Dodge ram truck 3500 1996 User manual

9
SERVICE
MANUAL
RAM TRUCK
1500- 3500
2 WHEEL DRIVE
4 WHEEL DRIVE
VOL.1 00-08

9
SERVICE
MANUAL
RAM TRUCK
1500 - 3500
2 WHEEL DRIVE
4 WHEEL DRIVE
VOL.2 09-25

CHRYSLER
CORPORATION
SERVICEMANUAL
1996
RAMTRUCK
1500- 3500
To order the special service tools used and
illustrated, please refer tothe instructions on
inside back cover.
NO PART OFTHISPUBLICATIONMAYBE
REPRODUCED, STORED INA RETRIEVAL
SYSTEM,ORTRANSMITTED,INANYFORMOR
BY ANYMEANS,ELECTRONIC,MECHANICAL,
PHOTOCOPYING,RECORDING,OROTHERWISE,
WITHOUTTHE PRIOR WRITTEN PERMISSION
OFCHRYSLERCORPORATION.
ChryslerCorporationreservestherighttomakechangesindesignorto
make additions to orimprovementsinits products without imposing any obli-
gations upon itselftoinstallthem on itsproductspreviouslymanufactured.
LithoinU.S.A. Copyright © 1995 Chrysler Corporation 20M0995
^CHRYSLER
mSf CORPORATION

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 forthe systems andcompo-
nents. To assist inlocatinga group title page, usetheGroupTabLocator onthe following page. The solid bar
afterthegroup title isalignedtoa solid tabonthe first page of each group.The first page ofthegrouphas
acontentssectionthatlistsmajortopics within thegroup.Ifyouarenot sure which Groupcontainsthe infor-
mation you 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. When
replacing fasteners, alwaysusethe same type(partnumber) fastener asremoved.
ChryslerCorporation reserves the right to change testingprocedures,specifications,diagnosis,repair
methods,orvehicle wiring atanytimewithoutpriornoticeorincurringobligation.

GROUP TAB LOCATOR
Introduction
life!
LubricationandMaintenance
2Suspension
DifferentialandDriveline
Brakes
Clutch
7CoolingSystem
8A Battery
8BStartingSystems
8CChargingSystem
8D IgnitionSystem
8EInstrumentPanelSystems
8FAudioSystems
8GHornSystems
8H VehicleSpeedControlSystem
8 J TurnSignalandHazardWarningSystems
8P
8KWiperandWasherSystems
8LLamps
8M PassiveRestraintSystems
PowerDoorLocks
8RPowerSeatSystems
8SPowerWindowSystems
8T PowerMirrorSystems
8U Chime/BuzzerWarningSystems
8V OverheadConsoleSystems
8W WiringDiagrams
QEngine
j1 ExhaustSystemandIntakeManifold
j3 FrameandBumpers
14 FuelSystem
j9 Steering
21
TransmissionandTransferCase
22TiresandWheels Hi
23 Body
24 Heatingand Air Conditioning
25 EmissionControlSystems
ComponentandSystemIndex
ServiceManualCommentForms (Rear ofManual)

BR
INTRODUCTION1
INTRODUCTION
CONTENTS
page
GENERAL INFORMATION
BODYCODEPLATE. 2
EQUIPMENTIDENTIFICATIONPLATE.........3
FASTENERIDENTIFICATION7
INTERNATIONALVEHICLECONTROLAND
page
DISPLAYSYMBOLS3
METRICSYSTEM10
VEHICLEDIMENSIONS3
VEHICLEIDENTIFICATIONNUMBER.........1
VEHICLESAFETYCERTIFICATIONLABEL.....2
GENERAL INFORMATION
VEHICLE IDENTIFICATIONNUMBER
The Vehicle Identification Number (VIN) plate is
located onthe lower windshield fence near theleft
A-pillar(Fig.1).TheVIN contains 17 characters that
provide data concerning the vehicle. Refer totheVIN
decoding chart to determine theidentificationofa
vehicle.
The Vehicle Identification Number is also
imprintedonthe:
• Body Code Plate.
® Equipment Identification Plate.
• Vehicle Safety CertificationLabel.
• Frame rail.
To protect the consumer from theft and possible
fraud the manufacturer is required to include a
Check Digitattheninth position ofthe Vehicle Iden-
tification Number. The check digitis used bythe
manufacturer and government agencies toverifythe
authenticity ofthe vehicle and official documenta-
tion.Theformulatousethe check digitisnot
released tothe general public.
Fig. 1 Vehicle Identification Number (VIN) Location

