Dodge Ram 3500 Series 1996 1997 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 3500 Series Years Covered: 1996, 1997 Codes Platform Code: BR/BE (Third Generation Ram Pickup) 👋 Introduction Market Position Segment: Heavy-Duty Pickup Truck Target Audience: Owners, DIY mechanics, professional technicians working on Dodge Ram 3500 trucks. Competitive Analysis Competitors: Ford F-350 Super Duty, Chevrolet Silverado 3500 HD, GMC Sierra 3500 HD. Key Features Vehicle Strengths: Renowned for its robust construction, powerful engine options (especially the Cummins diesel), and towing/hauling capabilities. Manual Value Proposition: Provides essential information for maintaining and repairing one of the most durable heavy-duty trucks of its era, enabling cost savings and ensuring longevity. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service and repair for Dodge Ram 3500 Series vehicles. Specific Coverage: All major mechanical and electrical systems, body and chassis components. Page Count Estimated Page Count: Over 1500 pages (typical for comprehensive service manuals of this era) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (5.2L Magnum V8, 5.9L Magnum V8, 5.9L Cummins Turbo Diesel), Transmission (46RE Automatic, NV4500 Manual, G360 Manual), Drivetrain (Rear Wheel Drive, Four Wheel Drive, Differentials, Axles, Transfer Case). Chassis: Suspension (Front Twin I-Beam/Solid Axle, Rear Leaf Spring), Steering (Power Steering, Steering Gear), Brakes (Front Disc, Rear Drum/Disc, ABS), Wheels, Tires. Electrical: Ignition System, Charging System, Starting System, Lighting, Instrumentation, Audio Systems, Power Accessories, Body Control Modules, Powertrain Control Modules (PCM), Diagnostic Trouble Codes (DTCs). Body And Trim: Body Panels, Doors, Hood, Tailgate, Interior Trim, Seats, Glass, HVAC System, Exterior Trim, Bumpers. Procedures Included Maintenance: Scheduled maintenance, fluid checks and changes, filter replacements, lubrication. Diagnostics: Troubleshooting guides, diagnostic trouble code (DTC) interpretation, symptom-based diagnostics, electrical schematics. Repair: Component removal and installation, rebuilding procedures, adjustments, alignment procedures. Special Tools: Identification and usage of specialized tools required for specific repairs. Engine Mechanical: Cylinder head removal/installation, piston and connecting rod service, crankshaft service, valve train adjustments, timing chain/gear inspection and replacement. Engine Performance: Fuel system diagnostics, injection pump testing and replacement (Diesel), spark plug and wire diagnostics (Gas), emissions control system service. Transmission Manual: Clutch inspection and replacement, gear shift linkage adjustments, transmission fluid service and fill procedures. Transmission Automatic: Torque converter replacement, valve body service, transmission fluid and filter changes, solenoid testing. Brakes Hydraulic: Master cylinder replacement, brake booster service, caliper and wheel cylinder overhaul, brake line replacement, bleeding procedures. Brakes Parking: Parking brake cable adjustment and replacement. Suspension Front: Twin I-beam alignment specifications, ball joint replacement, shock absorber replacement, radius arm service (if applicable). Suspension Rear: Leaf spring inspection and replacement, U-bolt torque specifications, shock absorber replacement. Steering System: Power steering pump and gear box diagnosis and replacement, tie rod end replacement, steering linkage alignment. Electrical Schematics: Detailed wiring diagrams for all major vehicle systems, including engine controls, lighting, power accessories, and body electronics. Body And Frame: Door hinge repair, tailgate mechanisms, body panel alignment, rust prevention and repair guidance. Technical Depth Depth: Detailed diagnostic procedures, torque specifications, clearance measurements, wiring diagrams, exploded views, service bulletins (if integrated). Torque Specs: Comprehensive listing of torque specifications for all critical fasteners throughout the vehicle. Clearances And Tolerances: Detailed specifications for engine internal clearances, bearing tolerances, and component gaps. Component Testing: Procedures for testing various sensors, actuators, and electrical components using multimeters and diagnostic tools. Trouble Shooting Charts: Diagnostic flowcharts and tables to help pinpoint the root cause of common malfunctions. 📊 Manual Specifications File Format File Format: PDF Print Quality Resolution: High-resolution, suitable for digital viewing and printing. Binding Type Binding: Not Applicable (PDF format) Paper Type Paper Type: Not Applicable (PDF format) Searchability Text Search: Searchable text within the PDF document. ⚙️ Engine Specifications Primary Engine Engine 1 Variant: 5.2L (318 ci) Magnum V8 Engine 1 Hp: Approx. 230 hp @ 4800 RPM Engine 1 Torque: Approx. 325 lb-ft @ 3200 RPM Engine 2 Variant: 5.9L (360 ci) Magnum V8 Engine 2 Hp: Approx. 245 hp @ 4400 RPM Engine 2 Torque: Approx. 345 lb-ft @ 3200 RPM Engine 3 Variant: 5.9L (359 ci) Cummins Turbo Diesel I6 Engine 3 Hp: Approx. 215 hp @ 2400 RPM (standard output) Engine 3 Torque: Approx. 420 lb-ft @ 1600 RPM (standard output) Performance Compression Ratio 5.2L: 9.1:1 Compression Ratio 5.9L V8: 8.7:1 Compression Ratio 5.9L Cummins: 17.0:1 Fuel System Fuel Delivery V8S: Multi-Port Fuel Injection (MPFI) Fuel Delivery Cummins: Inline Injection Pump (Bosch VP44 common on later 97 models, rotary on earlier) Fuel Type V8S: Unleaded Gasoline Fuel Type Cummins: Diesel Fuel 🔧 Transmission Standard Transmission Type Gas: 4-Speed Automatic (46RE) Transmission Type Diesel Auto: 4-Speed Automatic (47RE) Transmission Type Manual: 5-Speed Manual (NV4500) Optional Optional Transmission: No major optional transmissions beyond the primary offerings. Features Overdrive Gears: 46RE/47RE: Overdrive (4th gear), NV4500: 5 forward gears including overdrive. Transfer Case 4Wd: New Process NP241DHD (Heavy...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram 3500 Series

