Chrysler RAM TRUCK 2500 1994 User manual

199 4
SERVICE
MANUAL
RAM TRUCK
1500 - 3500
^CHRYSLER
^CORPORATION

CHRYSLER
CORPORATION
SERVICE MANUAL
1994
RAM TRUCK
1500- 3500
To order the special service tools used and
illustrated, please refertotheinstructionson
inside back cover.
^fe CHRYSLER
WCORPORATION
NOPARTOFTHISPUBLICATIONMAYBE
REPRODUCED,STOREDINA RETRIEVAL
SYSTEM, ORTRANSMITTED,INANYFORM
ORBYANYMEANS,ELECTRONIC,ME-
CHANICAL, PHOTOCOPYING,RECORDING,
OROTHERWISE,WITHOUTTHEPRIOR
WRITTEN PERMISSIONOFCHRYSLER
CORPORATION.
Chrysler Corporation reserves therightto make changes In design orto
make additions toor Improvements InIts products withoutimposinganyob-
ligations upon itselftoinstall them onits products previously manufactured.
Litho InU.S.A.Copyright© 1993 Chrysler Corporation20M0793

FOREWORD
Theinformationcontainedinthisservicemanualhas been preparedfortheprofessionalautomotivetech-
nician involvedindailyrepairoperations.Thismanual does notcovertheoryofoperation, which is addressed
in servicetrainingmaterial.Informationdescribingtheoperationanduseofstandardandoptionalequipment
isincludedintheOwner'sManualprovided with thevehicle.
Information inthismanualisdividedintogroups. These groupscontaingeneralinformation,diagnosis,
testing,adjustments,removal,installation,disassembly,andassembly procedures forthecomponents.Toas-
sistinlocatinga group title page, usetheGroupTabLocatoronthe following page. The solid barafterthe
group title isalignedtoa solid tabonthe first page of each group.The first page ofthegrouphasa contents
sectionthatlistsmajortopics within thegroup.Ifyouarenot sure which Groupcontainstheinformationyou
need, lookuptheComponent/Systeminthealphabeticalindexlocatedinthe rear ofthismanual.
A ServiceManualComment form isincludedatthe rear ofthismanual.Usethe form toprovideChrysler
Corporation with yourcommentsandsuggestions.
Tightening torquesareprovidedasa specificvaluethroughoutthismanual.Thisvalue represents the
midpoint ofthe acceptable engineeringtorque range fora given fastener application. These torquevaluesare
intendedforuseinserviceassemblyandinstallation procedures usingthecorrectOEM fasteners. Whenre-
placing fasteners, alwaysusethe same type(partnumber) fastener asremoved.
ChryslerCorporation reserves therightto change testingprocedures,specifications,diagnosis,repair
methods,orvehicle wiring atanytimewithoutpriornoticeorincurringobligation.
NOTE: Theacronyms,terminologyandnomenclature used to identify emissionsrelatedcomponentsin
this manualmay have changed from priorpublications. These newtermsareincompliance with S.A.E.
recommendedpracticeJ1930.

GROUP TABLOCATOR
«—«Introduction
f) LubricationandMaintenance
2FrontSuspensionandAxle
3RearSuspensionandAxles
5Brakes
6Clutch
7CoolingSystem
8Electrical
9Engines
"f1 ExhaustSystemandIntakeManifold
%3 FrameandBumpers
'f4 FuelSystem
*f0 PropellerShafts
°f0 Steering
2iTransmissionsandTransferCases
22wh®6lsand Tires
23BodyComponents
24HeatingandAirConditioning
25EmissionControlSystems
Index
ServiceManualCommentForms(RearofManual)

