Dodge RAM TRUCK 1500 1995 User manual

199 5
SERVICE
MANUAL
RAM TRUCK
1500 - 3500
ft
2WHEEL DRIVE
4WHEEL DRIVE
^CHRYSLER
WCORPORATION

CHRYSLER
CORPORATION
SERVICE MANUAL
1995
RAM TRUCK
1500 - 3500
Toorder the specialservicetoolsused and
illustrated,pleaserefer tothe instructions on
insidebackcover.
^WCHRYSLiR
w CORPORATION
NOPAET OF THISPUBLICATION MAYBE
REPRODUCED,STORED INA RETRIEVAL
SYSTEM, OR TRANSMITTED, INANY FORM
OR BYANY MEANS,ELECTRONIC, ME-
CHANICAL,PHOTOCOPYING,RECORDING,
OROTHERWISE,WITHOUT THE PRIOR
WRITTENPERMISSION OF CHRYSLER
CORPORATION.
Chrysler Corporation reserves the right to make changes in design orto
make additions toor improvements inIts productswithoutimposing anyob-
ligations uponitself to installthem onits products previously manufactured.
Litho in U.S.A.Copyright © 1994 ChryslerCorporation 20M0694
Paper Content
50%Recycled

FOREWORD
-Theinformationcontainedinthisservicemanualhasbeenpreparedfortheprofessionalautomotivetech-
nicianinvolvedindailyrepairoperations.Thismanualdoesnotcovertheoryofoperation,whichisaddressed
inservicetrainingmaterial.Informationdescribingtheoperationanduseofstandardandoptionalequipment
isincludedintheOwner'sManualprovidedwiththevehicle.
Informationinthismanualisdividedintogroups.Thesegroupscontaingeneralinformation,diagnosis,
testing,adjustments,removal,installation,disassembly,andassemblyproceduresforthecomponents,lbas-
sistinlocatinga grouptitlepage,usetheGroupTabLocatoronthefollowingpage.Thesolidbarafterthe
grouptitleisalignedtoa solidtabonthefirst pageofeachgroup.Thefirst pageofthegrouphasa contents
sectionthatlistsmajortopicswithinthegroup.IfyouarenotsurewhichGroupcontainstheinformationyou
need,lookuptheComponent/Systeminthealphabeticalindexlocatedintherearofthismanual.
A ServiceManualCommentformisincludedattherearofthismanual.UsetheformtoprovideChrysler
Corporationwithyourcommentsandsuggestions.
Tighteningtorquesareprovidedasa specificvaluethroughoutthismanual.Thisvaluerepresentsthe
midpointoftheacceptableengineeringtorquerangefora givenfastenerapplication.Thesetorquevaluesare
intendedforuseinserviceassemblyandinstallationproceduresusingthecorrectOEMfasteners.Whenre-
placingfasteners,alwaysusethesametype(partnumber)fastenerasremoved.
ChryslerCorporationreservestherighttochangetestingprocedures,specifications,diagnosis,repair
methods,orvehiclewiringatanytimewithoutpriornoticeorincurringobligation.
NOTE:Theacronyms,terminologyandnomenclatureusedtoidentifyemissionsrelatedcomponentsin
thismanualmayhavechangedfrompriorpublications.ThesenewtermsareincompliancewithS.A.E.
recommendedpracticeJ1930.

GROUP TAB LOCATOR
Introduction
0LubricationandMaintenance
2 Front Suspensionand Axle
3RearSuspensionand Axles
5 Brakes j- jv#::3
6 Clutch
HHHHHHjj
7 Cooling System
8Electricalv^i
9Engines
11 ExhaustSystemand Intake Manifold
13 FrameandBumpers
14 FuelSystem
16 PropellerShafts
19 Steering, v-.--.'\.
21TransmissionsandTransfer Cases
22WheelsandTires
23 Body Components
24HeatingandAirConditioning.,f..-'•7;.^'
25EmissionControlSystems
Index
Service Manual Comment Forms(RearofManual)

