Dodge Ram Truck 1989 1990 1991 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Generation: Second Generation (2nd Gen) Codes Platform Code: BR/BE 👋 Introduction Market Position Segment: Full-size pickup truck Key Competitors: Ford F-Series, Chevrolet C/K Series, GMC Sierra Competitive Analysis Strengths: Robust build, powerful engine options, spacious cabin, strong towing and payload capacity Key Features Design: Bold styling, signature Dodge grille, aerodynamic improvements over previous generation Powertrain: Wide range of V6 and V8 gasoline engines, and a diesel option Chassis: Body-on-frame construction for durability and towing capability 📋 Manual Details Coverage Areas Applicable Years: 1989, 1990, 1991 Vehicle Types: Light-duty pickup trucks, Chassis Cab Regions: North America (USA, Canada, Mexico) Page Count Total Pages: 1613 Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF (Digital) 📖 Manual Coverage Systems Covered Engine: All gasoline and diesel engines (detailed diagnostics, overhaul, tuning) Transmission: Manual and Automatic transmissions (repair, overhaul, clutch, torque converter) Drivetrain: 4x2 and 4x4 systems, axles, driveshafts, differentials (service, repair) Suspension: Front and Rear suspension (independent front suspension, leaf springs), steering system (power steering, steering gear) Brakes: Front and Rear disc/drum brakes, ABS system (troubleshooting, component replacement, bleeding) Electrical: Complete wiring diagrams, lighting, ignition, charging system, starting system, accessory circuits, diagnostic procedures Fuel: Fuel injection systems (MPI), fuel pumps, injectors, fuel tank, lines (diagnostics, replacement) Cooling: Radiator, water pump, thermostat, cooling fan, heater core (testing, replacement) Exhaust: Exhaust manifolds, catalytic converter, mufflers, pipes (inspection, replacement) Body: Body panels, doors, windows, interior trim, seats, bumpers (adjustment, repair, replacement) HVAC: Air conditioning system, heating system, ventilation (diagnostics, refrigerant handling, component repair) Procedures Included Maintenance: Routine maintenance schedules, oil changes, filter replacements, fluid checks and changes, lubrication Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, symptom-based troubleshooting Repair: Detailed step-by-step repair procedures for all major components and systems Overhaul: Complete engine and transmission overhaul instructions with specifications Adjustment: Alignment specifications, clutch adjustment, brake adjustment, parking brake adjustment Installation: Component installation and removal procedures Wiring Repair: Detailed electrical system repair and connector terminal replacement guidance Technical Depth Depth: Comprehensive (from basic maintenance to complete engine/transmission rebuilds and advanced diagnostics) Detail Level: Highly detailed, professional-level information suitable for mechanics and serious DIYers 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text within the PDF Print Quality Quality: High-resolution scans, clear text and diagrams Binding Type Type: N/A (Digital PDF) Paper Type Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code Examples: 3.9L V6 (3B), 5.2L V8 (5.2), 5.9L V8 (5.9), 5.9L Turbo Diesel (ISB) Performance 3.9L V6 Horsepower: Approx. 125 hp @ 4000 rpm 3.9L V6 Torque: Approx. 210 lb-ft @ 2000 rpm 5.2L V8 Horsepower: Approx. 170-185 hp @ 4000 rpm 5.2L V8 Torque: Approx. 260-280 lb-ft @ 2400 rpm 5.9L V8 Horsepower: Approx. 230-245 hp @ 4000 rpm 5.9L V8 Torque: Approx. 330-350 lb-ft @ 2000 rpm 5.9L Turbo Diesel Horsepower: Approx. 160-180 hp @ 2500 rpm 5.9L Turbo Diesel Torque: Approx. 360-380 lb-ft @ 1600 rpm Fuel System Type: Multi-Port Fuel Injection (MPI) for gasoline engines; Direct Injection for Diesel Fuel Type: Unleaded Gasoline (Octane 87 minimum), Diesel Fuel 🔧 Transmission Standard Type: 5-Speed Manual (Getrag G360) Optional Type: 3-Speed Automatic (A500/A518), 4-Speed Automatic (46RH/47RH for Diesel/V8) Features Overdrive: Available on 4-speed automatic transmissions Fluid Specifications Automatic Transmission Fluid: ATF+3 or Dexron-III (check manual for specific model) Manual Transmission Fluid: GL-5 Gear Oil (e.g., SAE 75W-90) 📐 Dimensions Exterior Body Styles: Regular Cab, Club Cab (Extended Cab) Bed Lengths: 6.5 ft (Standard Bed), 8 ft (Long Bed) Wheelbase: 112" (Regular Cab, Short Bed), 125" (Regular Cab, Long Bed), 145" (Club Cab, Long Bed) Weights Curb Weight: Varies significantly by configuration, typically 4,000 - 5,500 lbs Gross Vehicle Weight Rating Gvw: Varies by configuration, typically 6,000 - 8,500 lbs (depending on trim and chassis) 🛡️ Safety Features Ratings NHTSA Rollover Rating: Not explicitly rated for this era, typical for body-on-frame trucks of the time Active Features ABS: Available on select models/trims, primarily rear-wheel anti-lock (RWAL) Passive Features Airbags: Driver-side airbag standard from 1990 onwards, passenger airbag optional/unavailable in early models Seatbelts: Three-point seatbelts 💡 Technology Features Infotainment Audio Systems: AM/FM radio, Cassette player, optional CD player (later models) Driver Assistance Cruise Control: Optional on most trims Connectivity Phone Integration: Not applicable for this era 🔧 Maintenance Service Intervals Oil Change Gasoline: Every 3,000 miles or 3 months (severe service), 5,000-7,500 miles or 6 months (normal service with synthetic oil) Oil Change Diesel: Every 5,000 miles or 6 months (severe service), 7,500-10,000 miles or 12 months (normal service) Transmission Fluid Change: Every 30,000 - 60,000 miles depending on usage and transmission type Coolant Flush: Every 30,000 miles or 24 months Fluid Specifications Engine Oil Gasoline: API SG or SH, SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on temperature) Engine Oil Diesel: API CD or CE...