Years Covered:

1996, 1997

Codes

Platform Code:

BR/BE (Third Generation Ram Pickup)

👋 Introduction

Market Position

Segment:

Heavy-Duty Pickup Truck

Target Audience:

Owners, DIY mechanics, professional technicians working on Dodge Ram 3500 trucks.

Competitive Analysis

Competitors:

Ford F-350 Super Duty, Chevrolet Silverado 3500 HD, GMC Sierra 3500 HD.

Key Features

Vehicle Strengths:

Renowned for its robust construction, powerful engine options (especially the Cummins diesel), and towing/hauling capabilities.

Manual Value Proposition:

Provides essential information for maintaining and repairing one of the most durable heavy-duty trucks of its era, enabling cost savings and ensuring longevity.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive service and repair for Dodge Ram 3500 Series vehicles.

Specific Coverage:

All major mechanical and electrical systems, body and chassis components.

Page Count

Estimated Page Count:

Over 1500 pages (typical for comprehensive service manuals of this era)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (5.2L Magnum V8, 5.9L Magnum V8, 5.9L Cummins Turbo Diesel), Transmission (46RE Automatic, NV4500 Manual, G360 Manual), Drivetrain (Rear Wheel Drive, Four Wheel Drive, Differentials, Axles, Transfer Case).

Chassis:

Suspension (Front Twin I-Beam/Solid Axle, Rear Leaf Spring), Steering (Power Steering, Steering Gear), Brakes (Front Disc, Rear Drum/Disc, ABS), Wheels, Tires.

Electrical:

Ignition System, Charging System, Starting System, Lighting, Instrumentation, Audio Systems, Power Accessories, Body Control Modules, Powertrain Control Modules (PCM), Diagnostic Trouble Codes (DTCs).

Body And Trim:

Body Panels, Doors, Hood, Tailgate, Interior Trim, Seats, Glass, HVAC System, Exterior Trim, Bumpers.

Procedures Included

Maintenance:

Scheduled maintenance, fluid checks and changes, filter replacements, lubrication.