BR
INTRODUCTION1
INTRODUCTION
CONTENTS
pagepage
DESIiNATIONS, LA1ELS/PLATE8/DECALS, lEISUiEiENTANDTOFtQUE
COOES ANiDilENSIONS/WEIiHTS1 SPECIFICATIONS 21
DESIGNATIONS, LABELS/PLATES/DECALS, CODES AND DIMENSIONS/WEIGHTS
INDEX
page
Body CodePlate2
Engine and Transmission/Transfer Case
Identification 2
Equipment Identification Label2
International Vehicle Control andDisplaySymbols. . 3
Major Component Identification 2
VEHICLE DESIGNATION
TheVehicleCodeDesignationforRamTruckvehi-
clesis BR. Thecodeisusedtoidentifythevehiclein
charts,captionsandinserviceprocedures.Thevehi-
clecodeisdifferentthantheVehicleIdentification
Number(V1N)orthewheelbase/modelcode.
VEHICLE SAFETY CERTIFICATION LABEL
AcertificationlabelisattachedtotheleftsideB-
pillar(Fig. 1). Thelabelcertifiesthatthevehiclecon-
formstoFederalMotorVehicleSafetyStandards
(FMVSS).Thelabelalsoliststhe:
•Monthandyearofvehiclemanufacture.
•GrossVehicleWeightRating(GVWR).Thegross
frontandrearaxleweightratings(GAWR's)are
basedona minimumrimsizeandmaximumcoldtire
inflationpressure.
•VehicleIdentificationNumber(VIN).
•Typeofvehicle.
®Typeofrearwheels.
•Barcode.
•Month,DayandHour(SlDH)offinal assembly.
VEHICLE IDENTIFICATION NUMBER (VIN) PLATE
TheVehicleIdentificationNumber(VIN)plateis
attachedtothetopleftsideoftheinstrumentpanel
(Fig.2).TheVINcontains17charactersthatprovide
dataconcerningthevehicle.Refertothedecoding
charttodeterminetheidentificationofa vehicle.
page
Trailer Towing Specifications 19
Vehicle Designation. 1
Vehicle Dimensions. 3
Vehicle Identification Number(VIN)Plate1
Vehicle Safety Certification Label...............1
Vehicle Weights8
mrvBI
CORPORATION XX-XX 04800 LB 2223 KG
' GAWRFRONT
;
WITH TIRES > RIMSATPSI COLD >
| 2500 LB 1134 KG j P215/75R15j 15x7.030|
; GAWRREAR ' WITH TIRES \ RIMSATPSI COLD !
j 2700 LB 1225 KG j P215/7SR15 j 15x7.030j
TNIS VEHKLE CONFORMS TOALL APPLKAILE FEDERAL MOTOR VEHKLE SAFETY
STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE.
VIN: xxxxxxxxxxxxxxxxx TYPE: MPV SINGLE X DUAL
MDH: xxxxxx xxxMADEIN U.SJL. 4340503
J95IN-1
Fig. 1 Vehicle Safety Certification Label—Typical
TheVehicleIdentificationNumberisalsoim-
printedonthe:
•BodyCodePlate.
'EquipmentIdentificationPlate.
•VehicleSafetyCertificationLabel.
•Framerail.
Toprotecttheconsumerfromtheftandpossible
fraudthemanufacturerisrequiredtoincludea
CheckDigitattheninthpositionoftheVehicleIden-
tificationNumber.Thecheckdigitisusedbythe
manufacturerandgovernmentagenciestoverifythe
authenticityofthevehicleandofficialdocumenta-

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 xxxxxxxxxxxx XXX
XXX X XXXXXXXXXXXXXXXXX
Fig. 2 Vehicle Identification Number (VIN) Location
tion. The formula tousethe checkdigit isnotre-
leased tothe generalpublic.
BODY CODE PLATE
TheBodyCodePlate is located onthe floor panun-
der the passengersideseat.There are sevenlines of
information onthe bodycodeplate.Lines 4, 5, 6, and
7 arenot used to defineserviceinformation.Informa-
tionreadsfromleft to right,startingwithline 3in
thecenter of theplate to line 1atthe bottom ofthe
plate.
ENGINE AND TRANSMISSION/TRANSFER CASE
IDENTIFICATION
Refer to Group9,Engines forall engineidentifica-
tiondata.
VEHICLE IDENTIFICATION
ON j
CAR
LINE
SHELL
ENGINE
•TRIM
TRANSMISSION | VIN
AAARKET
93IN-8
Refer to Group 21, Transmissions forall transmis-
sion/transfercaseidentificationdata.
1AJ0R COiPONENTIDENTIFICATION
Refer tothe applicablegroup for identification
data.
E0U1P1ENTIDENTIFICATION LABEL
TheEquipmentIdentificationPlate (Fig.3)islo-
cated atthe right,frontcorner ofthe innerhood
panel. The platelistsinformationconcerning theve-
hicle as follows:
• The model.
• The wheelbase.
• The VIN(VehicleIdentificationNumber).
• The T.O.N,(ordernumber).
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 (4x 2)
F = Ram Chassis Cab/
Ram Pick-up (4x 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 = 5.9L6 cyl. Diesel
W=8.0L 10 cyl. MPI
X = 3.9L 6 cyl. MPI
Y = 5.2L8 cyl. MPI
Z = 5.9L8 cyl. MPI-LDC
5 = 5.9L8 cyl. MPI-HDC
Check Digit
Number or Letter
Body
3 = ClubCab
6 = Conventional Cab
Chassis Cab
Chassis
Sequential
Serial Number
Six Digit Numbers
100001
Plant Location
S = Dodge City
G= Saltillo
Lago AlbertoAssembly
J95IN-36

