

Printable:

Yes, without restriction

Delivery

Delivery Method:

Digital Download

Binding Type

Binding:

Digital (Downloadable PDF)

Paper Type

Paper Quality Analog:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine Gas

Engine Options Gasoline:

3.9L (239 ci) Magnum V6, 5.2L (318 ci) Magnum V8, 5.9L (360 ci) Magnum V8. (Note: The 'Magnum' designation for these engines became more prominent in later years, but these displacements were available.)

Primary Engine Diesel

Engine Options Diesel:

5.9L (360 ci) Cummins Turbo Diesel I6 (often denoted as 6BT).

Performance Gas

Typical Horsepower Torque Gas:

V6: Approx. 125-140 HP, 190-210 lb-ft. V8 (318): Approx. 170-190 HP, 250-280 lb-ft. V8 (360): Approx. 200-220 HP, 300-330 lb-ft. (Exact figures vary by year and specific tune).

Performance Diesel

Typical Horsepower Torque Diesel:

5.9L Cummins Turbo Diesel: Approx. 160-180 HP, 400-420 lb-ft. (This engine was known for its durability and torque).

Fuel System

Fuel Delivery Gasoline:

Fuel Injection (Throttle Body Injection - TBI, or Multi-Port Fuel Injection - MPI depending on specific engine variant).

Fuel System Diesel

Fuel Delivery Diesel:

Inline injection pump (Bosch VE or similar for early 5.9L).

Engine Block Material

Block Material:

Cast Iron for all gasoline and diesel engines.

Cylinder Head Material

Head Material:

Cast Iron for all gasoline and diesel engines.

Ignition System

Ignition Type:

Electronic Ignition System (Distributor with electronic ignition module).

🔧 Transmission

Standard Transmission

Transmission Options:

Manual transmissions (e.g., 4-speed, 5-speed) and Automatic transmissions (e.g., A500, A518, A727, A727 overdrive variants).

Optional Transmission

Automatic Transmission Details:

4-speed automatic (e.g., A500/A518 with overdrive), 3-speed automatic (e.g., A727).

Features

Transfer Case 4X4:

Part-time, 2-speed transfer case (e.g., NP205, NP241 or similar depending on configuration).

Transmission Fluid Manual

Manual Transmission Fluid:

Refer to manual for specific viscosity and type (e.g., GL-4 or GL-5 gear oil).

Gear Ratios

Manual Gear Ratios:

Varies by transmission model (e.g., 3.04:1, 1.77:1, 1.00:1 for a 4-speed, with overdrive gears in 5-speeds).

📐 Dimensions

Exterior

Wheelbase Options:

Various, depending on cab and bed configuration (e.g., ~115" for standard cab short bed, ~131" for standard cab long bed, ~164" for club cab long bed).

Frame Type:

Ladder frame construction for robust durability and towing capability.

Weights

Gross Vehicle Weight Rating Gvwr:

Ranges from approximately 6,000 lbs (W150/D150) to over 9,500 lbs (W350/D350), depending on configuration.

Curb Weight:

Varies significantly by configuration, but typically between 4,000 lbs and 6,000+ lbs.

Cargo Bed

Bed Length Options:

Short Bed (approx. 6.5 ft) and Long Bed (approx. 8 ft), depending on configuration.

🛡️ Safety Features

Passive Features

Seat Belts:

Standard 3-point lap and shoulder belts for front occupants, lap belts for rear passengers (if equipped).

Active Features

Brake System:

Front disc brakes, rear drum brakes. Optional Anti-lock Braking System (ABS) available on rear wheels or all four wheels depending on configuration.

Ratings

Crash Test Data:

Specific official crash test data for this exact model year may be limited or not directly comparable to modern standards. However, the construction was robust for its era.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player was standard. Optional features could include premium sound systems or compact disc players.

Driver Assistance

Cruise Control:

Optional 'Speed Control' system available on most models.

Connectivity

Phone Integration:

None from factory for this model year.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000 to 5,000 miles, or 6 months, depending on driving conditions. Diesel engines might have slightly longer intervals depending on oil type.

Transmission Fluid Change:

Automatic: Every 30,000-60,000 miles or as per manual. Manual: Inspect periodically, change as needed or every 60,000-100,000 miles.

Fluid Specifications

Engine Oil Spec:

API SG or SH classification. Viscosity grade typically 10W-30 or 10W-40 for gasoline engines, and specific heavy-duty diesel engine oil (e.g., 15W-40 API CD/CE/CF) for the Cummins.

Coolant Spec:

Ethylene glycol based antifreeze. Refer to manual for specific type (e.g., green conventional).

Transmission Fluid Auto:

ATF+3 or ATF+4 (depending on specific transmission variant, though ATF+3 was more common for this era, manual will specify).

Transfer Case Fluid:

Typically NP205/NP241 fluid (e.g., Dexron-III/Mercon or equivalent manual transmission fluid like 75W-90).

Known Issues

Common Wear Items:

Radiator, water pump, alternator, starter motor, fuel injectors (especially on early Magnum engines), exhaust system components, brake components (pads, rotors, drums), suspension bushings and ball joints. Diesel engines can experience injector pump issues and turbocharger wear.

Electrical Gremlins:

Common in older vehicles due to aging wiring harnesses, connectors, and ground points. The manual's detailed wiring diagrams are crucial for diagnosis.

Tire Pressure

Recommended Tire Pressure:

Varies by tire size and load. Typically found on a sticker in the driver's doorjamb or owner's manual. For this era, often in the 30-40 PSI range.

Filter Part Numbers

Oil Filter Examples:

Examples may include Wix 51515, Fram PH8A, Purolator L30001 (V8 engines); Wix 57712, Fram PH16 (V6 engines); and specific filters for the Cummins diesel.

📚 Vehicle History

Brand Heritage

Dodge Truck Legacy:

Dodge has a long history of producing rugged and capable trucks, dating back to the early 20th century. The Ram nameplate, introduced in 1981, became synonymous with toughness and utility.

Model Evolution

Second Gen Ram Updates:

The 1990 model represents a refinement of the 'Ram' generation that began in 1981. Key updates over the years included improved aerodynamics, interior comfort, and the introduction of more powerful engine options, including the legendary Cummins diesel.

Cab Styles:

Available in Regular Cab (2-door) and Club Cab (4-door, extended cab) configurations.

Production Years

Second Gen Production Range:

1972-1993 (with major redesigns and updates, including the 1981 'new' generation and subsequent facelifts).

🏆 Awards & Recognition

Recognitions

Diesel Engine Recognition:

The 5.9L Cummins Turbo Diesel engine, introduced in Ram trucks in 1989, quickly gained a reputation for unparalleled durability and torque, making it a highly sought-after powertrain option.