19 9 3
SERVICE
MANUAL
D& W150-350
RAMCHARGER
REAR WHEEL DRIVE
TRUCK
1991-1994
FOREWORD
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. This manual does not cover theory of operation, which is addressed
in service training material. Information describing the operation and use of standard and optional equipment
is included in the Owner's Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the components.
The Component and System Index of this manual identifies the correct group for the component or system
to be serviced. In addition, a Service Manual Comment form is included at the rear of this manual. Use the
form to provide Chrysler Corporation with your comments and suggestions.
To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When re-
placing fasteners, always use the same type (part number) fastener as removed.
Chrysler Corporation reserves the right to change testing procedures, specifications, diagnosis, repair
methods, or vehicle wiring at any time without prior notice or incurring obligation.
NOTE: The acronyms, terminology and nomenclature used to identify emissions related components in
this manual may have changed from prior publications. These new terms are in compliance with S.A.E.
recommended practice J1930. This terminology standard (J1930) is required to comply with the 1993
California Air Research Board (CARB) requirements.
GROUP TAB LOCATOR
Introduction
0 Lubrication and Maintenance
2 Front Suspension and Axle
3 Rear Suspension and Axles
5 Brakes
6 Clutch
7 Cooling System
8 Electrical
9 Engines
11 Exhaust System and Intake Manifold
1 3
F r a m e
and Bumpers
14
F u e l
System
1 6 Propeller Shafts
19 Steering
21 Transmission and Transfer Case
22 Wheels and Tires
23
B o d
y Components
24 Heating and Air Conditioning
25 Emission Control Systems
Component and System Index
Service Manual Comment Forms (Rear of Manual)
INTRODUCTION
INTRODUCTION
DESIGNATIONS, LABELS/PLATES/DECALS,
CODES AND DIMENSIONS/WEIGHTS .
CONTENTS
page
MEASUREMENT AND TORQUE
. . . 1 SPECIFICATIONS
page
. 11
DESIGNATIONS, LABELS/PLATES/DECALS, CODES AND DIMENSIONS/WEIGHTS
INDEX
page
Engine and Transmission/Transfer Case
Identification 2
Engine/Transmission/GVWR 4
Equipment Identification Plate 3
International Vehicle Control and Display
Symbols 10
Major Component Identification 3
VEHICLE DESIGNATIONS
The Vehicle Code chart lists description and code
for Ram Truck and Sport Utility vehicles. The codes
are used to identify vehicle types in charts, captions
and in service procedures. The vehicle codes are dif-
ferent than the Vehicle Identification Number (VIN)
or the wheelbase/model code.
VEHICLE SAFETY CERTIFICATION LABEL
A certification label is attached to the left side
B-pillar. The label certifies that the vehicle conforms
to Federal Motor Vehicle Safety Standards (FMVSS).
The label also lists the:
• Month and year of vehicle manufacture
• Gross Vehicle Weight Rating (GVWR). The gross
front and rear axle weight ratings (GAWR's) are
based on a minimum rim size and maximum cold tire
inflation pressure
Vehicle Identification Number (VIN)
Type of vehicle
Type of rear wheels (single or dual)
Bar code
Month, Day and Hour (MDH) of final assembly
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE
The Vehicle Identification Number (VIN) plate is
attached to the top left side of the instrument panel.
The VIN contains 17 characters that provide data
concerning the vehicle. Refer to the decoding chart to
determine the identification of a vehicle.
