1996-1997 Dodge Ram 2500 Series Service & Repair Manual

19 9 5 SERVICE MANUAL RAM TRUCK 1500 - 3500 ft 2 WHEEL DRIVE 4 WHEEL DRIVE ^CHRYSLER W CORPORATION

GROUP TAB LOCATOR Introduction 0 Lubrication and Maintenance 2 Front Suspension and Axle 3 Rear Suspension and Axles 5 Brakes j- j v # :: 3 6 Clutch HHHHHHjj 7 Cooling System 8 Electrical v ^i 9 Engines 11 Exhaust System and Intake Manifold 13 Frame and Bumpers 14 Fuel System 16 Propeller Shafts 19 Steering , v-.--.'\. 21 Transmissions and Transfer Cases 22 Wheels and Tires 23 Body Components 24 Heating and Air Conditioning . , f..- '• 7;.^' 25 Emission Control Systems Index Service Manual Comment Forms (Rear of Manual)

BR INTRODUCTION 1 INTRODUCTION CONTENTS page page DESIiNATIONS, LA1ELS/PLATE8/DECALS, l E I S U i E i E N T AND TOFtQUE COOES ANi DilENSIONS/WEIiHTS 1 SPECIFICATIONS 21 DESIGNATIONS, LABELS/PLATES/DECALS, CODES AND DIMENSIONS/WEIGHTS INDEX page Body Code Plate 2 Engine and Transmission/Transfer Case Identification 2 Equipment Identification Label 2 International Vehicle Control and Display Symbols . . 3 Major Component Identification 2 VEHICLE DESIGNATION The Vehicle Code Designation for Ram Truck vehi- cles is BR. The code is used to identify the vehicle in charts, captions and in service procedures. The vehicle code is different than the Vehicle Identification Number (V1N) or the wheelbase/model code. VEHICLE SAFETY CERTIFICATION LABEL A certification label is attached to the left side B- pillar (Fig. 1). 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 . • Bar code. • Month, Day and Hour (SlDH) 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 (Fig. 2). 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 19 Vehicle Designation . 1 Vehicle Dimensions . 3 Vehicle Identification Number (VIN) Plate 1 Vehicle Safety Certification Label ............... 1 Vehicle Weights 8 m r v B I CORPORATION XX-XX 04800 LB 2223 KG ' GAWR FRONT ; WITH TIRES > RIMS AT PSI COLD > | 2500 LB 1134 KG j P215/75R15 j 15x 7.0 30 | ; GAWR REAR ' WITH TIRES \ RIMS AT PSI COLD ! j 2700 LB 1225 KG j P215/7SR15 j 15x 7.0 30 j TNIS VEHKLE CONFORMS TO ALL APPLKAILE FEDERAL MOTOR VEHKLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE. VIN: xxxxxxxxxxxxxxxxx TYPE: MPV SINGLE X DUAL MDH: xxxxxx xxx MADE IN U.SJL. 4340503 J95IN-1 Fig. 1 Vehicle Safety Certification Label—Typical The Vehicle Identification Number is also im- printed on the: • Body Code Plate. ' Equipment Identification Plate. • Vehicle Safety Certification Label. • Frame rail. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden- tification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta-

2 INTRODUCTION BR NSTRUMENT -VEHICLE IDENTIFICATION NUMBER PLATE VIN J94SN -23 BODY CODE PLATE PRIMARY SECONDARY VINYL ROOF PAINT PAINT VEHICLE ORDER - NUMBER PAINT - (3) PROCEDURE (2) (1) XXX X _ ± _r XXXX> K XXX xxxxxx XXX xxxx xxxx xxxx XXX XXX X XXXXXXXXXXXXXXXXX Fig. 2 Vehicle Identification Number (VIN) Location tion. The formula to use the check digit is not re- leased to the general public. BODY CODE PLATE The Body Code Plate is located on the floor pan un- der the passenger side seat. There are seven lines of information on the body code plate. Lines 4, 5, 6, and 7 are not used to define service information. Informa- tion reads from left to right, starting with line 3 in the center of the plate to line 1 at the bottom of the plate. ENGINE AND TRANSMISSION/TRANSFER CASE IDENTIFICATION Refer to Group 9, Engines for all engine identification data. VEHICLE IDENTIFICATION ON j CAR LINE SHELL ENGINE •TRIM TRANSMISSION | VIN AAARKET 93IN-8 Refer to Group 21, Transmissions for all transmission/transfer case identification data. 1AJ0R COiPONENT IDENTIFICATION Refer to the applicable group for identification data. E0U1P1ENT IDENTIFICATION LABEL The Equipment Identification Plate (Fig. 3) is located at the right, front corner of the inner hood panel. The plate lists information concerning the vehicle as follows: • The model. • The wheelbase. • The VIN (Vehicle Identification Number). • The T.O.N, (order number). NUMBER (VIN) DECODING 1 B z. Moke B = Dodge Vehicle Type 4 = Multipurpose Passenger 5 = Bus 6 = Incomplete 7 = Truck 7 n z Line C = Ram Chassis Cab/ Ram Pick-up (4 x 2) F = Ram Chassis Cab/ Ram Pick-up (4 x 4) GVWR H = 6001 -7000 J - 7001-8000 K = 8001-9000 L = 9001-10,000 M = 10,001-14,000 W = Hydraulic Brakes Engine C = 5.9L 6 cyl. Diesel W= 8.0L 10 cyl. MPI X = 3.9L 6 cyl. MPI Y = 5.2L 8 cyl. MPI Z = 5.9L 8 cyl. MPI-LDC 5 = 5.9L 8 cyl. MPI-HDC Check Digit Number or Letter Body 3 = Club Cab 6 = Conventional Cab Chassis Cab Chassis Sequential Serial Number Six Digit Numbers 100001 Plant Location S = Dodge City G = Saltillo Lago Alberto Assembly J95IN-36

