Dodge Ram 3500 Series 1996 1997 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram 3500 Series Model Generation: Second Generation (BR/BE) Model Year: 1996, 1997 Codes Chassis Code: BR (2WD), BE (4WD) 👋 Introduction Market Position Market Segment: Heavy-Duty Pickup Truck Target Audience: Owners, DIY mechanics, professional technicians working on Dodge Ram 3500 trucks. Competitive Analysis Competitors: Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD. Key Features Vehicle Strengths: Renowned for its robust construction, powerful engine options, and towing/hauling capabilities. Manual Value Proposition: Provides in-depth technical knowledge essential for maintaining and repairing these durable trucks, saving time and money. 📋 Manual Details Coverage Areas Covered Trims: All Models/Engines Page Count Estimated Page Count: Approximately 2000+ pages (typical for comprehensive workshop manuals of this era) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: All gasoline and diesel engine overhauls, diagnostics, component testing, cooling, lubrication, fuel, ignition, emission control systems. Transmission: Manual and automatic transmission service, repair, overhaul, diagnostics, clutch service, driveline components. Brakes: Hydraulic brake system service, ABS diagnostics and repair, front and rear brake component replacement, fluid specifications. Suspension Steering: Front and rear suspension component repair and replacement, steering system diagnostics, power steering service, alignment specifications. Electrical: Complete electrical schematics, lighting systems, starting and charging systems, instrument cluster, comfort and convenience features, body control modules, wiring diagrams. Body Chassis: Body panel repair, door and latch mechanisms, glass replacement, interior trim, frame straightening, collision repair information. HVAC: Heating, ventilation, and air conditioning system diagnosis, refrigerant handling, component replacement. Emissions: Emission control system components, diagnostics, and specifications. Procedures Included Maintenance: Scheduled maintenance intervals, fluid level checks, filter replacements, lubrication points. Troubleshooting: Diagnostic flowcharts, common problem identification, symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for all major systems, including component removal and installation. Diagnostics: OBD-II diagnostic codes, testing procedures for sensors and actuators, diagnostic tool usage. Rebuilding: Complete engine and transmission rebuilding procedures, including torque specifications and assembly instructions. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to full engine/transmission overhauls and advanced diagnostics. 📊 Manual Specifications File Format File Format: PDF Searchable: Yes (typically, for well-digitized manuals) Print Quality Print Quality: High-resolution digital scans, suitable for printing. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Option 1: 5.9L Magnum V8 (360 ci) Gasoline Engine Option 2: 8.0L Magnum V10 (488 ci) Gasoline Engine Option 3: 5.9L Cummins Turbo Diesel I6 (359 ci) Performance 5.9L Magnum V8 Horsepower: Approx. 230 hp @ 4400 rpm 5.9L Magnum V8 Torque: Approx. 330 lb-ft @ 3200 rpm 8.0L Magnum V10 Horsepower: Approx. 300 hp @ 4000 rpm 8.0L Magnum V10 Torque: Approx. 450 lb-ft @ 3200 rpm 5.9L Cummins Horsepower: Approx. 190-230 hp @ 2500-2800 rpm (depending on specific engine code/tune) 5.9L Cummins Torque: Approx. 400-460 lb-ft @ 1600 rpm (depending on specific engine code/tune) Fuel System Gasoline Engines: Multi-point Fuel Injection (MPI) Diesel Engine: Rotary injection pump (VE or P7100 depending on sub-model/year for 5.9L Cummins), electronically controlled injection pump (ECI) on later 5.9L models. Engine Code Gasoline V8: 360 Gasoline V10: 488 Diesel: 5.9L Cummins (Various specific engine codes apply) 🔧 Transmission Standard Standard Transmission: 5-Speed Manual (NV4500 for most models, especially diesel) Optional Optional Transmission 1: 4-Speed Automatic (47RH for early 5.9L Cummins, 48RE for later models/gasoline) Optional Transmission 2: 4-Speed Automatic (for Gasoline V8/V10) Features Manual Transmission Features: Heavy-duty construction, integrated overdrive, optional PTO provision (NV4500). Automatic Transmission Features: Torque converter lock-up for improved efficiency, electronically controlled shift points (on 48RE). 📐 Dimensions Exterior Wheelbase Options: 135" (Regular Cab), 160" (Club Cab/Quad Cab), 174" (Crew Cab) Bed Length Options: 8.0 ft (Standard Bed), 9.25 ft (Long Bed) Weights Gvwr Range: 10,000 lbs to 13,500 lbs (depending on configuration) Curb Weight Range: Approximately 5,500 lbs to 7,500 lbs (depending on configuration) 🛡️ Safety Features Ratings NHTSA Side Impact: Refer to specific model year and configuration NHTSA data; generally good for its class, but side airbags were not standard. Active Features ABS: Standard Anti-lock Braking System (ABS) on rear wheels for 2WD, four-wheel ABS available/standard on 4WD models. Passive Features Airbags: Driver and passenger front airbags (SRS). Seatbelts: Front and rear seat belts, shoulder belts with pretensioners. 💡 Technology Features Infotainment Audio System: Factory AM/FM radio with cassette player, optional CD player. Upgraded speaker systems available. Driver Assistance Cruise Control: Standard or optional depending on trim level. Connectivity Phone Integration: None from factory; aftermarket solutions required. 🔧 Maintenance Service Intervals Oil Change Gasoline: Every 3,000-5,000 miles or 6 months, whichever comes first (check manual for specific recommendations based on oil type and driving conditions). Oil Change Diesel Cummins: Every 5,000-7,500 miles or 6 months (using appropriate diesel oil). Cummins recommended 10W-30 synthetic blend or 15W-40. Transmission Fluid Change Automatic: Every 30,000-50,000 miles,...