page
Trailer Towing Specifications 4
Vehicle Code Plate 2
Vehicle Designations 1
Vehicle Dimension 4
Vehicle Identification Number (VIN) Plate 1
Vehicle Safety Certification Label ............. 1
Vehicle Weights 4
VEHICLE CODE DESIGNATIONS
VEHICLE CODE = A D (DODGE RAM
PICKUP & CHASSIS CAB)
VEHICLE
FAMILY LINE
DESCRIPTION
AD1 D150
AD2 D250
AD3 D350
PICKUP
4x2
AD5 W150
AD6 W250
AD7 W350
PICKUP
4x4
AD2 D250
AD3 D350
CHASSIS CAB
4x2
AD6 W250
AD7 W350
CHASSIS CAB
4x4
AD4 AD100
AD4 AD150
SPORT UTILITY
4x2
AD8 AD100
AD8 AD 150
SPORT UTILITY
4x4
J90IN-32
2 INTRODUCTION
•
MFD BY
GAWR FRONT
GAWR REAR
CHRYSLER
CORPORATION
DATE OF MFR GVWR
WITH TIRES
WITH TIRES
RIMS AT
RIMS AT
PSI COLD
PSI COLD
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY
STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.
SINGLE DUAL
MDH:
BAR CODE
VEHICLE MADE IN
4648503 J9HN-25
Fig. 1 Vehicle Safety Certification Label
The Vehicle Identification Number is also im-
printed on the:
• Body Code Plate
• Equipment Identification Plate
• Vehicle Safety Certification Label
• And on a frame rail.
VEHICLE CODE PLATE
A metal vehicle code plate (Fig. 2) is attached to
top, right side of cowl below cowl grille. There can be
a maximum of seven rows of vehicle information im-
printed on the plate. The information should be read
from left to right, starting with line 1 at the bottom
of the plate up to line 7 (as applicable) at the top of
the code plate.
Refer to the decoding chart to decode lines 1
through 3.
Lines 4 through 7 on the plate are imprinted in se-
quence according to the following descriptions:
• 3-character sales code
• 3-digit numerical code
• 6-digit SEC code
If there is not enough space left in the row for all
of the 6-digit SEC code:
• The unused space will remain blank
• The code will be listed in the next row.
The last nine positions of row 7 will contain a
2-digit code and a 6-digit serial number.
The last code on a vehicle code plate will be fol-
lowed by the imprinted word END. When two plates
are required, the last available spaces on the first
plate will be imprinted with the letters CTD (for con-
tinued).
When a second vehicle code plate is necessary, the
first four spaces on each row will not be used because
of the plate overlap.
To retrieve information from a vehicle code plate:
• Illuminate the plate with a shop light
• View the plate via the cowl grille slots
• Record the needed coded information.
ENGINE AND TRANSMISSION/TRANSFER CASE
IDENTIFICATION
Refer to Group 9—Engines for all engine identifi-
cation data.
Refer to Group 21—Transmissions for all transmis-
sion/transfer case identification data.
VEHICLE IDENTIFICATION NUMBER (VIN) DECODING
Country
1 = United States
2 = Canada
3 = Mexico
Vehicle Type
4 = Multipurpose
Passenger
5 = Bus
6 = Incomplete
7 = Truck
GVWR and
Hydraulic Brakes
0001
3001
4001
5001
6001
7001
8001
9001
10,001
Bus or I
3000
4000
5000
6000
7000
8000
9000
10,000
14,000
nc.
Truck Line
E = Ramcharger 4x2
Chassis Cab 4x2
Pickup 4x2
M = Ramcharger 4x4
Chassis Cab 4x2
Pickup 4x4
Engines
X = 3.9L (MPI)
Y = 5.2L (MPI)
Z = 5.9L (EFI)
5 = 5.9L HDC
8 = 5.9L Turbo Diesel
Sequential
Serial Number
Six Digit Numbers
Series
0 = 150S Job Rated
1 = 150 Job Rated
2 = 250 Job Rated
3 = 350 Job Rated
Body
3 = Club Cab
6 = Conventional Cab
9 = Sport Utility 2 DR
Plant Location
S = Dodge City
M = Lago Alberto
J931N-18
INTRODUCTION
PRIMARY SECONDARY
PAINT PAINT
VINYL ROOF
CODE
VEHICLE
ORDER-
NUMBER
PAINT-
PI
PROCEDURE (2)
(1)
XXX ) XXXXX) X XXX xxxxxx
X )0C xxxx xxxx xxxx xxx
XXX x xxxxxxxxxxxxxxxxx
TRANSMISSION I VEHICLE IDENTIFICATION
CODE J NUMBER
MARKET U-C-B-M
CODE 90IN-3
Fig. 2 Vehicle Code Plate
VEHICLE CODE DECODING
VEHICLE
MODEL
•NUMBER
ENGINE
-CODE
-INTERIOR
TRIM CODE
Line #1 Digit 1-3 Transmission Sales Code
Digit 4
Open Space
Digit 5
Market Code - U-C-B-M
Digit 6
Open Space
Digit 7-23
Vehicle Identification No.