3-Speed Automatic (A500/A518), 4-Speed Automatic (46RH/47RH for Diesel/V8)
Features
Overdrive:
Available on 4-speed automatic transmissions
Fluid Specifications
Automatic Transmission Fluid:
ATF+3 or Dexron-III (check manual for specific model)
Manual Transmission Fluid:
GL-5 Gear Oil (e.g., SAE 75W-90)
📐 Dimensions
Exterior
Body Styles:
Regular Cab, Club Cab (Extended Cab)
Bed Lengths:
6.5 ft (Standard Bed), 8 ft (Long Bed)
Wheelbase:
112" (Regular Cab, Short Bed), 125" (Regular Cab, Long Bed), 145" (Club Cab, Long Bed)
Weights
Curb Weight:
Varies significantly by configuration, typically 4,000 - 5,500 lbs
Gross Vehicle Weight Rating Gvw:
Varies by configuration, typically 6,000 - 8,500 lbs (depending on trim and chassis)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
Not explicitly rated for this era, typical for body-on-frame trucks of the time
Active Features
ABS:
Available on select models/trims, primarily rear-wheel anti-lock (RWAL)
Passive Features
Airbags:
Driver-side airbag standard from 1990 onwards, passenger airbag optional/unavailable in early models
Seatbelts:
Three-point seatbelts
💡 Technology Features
Infotainment
Audio Systems:
AM/FM radio, Cassette player, optional CD player (later models)
Driver Assistance
Cruise Control:
Optional on most trims
Connectivity
Phone Integration:
Not applicable for this era
🔧 Maintenance
Service Intervals
Oil Change Gasoline:
Every 3,000 miles or 3 months (severe service), 5,000-7,500 miles or 6 months (normal service with synthetic oil)
Oil Change Diesel:
Every 5,000 miles or 6 months (severe service), 7,500-10,000 miles or 12 months (normal service)
Transmission Fluid Change:
Every 30,000 - 60,000 miles depending on usage and transmission type
Coolant Flush:
Every 30,000 miles or 24 months
Fluid Specifications
Engine Oil Gasoline:
API SG or SH, SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on temperature)
Engine Oil Diesel:
API CD or CE or CF-4, SAE 15W-40
Coolant:
Ethylene Glycol (50/50 mix with distilled water)
Known Issues
Common Problems:
Premature ball joint wear (especially front suspension), potential for head gasket leaks on some V8s, rust on body panels and frame, transmission cooler line leaks, intermittent electrical issues (wiring harness chafing).
Diesel Specific Issues:
Injector pump issues, turbocharger wear, injector nozzle clogs, exhaust manifold cracking on early 6BT Cummins (though not standard in these specific years, it's a common association).
📚 Vehicle History
Brand Heritage
Dodge Trucks:
Dodge has a long history of producing robust and capable trucks, dating back to the 1930s.
Model Evolution
Ram Introduction:
The Ram nameplate was introduced in 1981. The 1989-1993 models represent the first generation of the 'new' Ram design, with significant updates leading into the second generation.
Second Generation Launch:
The second generation Ram (BR/BE platform) was introduced for the 1994 model year, so these 1989-1991 models are often considered part of the first generation's evolution or transitional models.
Production
Manufacturing Locations:
St. Louis Assembly, Missouri, USA
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
While specific awards for 1989-1991 models are less prominent, the Dodge Ram platform consistently received praise for its capability and powerful engine offerings during this period.
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