•
INTRODUCTION 1
INTRODUCTION
CONTENTS
pagepage
FASTENER TORQUE INFORMATIONAND GENERAL INFORMATION1
METRIC CONVERSION .17
GENERALINFORMATION
INDEX
page
Body Code Plate 1
EquipmentIdentificationLabel2
GrossVehicleWeightRating—2WDPickup6
Gross VehicleWeightRating—4WDPickup7
Gross VehicleWeightRating—Pickup8.0LorDiesel...8
Gross VehicleWeightRating—2WD Chassis Cab5.9L. . 9
Gross VehicleWeightRating-4WD Chassis Cab5.9L. 10
Gross VehicleWeightRating—2WD Chassis Cab
8.0LorDiesel. . 11
Gross VehicleWeightRating—4WD Chassis Cab
8.0LorDiesel12
page
InternationalVehicelControlandDisplaySymbols. . 3
TrailerTowing—ChassisCab16
TrailerTowing—Pickup13
VehicleExterior Dimensions—Chassis Cab5
VehicleExteriorDimensions—Pickup4
VehicleIdentificationNumber (VIN) 1
VehicleInteriorDimensions. . . 3
Vehicle Safety CertificationLabel1
VEHICLE IDENTIFICATIONNUMBER(VIN)
TheVehicleIdentificationNumber (VIN) plate (Fig.
1)islocatedonthelowerwindshield fence near the
left A-pillar. TheVIN contains 17 characters that
provide data concerningthevehicle.Refertothe VIN
decodingchartto determine theidentificationofa ve-
hicle.
Fig. 1 Vehicle Identification Number (VIN) Location
TheVINisincludedonthe:
•Body Code Plate
•EquipmentIdentification Plate
•Vehicle Safety CertificationLabel
• Frame rail.
Toprotectthe consumer fromtheftand possible
fraudthemanufacturerisrequiredtoincludea
Check Digit attheninthpositionoftheVehicleIden-
tification Number.The check digitis used bythe
manufacturerandgovernment agencies toverifythe
authenticityofthevehicleand official documenta-
tion. Theformulatousethe check digitisnotre-
leased tothe general public.
BODY CODE PLATE
TheBody Code Plate islocatedonthefloorpan
rearwardofthe passenger side seat. There are seven
linesofinformationonthebody code plate.Lines4,
5,6,and7 arenot used todefine service information.
Information reads fromlefttoright,starting with
line 3 inthe center ofthe plate toline1 atthebot-
tom oftheplate.
VEHICLE SAFETY CERTIFICATION LABEL
A Vehicle Safety CertificationLabel(Fig.2)isat-
tached tothedriversdoorlockpillar.Thelabelcerti-
fiesthatthevehicleconformsto Federal Motor
Vehicle Safety Standards (FMVSS).Thecertification
labelliststhe following:

2 INTRODUCTION
•
VIN DECODING CHART
POSITlON-INTERPiETATIOIf . . . CODE=DESCRIPTION
1 -Countryoforigin...1 = United States
2 = Canada
3= Mexico
2-Make........... B = Dodge
3-VehicleType4 = Multipurpose Passenger Vehicle
5= Bus
6= IncompleteVehicles
7= Truck
4-Gross Vehicle.
WeightRating
D = 0-1360kg (1-3,000 lbs.)
E = 1361-1814kg (3,001-4,000 lbs.
F = 1815-2267kg (4,001-5,000 lbs
G = 2268-2721kg (5,001-6,000 lbs/
H « 2722-3175kg 6,001-7,000 lbs.
J« 3176-3628kg 7,001-8,000 lbs.
K = 3629-4082kg (8,001-9,000 lbs.,
L«4083-4535kg 9,001-10,000Ibs.J
M = 4536-6350kg (10,001-14,000 lbs.)
W = Busses/Incomplete Vehicles with
Hydraulic Brakes
5-CarLineC = 2WD-Dodge/RamPickup, Chassis Cab
F = 4WD-Dodae/RamPickup, Chassis Cab
6- Series 1 = 1500JobRating
2= 2500 JobRating
3= 3500 JobRating
7-BodyStyle6 = Conventional Cap/Chassis Cab
8- Engine C = 5.9L6 cyl. TURBODiesel
W = 8.0L10 cyl. Gasoline MFI
X = 3.9L6cy(. Gasoline MFI
Y = 5.2L8 cyl. Gasoline MFI
Z = 5.9L8cyl.Gasloline MFI-LDC
5= 5.9L8 cyl. Gasoline MFI-HDC
9- Check Digit See VIN paragraph
10-ModelYearR=1994
11 -Assembly Plant ....M = Logo,Mexico
S= Dodge City J94IN-24
12THRU17-Vehicle Build Sequence
BODY CODE PLATE
PRIAAARY SECONDARY VINYL ROOF
PAINT PAINT
VEHICLE
ORDER
NUMBER
PAINT -
PROCEDURE(2)
(1)
XXX XXXXXXXXXXXXXXX
XXX X xxxxxxxxxxxxxxxxx
ION I
ENGINE
• TRIM
TRANSMISSION | VIN
MARKET
93IN-8
• Month andyearofvehiclemanufacture
• Gross VehicleWeightRating (GVWR). The gross
front and rear axleweightratings(GAWR's)are
based ona minimumrim size andmaximumcoldtire
inflation pressure
• VehicleIdentificationNumber (VIN)
• Typeofvehicle
• Typeof rear wheels(singleordual)
• Bar code
• Month, DayandHour (MDH) of final assembly
MFD BY
GAWR FRONT
GAWR REAR
CHRYSLER
CORPORATION
WITH TIRES
WITH TIRES
DATE OF MFR
GVWR
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.
VIN:
TYPE:
SINGLE
DUAL
BAR CODE
VEHICLE MADEIN
4648503 J91IN-25
Fig. 2 Vehicle Safety Certification Label
EQUIPMENTIDENTIFICATION LABEL
TheEquipmentIdentificationPlateislocatedat
theright,frontcorneroftheinnerhoodpanel.The
platelistsinformationconcerningthevehicleas fol-
lows:
• Themodel
• The wheelbase
• The VIN (VehicleIdentificationNumber)
• The T.O.N, (ordernumber)
• Theoptionalandspecialequipmentinstalledon
thevehicle
Refertotheinformationlistedontheplatewhen
ordering serviceparts.
r£aRMB
EQUIPMENTIDENTIFICATION 421MM
MODELS V.I.N.T.O.N.
CODE NO. DESCRIPTION
CODE NO. DESCRIPTION
Fig. 3 Equipment Identification Plate