Line #2 Digit 1-3 Paint Procedure
Digit 4
Open Space
Digit 5-8
Primary Paint
Digit 9
Open Space
Digit 10-13
Secondary Paint
Digit 14
Open Space
Digit 15-18
Trim Code
Digit 19
Open Space
Digit 20-22
Engine Sales Code
Digit 23
Open Space
Line #3 Digit 1-12 Vehicle Order Number
Digit 13
Open Space
Digit 14-16
Vinyl Roof Code (Door Combo Digit
Code - Pillette)
Digit 17 Open Space
Digit 18-23
Model
J901N-20
MAJOR COMPONENT IDENTIFICATION
Refer to the applicable group for identification
data.
EQUIPMENT IDENTIFICATION PLATE
The Equipment Identification Plate is located at
the right, front corner of the inner hood panel. The
plate lists information concerning the vehicle as fol-
lows:
The model
The wheelbase
The VIN (Vehicle Identification Number)
The T.O.N, (order number)
The optional and special equipment installed on
the vehicle
Refer to the information listed on the plate when
ordering replacement parts.
r
§ W l l EQUIPMENT IDENTIFICATION mmm
MODELS V.I.N. T.O.N.
CODE NO. DESCRIPTION CODE NO. DESCRIPTION
. ^
Fig. 3 Equipment Identification Plate
4 INTRODUCTION
•
VEHICLE DIMENSIONS
VEHICLE
FAMILY
WHEELBASE
AVAILABLE
CAB TO
AXLE
BODY
TYPE
SfANDAID SODIES AVAILABLE
VEHICLE
FAMILY
WHEELBASE
AVAILABLE
CAB TO
AXLE
BODY
TYPE
NOMINAL
LENGTH
(LOAD SPACE D MENSIONS (2)
VEHICLE
FAMILY
WHEELBASE
AVAILABLE
CAB TO
AXLE
BODY
TYPE
NOMINAL
LENGTH
LENGTH
MAX.
WIDTH HEIGHT VOLUME
AD-1 AD-5 2921 mm
(115 in)
— Sweptline 1981 mm
(6.5 ft)
1981 mm
(78 in)
1778 mm
(70 in)
485 mm
19.1 in)
1.71 m
3
(60.35 ft
3
)
AD-1 AD-2
AD-3 AD-5
AD-6 AD-7
3327 mm
(131 in)
—
Sweptline 2438 mm
(8 ft)
2489 mm
(98 in)
1778 mm
(70 in)
485 mm
(19.1 in)
2.15 m
3
(75.8 ft
3
)
AD-2 AD-3
AD-7
3327 mm
(131 in)
1422 mm
(56 in)
Chassis
Cab
2438 mm
(8 ft)
— — — —
AD-3 AD-7 3249 mm
(135 in)
1524 mm
(60 in)
Chassis
Cab
2896 mm
(9.5 ft)
— — — —
AD-3 4039 mm
(159 in)
2134 mm
(84 in)
Chassis
Cab
3810 mm
(12.5 ft)
— — —
AD-4 2692 mm
(106 in)
Sport
Utility
4x2
— 1778 mm 1588 mm
(62.5 in)
1062 mm
(41.8 in)
2.99 m
3
(105.8 ft
3
)
AD-8 2692 mm
(106 in)
Sport
Utility
4x4
— 1778 mm 1588 mm
(62.5 in)
1062 mm
(41.8 in)
2.99 m
3
(105.8 ft
3
)
AD-1 3378 mm
(133 in)
— Sweptline 1981 mm
(6.5 ft)
1984 mm
(78.1 in)
1778 mm
(70 in)
485 mm
(19.1 in)
1.71 m
3
(60.4 ft
3
)
AD-1 AD-2
AD-5 AD-6
3785 mm
(149 in)
— Sweptline
Club Cab
2438 mm
(8 ft)
2489 mm
(98 in)
1778 mm
(70 in)
485 mm
(19.1 in)
2.15 M
3
(75.8 ft
3
)
® Driver seat to tailgate.