Hydraulic brake system service, ABS diagnostics and repair, front and rear brake component replacement, fluid specifications.
Suspension Steering:
Front and rear suspension component repair and replacement, steering system diagnostics, power steering service, alignment specifications.
Electrical:
Complete electrical schematics, lighting systems, starting and charging systems, instrument cluster, comfort and convenience features, body control modules, wiring diagrams.
Body Chassis:
Body panel repair, door and latch mechanisms, glass replacement, interior trim, frame straightening, collision repair information.
HVAC:
Heating, ventilation, and air conditioning system diagnosis, refrigerant handling, component replacement.
Emissions:
Emission control system components, diagnostics, and specifications.
10,000 lbs to 13,500 lbs (depending on configuration)
Curb Weight Range:
Approximately 5,500 lbs to 7,500 lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Side Impact:
Refer to specific model year and configuration NHTSA data; generally good for its class, but side airbags were not standard.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on rear wheels for 2WD, four-wheel ABS available/standard on 4WD models.
Passive Features
Airbags:
Driver and passenger front airbags (SRS).
Seatbelts:
Front and rear seat belts, shoulder belts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM radio with cassette player, optional CD player. Upgraded speaker systems available.
Driver Assistance
Cruise Control:
Standard or optional depending on trim level.
Connectivity
Phone Integration:
None from factory; aftermarket solutions required.
🔧 Maintenance
Service Intervals
Oil Change Gasoline:
Every 3,000-5,000 miles or 6 months, whichever comes first (check manual for specific recommendations based on oil type and driving conditions).
Oil Change Diesel Cummins:
Every 5,000-7,500 miles or 6 months (using appropriate diesel oil). Cummins recommended 10W-30 synthetic blend or 15W-40.
Transmission Fluid Change Automatic:
Every 30,000-50,000 miles, depending on towing and driving conditions. Use ATF+4 or equivalent.
Transmission Fluid Change Manual:
Check manual for specific interval, often around 60,000 miles. Use appropriate gear oil (e.g., NV4500 typically uses GL-4 75W-90 or 80W-90).
Fluid Specifications
Engine Oil Gasoline:
API SG or higher; SAE 10W-30, 10W-40, or 5W-30 depending on climate (check owner's manual).
Engine Oil Diesel Cummins:
API CH-4 or higher; SAE 10W-30 or 15W-40 (synthetic blends or full synthetic recommended for heavy use).
Coolant:
Ethylene Glycol-based coolant, typically Mopar OAT (Orange) or HOAT (Hybrid Organic Additive Technology) for later models; consult manual for specific type and capacity. Pre-mixed 50/50 is common.
Brake Fluid:
DOT 3 or DOT 4.
Power Steering Fluid:
ATF+4 or equivalent.
Known Issues
Common Problems:
Lift pump failures (Cummins), fuel sender unit issues, heater core leaks, HVAC blend door actuator problems, front end wear (ball joints, tie rods), exhaust manifold cracks (Cummins), dashboard pad delamination.
📚 Vehicle History
Brand Heritage
Dodge Trucks:
Dodge has a long history of producing robust and capable trucks, particularly with the Ram line, known for their workhorse reputation.
Model Evolution
Second Generation Ram:
This generation (1994-2001) marked a significant redesign with a more aerodynamic and modern exterior, introduction of the Magnum V8 and V10 engines, and the popular 5.9L Cummins turbodiesel.
Production
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan, USA.
🏆 Awards & Recognition
Recognitions
Diesel Engine Accolades:
The 5.9L Cummins turbo diesel is widely regarded as one of the most reliable and durable diesel engines ever placed in a pickup truck, earning numerous accolades from enthusiasts and industry publications over its production run.
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