Diagnostics:

Troubleshooting guides, diagnostic trouble code (DTC) interpretation, symptom-based diagnostics, electrical schematics.

Repair:

Component removal and installation, rebuilding procedures, adjustments, alignment procedures.

Special Tools:

Identification and usage of specialized tools required for specific repairs.

Engine Mechanical:

Cylinder head removal/installation, piston and connecting rod service, crankshaft service, valve train adjustments, timing chain/gear inspection and replacement.

Engine Performance:

Fuel system diagnostics, injection pump testing and replacement (Diesel), spark plug and wire diagnostics (Gas), emissions control system service.

Transmission Manual:

Clutch inspection and replacement, gear shift linkage adjustments, transmission fluid service and fill procedures.

Transmission Automatic:

Torque converter replacement, valve body service, transmission fluid and filter changes, solenoid testing.

Brakes Hydraulic:

Master cylinder replacement, brake booster service, caliper and wheel cylinder overhaul, brake line replacement, bleeding procedures.

Brakes Parking:

Parking brake cable adjustment and replacement.

Suspension Front:

Twin I-beam alignment specifications, ball joint replacement, shock absorber replacement, radius arm service (if applicable).

Suspension Rear:

Leaf spring inspection and replacement, U-bolt torque specifications, shock absorber replacement.

Steering System:

Power steering pump and gear box diagnosis and replacement, tie rod end replacement, steering linkage alignment.

Electrical Schematics:

Detailed wiring diagrams for all major vehicle systems, including engine controls, lighting, power accessories, and body electronics.

Body And Frame:

Door hinge repair, tailgate mechanisms, body panel alignment, rust prevention and repair guidance.

Technical Depth

Depth:

Detailed diagnostic procedures, torque specifications, clearance measurements, wiring diagrams, exploded views, service bulletins (if integrated).

Torque Specs:

Comprehensive listing of torque specifications for all critical fasteners throughout the vehicle.

Clearances And Tolerances:

Detailed specifications for engine internal clearances, bearing tolerances, and component gaps.

Component Testing:

Procedures for testing various sensors, actuators, and electrical components using multimeters and diagnostic tools.

Trouble Shooting Charts:

Diagnostic flowcharts and tables to help pinpoint the root cause of common malfunctions.

📊 Manual Specifications

File Format

File Format:

Print Quality

Resolution:

High-resolution, suitable for digital viewing and printing.

Binding Type

Binding:

Not Applicable (PDF format)

Paper Type

Paper Type:

Not Applicable (PDF format)

Searchability

Text Search:

Searchable text within the PDF document.

⚙️ Engine Specifications

Primary Engine

Engine 1 Variant:

5.2L (318 ci) Magnum V8

Engine 1 Hp:

Approx. 230 hp @ 4800 RPM

Engine 1 Torque:

Approx. 325 lb-ft @ 3200 RPM

Engine 2 Variant:

5.9L (360 ci) Magnum V8

Engine 2 Hp:

Approx. 245 hp @ 4400 RPM

Engine 2 Torque:

Approx. 345 lb-ft @ 3200 RPM

Engine 3 Variant:

5.9L (359 ci) Cummins Turbo Diesel I6

Engine 3 Hp:

Approx. 215 hp @ 2400 RPM (standard output)

Engine 3 Torque:

Approx. 420 lb-ft @ 1600 RPM (standard output)

Performance

Compression Ratio 5.2L:

9.1:1

Compression Ratio 5.9L V8:

8.7:1

Compression Ratio 5.9L Cummins:

17.0:1

Fuel System

Fuel Delivery V8S:

Multi-Port Fuel Injection (MPFI)

Fuel Delivery Cummins:

Inline Injection Pump (Bosch VP44 common on later 97 models, rotary on earlier)

Fuel Type V8S:

Unleaded Gasoline

Fuel Type Cummins:

Diesel Fuel

🔧 Transmission

Standard

Transmission Type Gas:

4-Speed Automatic (46RE)

Transmission Type Diesel Auto:

4-Speed Automatic (47RE)

Transmission Type Manual:

5-Speed Manual (NV4500)

Optional

Optional Transmission:

No major optional transmissions beyond the primary offerings.