BR INTRODUCTION 3 BODY CODE DECODING • The optional and special equipment installed on the vehicle. Refer to the information listed on the plate when ordering service parts. Ifrmeum EQUIPMENT IDENTIFICATION wmm' MODELS V.I.N. T.O.N. CODE NO. DESCRIPTION CODE NO. DESCRIPTION J90IN-3> Fig. 3 Equipment Identification Plate INTERNATIONAL VEHICLE CONTROL AND DISPLAY SfiBOLS The graphic symbols illustrated on the following chart are used to identify various instrument controls. The symbols correspond to the controls and dis- plays that are located on the instrument panel. VEHICLE DIMENSIONS The Vehicle Interior and Exterior Dimension charts provides the dimensions for each type of Ram truck. 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 Code - Pillette) Digit 17 Open Space Digit 18-23 Model " ~ ' " J901N-20 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS 10 HIGH BEAM £0 FOG LIGHTS HEADLIGHTS, PARKING UGHTS, PANEL LIGHTS TURN SIGNAL A HAZARD WARNING WINDSHIELD WASHER WINDSHIELD WIPER %? WINDSHIELD WIPER AND WASHER WINDSCREEN DEMISTING AND DEFROSTING VENTILATING FAN ISP REAR WINDOW DEFOGGER GP REAR WINDOW WIPER CD i m i E 3 * REAR WINDOW WASHER FUEL ENGINE COOLANT TEMPERATURE BATTERY CHARGING CONDITION ENGINE OIL SEAT BELT (©) & LIGHTER BRAKE FAILURE PARKING BRAKE FRONT HOOD REAR HOOD (TRUNK) HORN LIGHTER J95IN-23

4 INTRODUCTION BR VEHICLE INTERIOR DIMENSIONS—STD CAB A Head Room 40.2 B Hip Room 65.8 C Shoulder Room 66.3 D Seat Width 60.2 E Seat Height 13.2 F Seat Depth 19.0 c§ Seat Adjustment (Fore and aft) 7.5 H Leg Clearance (Seat to steering wheel) 5.9 I Steering Wheel To Seatback (Max) 15.9 J Leg Room 41.0 §c Back Of Seat To Back Of Cab —Top —Bottom 3.8 13.2 Seatback Angle (Degrees) 21.0 Door Opening Height 47.1 Door Opening Width 41.8 Note: All dimensions are in inches unless noted. J94IN-26 VEHICLE INTERIOR DIMENSIONS—CLUB CAB Front Rear A Head Room 40.2 39.4 B Hip Room 65.8 66 8 C Shoulder Room 66.3 67.7 D Seat Width 60.2 NA E Seat Height 13.2 NA F Seat Depth 19.0 NA G Seat Adjustment (Fore and aft) 7.5 NA H Leg Clearance (Seat to steering wheel) 5.9 NA 1 Steering Wheel To Seatback (Max) 15.9 NA J Leg Room 41.0 33.2 K Back Of Seat To Back Of Cab —Top —Bottom 3.8 13.2 NA NA Seatback Angle (Degrees) 21.0 16.0 Door Opening Height 47.1 NA Door Opening Width 41.8 NA Behind-Seat Storage—Seat Up (cu ft) — NA Note: All dimensions are in inches unless noted. J95IN-25

BR INTRODUCTION 5 VEHICLE EXTERIOR DIMENSIONS—STD CAB 1500/ 1500 4x4 2500/ 2500 4x4 3500/ 3500 4x4 A Wheelbase 119" 135" 135" 135" 1 Box Length (feet) 6.5 8.0 8.0 8.0 C Ground Clearance {Empty) —Front 9.7/8.1 10.0/8.1 10.1/8.1 13.1/10.2 —Rear 10.1/9.8 10.1/9.8 10.1/9.8 10.1/9.8 D Overall Length -—Without rear bumper 199.9 220.1 220.1 220.1 —With rear bumper 204.1 224.3 224.3 224.3 1 Overall Height (Empty) 72.1/75.9 72.1/75.9 73.7/78.0 73.6/75.9 F Overall Width —At Front Wheel Lip 79.4 79.4 79.4 79.5 1 G Track ' —Front 68.5 68.5 68.6 68.6 —Rear 68.0 68.0 68.0 73.0 H Tailgate Load Height 31.2/35.6 31.5/35.6 31.5/35.6 31.4/35.6 1 Overhang—Front 37.9 37.9 37.9 37 Q J Overhang—Rear —Without Rear lumper 47.6 47.6 47.6 47.6 —With Rear lumper 51.7 51.7 51.7 51.7 K Back Of Cab To Rear Bumper 87.2 107.4 107.4 107.4 L Front Bumper To Back Of Cab 116.9 116.9 116.9 116.9 M Approach Angle (Degrees) 25.3/29.7 25.3/29.7 25.3/29.7 25.3/29.7 M Breakover Angle (Degrees) 17.8/21.0 17.8/21.0 17.8/21.0 17.8/21.0 o Departure Angle (Degrees) 30.6/36.2 30.6/36.2 30,6/36.2 30.6/36.2 5u_ KV 50.0 C } 93.5 at cargo box. J94IN-25