INTRODUCTION
BR
GENERAL INFORMATION(Continued)
POSITION INTERPRETATION CODE= DESCRIPTION
1 CountryofOrigin 1= UnitedStates
3= Mexico
2 Make B = ^odge
3 VehicleType 4= MultipurposePassenger
5= Bus
6= Incomplete
7= Truck
4 GrossVehicleWeightRating H= 6001-7000
J= 7001-8000
K = 8001-9000
L= 9001-10,000
M= 10,001-14,000
W= HydraulicBrakes
5 VehicleLine C= RamCabChassis/RamPickUp(4x2)
F= RamCabChassis/RamPickUp(4x4)
6 Series 1 = 1500
2= 2500
3= 3500
7 BodyStyle 3= ClubCab
6= ConventionalCabCabChassis
8 Engine C = 5.9L
6cyl. Diesel
W= 8.0L10cyl.MPI
X= 3.9L6 cyl.MPI
Y= 5.2L8 cyl.MPI
Z= 5.9L8 cyl.MPI-LDC
5= 5.9L 8cyl. MPI-HDC
9 CheckDigit
10 ModelYear T=1996
11 PlantLocation J= St.LouisNorth
S= DodgeCity
G= Saltillo
M= LagoAlbertoAssembly
12thru17 VehicleBuildSequence
VEHICLESAFETY CERTIFICATION LABEL
A certification label is attached totheleft side
B-pillar(Fig.2).The label certifies that the vehicle
conforms to Federal Motor Vehicle Safety Standards
(FMVSS).The label also lists the:
•Monthand year of vehicle manufacture.
• Gross Vehicle Weight Rating (GVWR).The gross
frontand rear axle weight ratings (GAWR's) are
based ona minimumrim size and maximum cold tire
inflation pressure.
• Vehicle Identification Number (VIN).
• Type of vehicle.
• Type of rear wheels.
•Bar code.
• Paint Code.
•Month,Dayand Hour (MDH)offinal assembly.
BODY CODE PLATE
The Body Code Plate is located onthefloorpan
under the passenger seat (Fig.3). There canbea
maximum of seven rows of vehicle information
imprinted onthe plate. The information should be
read fromlefttoright, starting withline1 atthe
bottom ofthe plate up through line7 (as applicable)
atthetopofthe code plate.
Refer tothe decoding chart to decode lines 1 up
through 3.
Lines 4 through 7 (if used) onthe vehicle code
plate are imprinted onthe plate (in sequence) accord-
ingtothefollowing:
• 3-character sales code.