(2) Based on S.A.E. procedure Jl 100. J901N-34
VEHICLE WEIGHTS
The Vehicle Weights chart provides:
• The Gross Vehicle Weight Rating (GVWR),
• The payload
• The curb weight for each vehicle type/wheelbase
TRAILER TOWING SPECIFICATIONS
The Trailer Towing Specifications chart provides:
• The maximum trailer tongue weight
• The maximum trailer weight
• The maximum combined weight of the trailer/load/
towing vehicle with a specific engine/transmission/
axle combination.
VEHICLE DIMENSION
The Vehicle Dimension chart provides the dimen-
sions for each type of Ram Truck, Ram Chassis Cab
and Ramcharger vehicle.
ENGINE/TRANSMISSION/GVWR
The Engine/Transmission/GVWR chart provides
the maximum load data for each vehicle combina-
tion.
•
INTRODUCTION 5
ENGINE/TRANSMISSION/QVWR
RAM PICKUP
VEHICLE
LINE
WHEELBASE GVWR
ENGINE & SALES CODE TRANSMISSION
VEHICLE
LINE
WHEELBASE GVWR
3.9L
EFI
EHB
5.2L
EFI
ELG
5.9L
EFI
EMG
5.9L
EFI
EMJ
5.9L
DIESEL
ETA
5-SP
MAN.
O.D.
4-SP
MAN.
O.D.
4-SP
MAN.
3-SP
AUTO
4-SP
AUTO
O.D.
D150
4x2
2921 mm
(115 in)
3327 mm
(131 in)
2495 kg
(5500 lbs)
S S O
o
D150
4x2
2921 mm
(115 in)
3327 mm
(131 in)
2495 kg
(5500 lbs)
O S
o o o
D150
4x2
2921 mm
(115 in)
3327 mm
(131 in)
2495 kg
(5500 lbs)
O s o
D150
4x2
3327 mm
(131 in)
2722 kg
(6000 lbs)
S
s o o
D150
4x2
3327 mm
(131 in)
2722 kg
(6000 lbs)
o s o o o
D150
4x2
3327 mm
(131 in)
2722 kg
(6000 lbs)
o s o
D150
4x2
3378 mm
(±33 in)
3785 mm
(149 in)
2722 kg
(6000 lbs)
s s o
D150
4x2
3378 mm
(±33 in)
3785 mm
(149 in)
2722 kg
(6000 lbs)
o s o
D250
4x2
3327 mm
(131 in)
3357 kg
(7400 lbs)
s
s© o
D250
4x2
3327 mm
(131 in)
3357 kg
(7400 lbs)
o s© o o
D250
4x2
3327 mm
(131 in)
3357 kg
(7400 lbs)
o s o
D250
4x2
3785 mm
(149 in)
3357 kg
(7400 lbs)
s s o
D250
4x2
3785 mm
(149 in)
3357 kg
(7400 lbs)
o s o
D250
4x2
3327 mm
(131 in)
3785 mm
(149 in)
3860 kg
(8510 lbs)
s s o
D250
4x2
3327 mm
(131 in)
3785 mm
(149 in)
3860 kg
(8510 lbs)
O s o
D350
4x2
3327 mm
(131 in)
3946 kg
(8700 lbs)
s s o
D350
4x2
3327 mm
(131 in)
3946 kg
(8700 lbs)
O
s o
D350
4x2
3327 mm
(131 in)
4581 kg
(10,100 lbs)
S
s o
D350
4x2
3327 mm
(131 in)
4581 kg
(10,100 lbs)
o s o
W150
4x4
2921 mm
(115 in)
3327 mm
(131 in)
2858 kg
(6300 lbs)
2903 kg
(6400 lbs)
s® s o
W150
4x4
2921 mm
(115 in)
3327 mm
(131 in)
2858 kg
(6300 lbs)
2903 kg
(6400 lbs)
o s© o
W150
4x4
2921 mm
(115 in)
3327 mm
(131 in)
2858 kg
(6300 lbs)
2903 kg
(6400 lbs)
o s o
W150
4x4
3785 mm
(149 in)
2903 kg
(6400 lbs)
s s© o
W150
4x4
3785 mm
(149 in)
2903 kg
(6400 lbs)
o s o
W250
4x4
3327 mm
Q31 in)
3/85 mm
(149 in)
3402 kg
(7500 lbs)
s s© o
W250
4x4
3327 mm
Q31 in)
3/85 mm
(149 in)
3402 kg
(7500 lbs)
o s o
W250
4x4
3327 mm
(131 in)
3785 mm
(149 in)
3860 kg
(8510 lbs)
s s o
W250
4x4
3327 mm
(131 in)
3785 mm
(149 in)
3860 kg
(8510 lbs)
o s o
W350
4x4
3327 mm
(131 in)
3946 kg
(8700 lbs)
s s o
W350
4x4
3327 mm
(131 in)
3946 kg
(8700 lbs)
o s o
W350
4x4