BR
INTRODUCTION 3
BODY CODE DECODING
• The optional and specialequipmentinstalled on
thevehicle.
Refer tothe informationlisted onthe platewhen
orderingserviceparts.
Ifrmeum EQUIPMENTIDENTIFICATION wmm'
MODELS V.I.N.T.O.N.
CODENO.DESCRIPTION CODE
NO. DESCRIPTION
J90IN-3>
Fig. 3 Equipment Identification Plate
INTERNATIONAL VEHICLE CONTROLAND DISPLAY
SfiBOLS
Thegraphicsymbolsillustrated onthe following
chart are used to identifyvariousinstrumentcon-
trols.Thesymbolscorrespond to thecontrolsanddis-
playsthat are located onthe instrumentpanel.
VEHICLE DIMENSIONS
TheVehicleInteriorandExteriorDimensioncharts
provides the dimensions for eachtype of Ramtruck.
Line #1 Digit 1-3 TransmissionSalesCode
Digit 4 OpenSpace
Digit 5 MarketCode - U-C-B-M
Digit 6 OpenSpace
Digit 7-23 VehicleIdentification No.
Line #2 Digit 1-3 PaintProcedure
Digit 4 OpenSpace
Digit 5-8 PrimaryPaint
Digit 9 OpenSpace
Digit 10-13 SecondaryPaint
Digit 14 OpenSpace
Digit 15-18 TrimCode
Digit 19 OpenSpace
Digit 20-22 EngineSalesCode
Digit 23 OpenSpace
Line #3 Digit 1-12 VehicleOrderNumber
Digit 13 OpenSpace
Digit 14-16 VinylRoofCode(DoorCombo
Code - Pillette)
Digit 17 OpenSpace
Digit 18-23 Model
" ~ ' " J901N-20
INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS
10
HIGH BEAM
£0
FOG LIGHTS
HEADLIGHTS,
PARKING UGHTS,
PANEL LIGHTS TURNSIGNAL
A
HAZARDWARNING
WINDSHIELD
WASHER
WINDSHIELD
WIPER
%?
WINDSHIELD WIPER
AND WASHER
WINDSCREEN
DEMISTING
AND DEFROSTING
VENTILATINGFAN
ISP
REAR WINDOW
DEFOGGER
GP
REAR WINDOW
WIPER
CD
i
m
i
E3
*
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

4INTRODUCTION
BR
VEHICLE INTERIORDIMENSIONS—STD CAB
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
c§
Seat Adjustment(Fore andaft) 7.5
H LegClearance(Seattosteeringwheel) 5.9
I
Steering WheelToSeatback(Max) 15.9
J
Leg Room 41.0
§c
Back OfSeatTo Back OfCab
—Top
—Bottom
3.8
13.2
Seatback Angle(Degrees) 21.0
DoorOpeningHeight 47.1
DoorOpeningWidth 41.8
Note:Alldimensionsareininchesunlessnoted.
J94IN-26
VEHICLE INTERIOR DIMENSIONS—CLUB CAB
Front
Rear
A HeadRoom 40.2 39.4
B HipRoom 65.8 668
C ShoulderRoom 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 (Foreandaft) 7.5 NA
H LegClearance (Seat to steering wheel) 5.9 NA
1 SteeringWheelToSeatback(Max) 15.9 NA
J LegRoom 41.0 33.2
K
Back Of Seat To BackOfCab
—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-SeatStorage—SeatUp(cuft) — NA
Note:All dimensions arein 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 OverallLength
-—Withoutrear 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
OverallWidth
—AtFrontWheel Lip
79.4 79.4 79.4
79.51
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
—WithoutRear 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 FrontBumper
To
Back Of Cab 116.9 116.9 116.9
116.9
M
ApproachAngle(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 DepartureAngle(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