INTRODUCTION 3
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS
ID
HIGH BEAM
FOG LIGHTS
HEADLIGHTS,
PARKINGLIGHTS,
PANEL UGHTS TURNSIGNAL
A
HAZARDWARNING WINDSHIELD
WASHER
WINDSHIELD
WIPE! WINDSHIELD
WIPER
AND WASHER
<9
WINDSCREEN
DEMISTING
AND DEFROSTING
*
VENTILATING FAN
99 9
REARWINDOW
DEFOGGER
REARWINDOW
WIPER
m
•
REARWINDOW
WASHER FUEL ENGINECOOLANT
TEMPERATURE
Lt3
BATTERYCHARGING
CONDITION ENGINEOIL
M-
SEAT BELT
CD
BRAKEFAILURE
(®)
PARKINGBRAKE
FRONT HOOD REARHOOD
(TRUNK) HORN
n,i
LIGHTER
93IN-9
VEHICLE INTERIOR DIMENSIONS
A HeadRoom 40.2
B HipRoom 65.8
C
Shoulder Room 66.3
D Seat Width
60.2
E
Seat Height 13.2
F Seat Depth 19.0
G
Seat Adjustment(Foreandaft) 7.5
H
Leg Clearance(Seattosteeringwheel) 5.9
1
Steering WheelToSeatback(Max) 15.9
J Leg
Room 41.0
K
Back OfSeatTo Back OfCab
—Top
—Bottom 3.8
13.2
Seatback Angle(Degrees) 21.0
DoorOpeningHeight 47.1
DoorOpening Width
41.8
Note:Alldimensionsarein inches unless noted.
J94IN-26

4INTRODUCTION •
VEHICLE EXTERIOR DIMENSIONS—PICKUP
1500/
15004x4
2500/
2500 4x4
3500/
3500 4x4
A Wheelbase
119"
135" 135" 135"
B 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
C
—Rear
10.1/9.8 10.1/9.8 10.1/9.8 10.1/9.8
D
Overall Length
—Without rearbumper 199.9 220.1 220.1 220.1
D
—With rearbumper 204.1 224.3 224.3 224.3
E
Overall Height(Empty) 72.1/75.9 72.1/75.9 73.7/78.0
73.6/75.9
F Overall Width
—AtFrontWheelLip 79.4 79.4 79.4
79.5'
G
Track
—Front 68.5 68.5 68.6 68.6
G
—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 37.9
J
Overhang—Rear
—Without Rear Bumper 47.6 47.6 47.6 47.6
J
—With Rear Bumper 51.7 51.7 51.7 51.7
K
Back OfCabTo
Rear Bumper 87.2 107.4 107.4 107.4
L
Front BumperTo
Back OfCab 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
N
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
'93.5 atcargobox.
J94IN-25

EXTERIOR
Model
4x2 Models
4x4 Models
Model
2500
HD
3500
DRW
3500
DRW
2500
HD
3500
DRW
3500
DRW
A
Wheelbase 135 139 163 135 139 163
B
Cab ToAxle 55.7 59.7 83.7 55.7 59.7 83.7
C
OverallLength 216.7
220.7 244.7
216.7 220.7 244.7
D OverallHeight(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
G
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
AxleToEndOfFrame 44.1 44.1 44.1 44.1 44.1 44.1
K
CenterOfFrontWheel
ToBackOfCab 79.0 79.0 79.0 79.0 79.0 79.0
L
FrameToTopOfCab 52.9 52.9 52.9 52.9 52.9 52.9
Ni TopOfFrameToGround 29.6 34.3 34.1 34.0 34.3 34.2
N Inside
Width Between
FrameRails 31.7 31.7 31.7 31.7 31.7 31.7
O Outside
Width Between
FrameRails 37.6 37.6 37.6 37.6 37.6 37.6
P
FrontBumperToBack
OfCab 1169 116.9 1169 116.9 116.9 116.9
Q FrontOfDashTo
Back OfCab NA NA NA NA NA NA
R
GroundClearance
—Front 10.1 15.2 15.2 8.1 8.6 8.6
R
—Rear
8.5 90 9.0 8.4 9.0 9.0
NOTE: Alldimensionsarein
DRW= Dual-rearwheel.
NA= Notavailableat time
inches unlessnoted,
ofprinting.
QJD