Features

Overdrive Gears:

46RE/47RE: Overdrive (4th gear), NV4500: 5 forward gears including overdrive.

Transfer Case 4Wd:

New Process NP241DHD (Heavy Duty)

📐 Dimensions

Exterior

Wheelbase 134.5In:

134.5 inches (Standard Cab, Long Bed)

Wheelbase 154.5In:

154.5 inches (Crew Cab, Long Bed)

Bed Length Standard:

8.0 ft (96 inches)

Bed Length Short:

6.0 ft (72 inches) - Less common for 3500 models.

Weights

Gvwr Gas:

Typically 9,600 lbs to 10,000 lbs depending on configuration.

Gvwr Diesel:

Typically 10,000 lbs to 12,000 lbs depending on configuration and axle options.

Curb Weight:

Varies significantly by configuration, but generally 6,000 - 7,500+ lbs.

🛡️ Safety Features

Ratings

NHTSA Crash Tests:

Limited public data for specific model years, but generally designed for robust occupant protection in heavy-duty applications. Likely performed well for their era.

Active Features

Anti-lock Braking System (ABS) standard on most models, especially those with heavier GVWR or 4WD.

Passive Features

Airbags:

Driver and Passenger Airbags.

Seat Belts:

Three-point seat belts.

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo, cassette player, optional CD player. Basic speaker configurations.

Driver Assistance

Cruise Control:

Standard on most trims.

Towing Features:

Integrated trailer brake controller wiring, heavy-duty cooling, tow mirrors often optional or standard on higher trims.

Connectivity

Bluetooth:

Not available.

Usb Ports:

Not available.

🔧 Maintenance

Service Intervals

Oil Change Gas:

Every 3,000-5,000 miles or 3-6 months, depending on usage (severe vs. normal).

Oil Change Diesel:

Every 5,000-7,500 miles or 6 months (using appropriate diesel oil).

Air Filter Replacement:

Check every 15,000 miles, replace as needed (more frequently in dusty conditions).

Fuel Filter Diesel:

Every 15,000-30,000 miles (critical for diesel longevity).

Transmission Fluid:

Check every 15,000 miles. Replace fluid and filter every 30,000-60,000 miles (depends on towing/heavy use).

Fluid Specifications

Engine Oil Gas:

API SG or higher, SAE 10W-30 (or 5W-30 for colder climates).

Engine Oil Diesel:

API CG-4 or CH-4, SAE 15W-40.

Transmission Fluid Auto:

ATF+3 or ATF+4 (Mopar specification).

Transmission Fluid Manual Nv4500:

NV4500 GL-4, SAE 75W-90 synthetic gear oil (Mopar specification).

Coolant:

Mopar OAT (Orange) or HOAT (Yellow) Antifreeze/Coolant, 50/50 mix with distilled water.

Known Issues

Common Problems Gas:

Intake manifold gasket leaks, EGR valve issues (if equipped), distributor and ignition coil failures.

Common Problems Diesel:

VP44 injection pump failure (especially on later 97 models), lift pump issues, injector line leaks, potential cracking in exhaust manifolds.

Chassis Issues:

Rust on body panels, suspension component wear (ball joints, tie rods), brake component wear.

📚 Vehicle History

Brand Heritage

Dodge Truck Legacy:

Dodge has a long history of producing capable and durable trucks, building on decades of engineering.

Model Evolution

Third Gen Ram:

The 1994-2001 generation (BR/BE platform) marked a significant redesign for the Ram, featuring a bolder, more aggressive styling that proved highly popular and set new industry trends.

Key Updates 96 97:

Minor refinements often occurred. The 5.9L Cummins received power upgrades in subsequent years, and transmissions were refined. The 1996 and 1997 models represent a mature iteration of this popular heavy-duty platform.

Production

Manufacturing Location:

Saltillo, Mexico and Warren, Michigan, USA

🏆 Awards & Recognition

Recognitions

Truck Of The Year:

While this specific generation received various accolades and was highly regarded for its styling, specific 'Truck of the Year' awards for the 1996-1997 Ram 3500 are not as prominent as later models. However, its overall design and powertrain options were highly competitive and lauded.