INTRODUCTION VEHICLE EXTERIOR DIMENSIONS—CLUB CAB 1500/ 15004x4 2500/ 25004x4 3500/ 35004x4 A Wheelbase 139" 155" 139" 155" 155" 1 Box Length (Feet) 6.5 8.0 8.0 6.5 8.0 C Ground Clearance— (Empty) —Front 87/8.5 8.6/8.5 9.9/9.0 9.8/9.1 9.8/8.1 C —Rear 7.5/7.7 75/7.7 8.6 8.6 8.6 D Overall Length —Without rear bumper 220.1 240.1 220.1 240.1 240.1 D —With rear bumper 224.0 244.0 224.0 244.0 244.0 1 Overall Height (Empty) 71.6/74.6 71.5/74.5 72.9/77.2 72.8/77.1 72.8/77.2 F Overall Width Of Cab 79.4 79.4 79.4 79.4 79.4 G Track —Front 66.9/68.5 66.9/68.5 68.6/68.9 68.6/68.9 69.8 G —Rear 66.9 66.9 68.0 68.0 73.0 H Tailgate Load Height 31.3/33.9 31.3/34.4 34.4/373 33.3/37.2 33.8/37.8 I Overhang—Front 37 9 37.9 37.9 37.9 37.9 J Overhang—Rear —Without rear bumper 43.5 47.5 47.5 43.5 47.5 J —With rear bumper 47.5 51.5 51.5 47.5 51.5 K Back of Cab To Rear Bumper 87.1 107.1 107.1 87.1 107.1 L Front Bumper To Back Of Cab 136.9 136.9 136.9 136.9 136.9 M Approach Angle (Degrees) 25.1/30.6 25.2/30.6 26.7/33.7 26.8/33.8 26.3/33.4 N Breakover Angle (Degrees) 16.7/18.4 15.8/17.1 19.2/23.0 18.1/21.3 18,0/21 4 © Departure Angle (Degrees) 23.8/26.9 21.8/24.7 26.0/31.0 24.1/28.4 24.6/28.9 (1) 93.8 at cargo box with dual-rear wheels. Note: All dimensions in inches unless otherwise noted.

BR INTRODUCTION 7 VEHICLE EXTERIOR DIMENSIONS—CHASSIS CAB EXTERIOR Model 4x2 Models 4x4 Models Model 28§0 HD 35§t DRW 3500 DRW 2500 HD 3500 DRW 3500 PRW A Wheelbase 135 139 163 135 139 163 B Cab To Axle 55.7 59.7 83.7 55.7 59.7 83.7 C Overall Length 216.7 220.7 244.7 216.7 220.7 244.7 D Overall Height (Empty) 72.4 77.3 77.1 75.9 77.2 77.1 E Overall Width 79.4 94.6 94.6 79.4 94.6 94.6 F Track —Front 68.6 69.8 69.8 68.9 69.8 69.8 F —Rear 68.0 73.0 73.0 68.0 73.0 73.0 6 Rear Track, Inside 58.0 51.4 51.4 58.0 51.4 51 4 H Rear Track, Outside 78.0 94.6 94.6 78.0 94.6 94.6 1 Overhang—Front 37.9 37.9 37.9 37.9 37.9 37.9 J Axle To End Of Frame 44.1 44.1 44.1 44.1 44.1 44.1 K Center Of Front Wheel To Back Of Cab 79.0 79.0 79.0 79.0 79.0 79.0 L Frame To Top Of Cab 52.9 52.9 52.9 52.9 52.9 52.9 M Top Of Frame To Ground 29.6 34.3 34.1 34.0 34.3 34.2 N Inside Width Between Frame Rails 31.7 31.7 31.7 31.7 31.7 31.7 o Outside Width Between Frame Rails 37.6 37.6 37 6 37.6 37.6 37.6 P Front Bumper To Back Of Cab 116.9 116.9 116.9 116.9 116.9 116.9 Q Front Of Dash To Back Of Cab NA NA NA NA NA NA ft Ground Clearance —Front 10.1 15.2 15.2 8.1 8.6 8.6 ft —Rear 8.5 9.0 90 8.4 9.0 9.0 NOTE: All dimensions are in DRW = Dual-rear wheel. NA = Not available at time inches unless noted, of printing. J94IN-27

1996-1997 Dodge Ram 2500 Series Service & Repair Manual

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