3327 mm
(131 in)
4581 kg
(10,100 lbs)
s s o
W350
4x4
3327 mm
(131 in)
4581 kg
(10,100 lbs)
o s o
S = STANDARD O = OPTIONAL ©= Not available in California J90IN-39
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1991-1994 Dodge D150 Ramcharger Service & Repair Manual
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The Dodge D150 Ramcharger 1991 1992 1993 1994 Workshop Service Manual for Repair is an essential resource for both professional mechanics and DIY enthusiasts. This comprehensive manual provides detailed data, characteristics, instructions, and methodology for performing repair interventions on the vehicle and its components.
It includes special notes, important points, service data, precautions, and more that are necessary for maintenance, adjustments, service, removal, and installation of vehicle components. The manual offers the most detailed, comprehensive step-by-step procedures, explanations, and pictorial diagrams from bumper to bumper for the Dodge D150 Ramcharger 1991 1992 1993 1994.
With detailed illustrations, exploded diagrams, drawings, and photos, this manual guides users through every service repair procedure. It also provides information on service tool numbers and their usage, ensuring efficient repair operations.
This service manual is viewable on any computer, allowing users to zoom in, print, and access the information easily. It has been specially prepared to provide simple explanations, making it suitable for individuals with varying levels of experience in vehicle maintenance and repair.
Additionally, the manual contains general descriptions for accomplishing service and repair work with tested, effective techniques, ensuring reliability and safety. It covers information on construction, function, troubleshooting, servicing specifications, and more.
For the maintenance and repair of the Dodge D150 Ramcharger 1991 1992 1993 1994, it is essential to strictly observe all accident prevention guidelines and use the correct tools and equipment. The manual also emphasizes the importance of using genuine parts and approved lubricants to maximize the vehicle's lifespan.
Overall, this Dodge D150 Ramcharger 1991 1992 1993 1994 Workshop Service Manual for Repair is a complete and intact resource, providing technical information, adjustment values, and valuable reference data for maintenance and repair work.
It is designed for use by trained technicians in a properly equipped workshop, but it contains enough detail and basic information to be useful to owners who wish to perform their own basic maintenance and repair work, provided they have the necessary tools and knowledge of mechanics.
For a complete repair work and to ensure the vehicle remains in optimum condition, it is recommended to fully utilize this manual and follow the maintenance requirements and procedures outlined within.