BR
INTRODUCTION 3
GENERAL INFORMATION(Continued)
flFDBY
CHRYSLER DATEOF m
CORPORATIONMM
GftPR FRONT U1IH TIRES
3309LB149? KG P235/75R15KL
mm WITH !!KS
3850LB1747 KG P235/75R15XL
THIS UEHICLE COHFOPtlS !0 ALL APPLICABLE FEDERAL
I EFFECI OH THE DATE OF I
xxxxxx
II II!
IIIII TVPE:TRUCK
88488 LB 2903 KG
RIMSft? PSICOO
15X GiHD35
MSft! PSI COLD
15X BiHD41
TOR UEHJ CLE WW
yn ABOVE.
SINGLE X DOHL
)H: liUliHI PftIHT:PUS UEH ICLE HADE IN TIM« 4G4B<*5
8020cd69
Fig.2 Vehicle Safety Certification Label—Typical
PRIMARYSECONDARYVINYLROOF
PAINTPAINTCODE
I
VEHICLE
ORDER-
NUMBER
PAINT-
(3)
PROCEDURE(2)
0)
XXX > XXXXX) XXXXxxxxxx
XXXxxxxxxxxxxxxXXX
XXXX XXXXXXXXXXXXXXXXX
VEHICLE
MODEL
-NUMBER
ENGINE
-CODE
-INTERIOR
TRIM CODE
TRANSMISSIONVEHICLEIDENTIFICATION
CODEJ NUMBER
MARKET U-C-B-M
CODE90IN-3
Fig. 3 Body Code Plate
BODY CODE DECODING
Line#1Digit1-3TransmissionSalesCode
Digit4 OpenSpace
Digit5 MarketCode- U-C-B-M
Digit6 OpenSpace
Digit7-23VehicleIdentificationNo.
Line#2Digit1-3
Digit4 PaintProcedure
OpenSpace
Digit5-8PrimaryPaint
Digit9 OpenSpace
Digit10-13SecondaryPaint
Digit14OpenSpace
Digit15-18TrimCode
Digit19OpenSpace
Digit20-22EngineSalesCode
Digit23OpenSpace
Line#3Digit1-12VehicleOrderNumber
Digit13OpenSpace
Digit14-16VinylRoofCodeCDoorCombo
Code- Pillette)
Digit17OpenSpace
Digit18-23Model
J901N-20
• 3-digit numerical code.
• 6-digitSEC code.
If there isnot enough space leftintherowforall
of the6-digitSEC code (if used):
• The unused space will remain blank.
• The code will belistedinthe next row.
The last nine positions ofrow7 will contain a
2-digit code, when applicable, anda 6-digit gateline
serial number (same asthe last 6 numbers ofthe
VIN).
The last code imprintedona vehicle code plate will
befollowedbytheimprintedwordEND. When two
vehicle code plates are required, the last available
spaces onthefirst plate will beimprinted with the
letters CTD(for continued).
When a second vehicle code plate is necessary, the
first four spaces on each row will notbe used because
of the plate overlap.
EQUIPMENT IDENTIFICATION PLATE
The Equipment Identification Plate (Fig.4)is
located attheleft,frontofthe inner hood panel. The
plate lists information concerning the vehicle as fol-
lows:
• The model.
• The wheelbase.
• TheVIN (Vehicle Identification Number).
• TheT.O.N, (order number).
• The optional and special equipment installed on
the vehicle.
Refer totheinformationlistedonthe plate when
ordering replacement parts.
r
Qmmsi EQUIPMENT !Dem¥iE^
MODELSV.I.N.\^.\.
CODENO.DESCRIPTION
CODENO.DESCRIPTION
—u
Fig. 4 Equipment Identification Plate
VEHICLE DIMENSIONS
The Vehicle Dimension charts provides the dimen-
sions for each type ofRam truck.
INTERNATIONAL VEHICLE CONTROL AND DISPLAY
SYMBOLS
The graphic symbols illustrated inthefollowing
chart are used toidentify various instrument con-
trols.The symbols correspond tothe controls and dis-
plays that are located onthe instrument panel.

4INTRODUCTION
GENERAL INFORMATION(Continued)
vehicle exterior dimensions—STD cab
1500/ 1500 4x4
2500/
3500/
3500 4x4
A Wheelbase
1 19" 135" 135" 135"
e Box
Length(feet) 6.5 8.0
8.0
€ Ground
Clearance (Empty)
—Front 9.7/8.1
10.0/8.1 10.1/8.1 7
7/'.12
€
—Rear
10.1/9.8 !10.179J!
10.1/9.3
71 ..77
D
Overall Length
—Without rear bumper 199.9 220.1 220.1 220.1
D
—With rear bumper 204.1
224.3 224.3 224.3
1
Overall Height (Empty)
72.1/75.91
72.1/75.9
73.7/78.0
7777:7
¥
Overall Width
—At FrontWheelLip
70.4
79.4 79.4
79.51
8 Track
—Front 68.5 68,5 68.6
63.6
8
—Rear 68.0 68.0
73.0
H
TailgateLoadHeight 3
72/35.6 31.5/35.6 31.5/35.6 31.4/35.6
i Overhang—Front 37.9
3^
37.9 37.9
J
Overhang—Rear
—Without Rear Bumper
47.6 47.6 47.6 47.6
J
—With Rear Bumper r
51.7 51.7
51.7 5
77
f€
BackOfCabTo
Rear Bumper
87.2 107.4 107.4 77,-
I
Front Bumper To
Back OfCab
" \ \v 116.9 116.9
116.9
ApproachAngle (Degrees} 25.3/297 25.3/29.7
25.3/29.7
1
"25.3/29.7 1
M
BreakoverAngle (Degrees]
: 7.8/270 I
17.8/21.0
7-'•;:
0
Departure Angle (Degrees)
1076/35.2 ^30^56.2 130.6/3o.2~
30.6/36.2
193.5
at cargo box.
J941N-25