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

GENERAL INFORMATION (Continued)
VEHICLE EXTERIOR DIMENSIONS—CLUE CAB
1500/
15004x4
2500/
25004x4
3500/
3500 4x4
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 7.5/7.7
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
E
Overall Height (Empty)
71.6/74.6
7).5/74.5
72.9/77.2 72.8/77.1 72.8/77.2
f
OverallWidthOf Cab 79.4 79.4 79.4 79.4 79.4
G Track
—?rorii
66.9/68.5
66.9/68.5 68.6/68.9 68.6/68.9 69.8
G
—Rear
66.9 667 68 0 68.0 73.0
H Tailgate Load Height 31.3/33.9 31
3/34.4 34.4/37.3 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 rearbumper
.a.s
47.5 A7.5
43.5
5
J
—Withrear bumper
475 51.5
51.5 47.5 51.5
K Back ofCab To Rear Bumper
87.1 107.1 !
107.1 87.1 '
107.1
L
Front Bumper To Back Of Cab 136.9 136.9
•; 36.9
136.9
136/'
M
Approach Angle (Degrees) 25.1/30.6
25.2/30.6
.267/33.7 26.8/33.8
26.3/33/
N Breakover Angle (Degrees)
16.7/18.4 15.8/17.1 19.2/23.0 18.1/21.3
18.0/2i/i
0
Depariure Angle (Degrees) 23.8/26.9
21.8/247
26.0/31.0 24.1/28.4 24.6/28.9
(1) 93.3atcargoboxwith dual-rear wheels.
Note: Alldimensionsininchesunlessotherwisenoted.
J95IN-26

6INTRODUCTION —
GENERAL INFORMATION(Continued)
VEHICLEEXTERIORDIMENSIONS—CHASSIS CAB
BR
EXTERIOR
Model
4x2 Models 4x4
models
Model HD mm
mw 35§§
mw 2500
HD
3500
DRW 3500
mw
A
Wheelbase
135
139
163
135
139
163
i 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
OverallWidth .
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 Axle
ToEndOf Frame
44.1
44.1 44.1
44.1 44.1 44.1
K
Center Of FrontWheel
To Back OfCab
79.0 79.0 79.0 79.0 79.0 79.0
L
Frame To Top OfCab
52.9 52.9 52.9 52.9 52.9 52.9
M Top
OfFrame To Ground
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
Front Bumper To Back
Of Cab 116.9
116.9 116.9 116.9 116.9 116.9
Q
Front Of Dash To
lack OfCab
NA NA NA
NA
NA
NA
R
Ground Clearance
—Front
10.1 15.2 15.2 8.1 8.6 8.6
R
—Rear 8.5 9.0 9.0 8.4 9.0 9.0
inchesunlessnoted. NOTE: All dimensions arein
DRW = Dual-rearwheel.
NA = Not available at time of printing.
/ n n anr/3HD n n \
J94IN-27

BR ———• • • • • — • •
GENERAL INFORMATION (Continued)
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
INTRODUCTION 7
10
HIGH BEAM
$0
FOG UGHTS *
HEADLIGHTS,
PARKINGLIGHTS,
PANEL LIGHTS TURNSIGNAL
A
HAZARD WARNING
WINDSHIELD
WASHER
WINDSHIELD
WIPER WINDSHIELDWIPER
ANDWASHER
<W
WINDSCREEN
DEMISTING
ANDDEFROSTING VENTILATINGFAN
REAR WINDOW
DEFOGGER
REAR WINDOW
WIPER
tD
i
B
£3
REAR WINDOW
WASHER
FUEL
ENGINECOOLANT
TEMPERATURE
BATTERY CHARGING
CONDITION ENGINEOIL
SEAT BELT
(©) ky
> i ... i
UGHTtR
BRAKE FAILURE
PARKING BRAKE
FRONT HOOD
REAR HOOD
(TRUNK)
HORN
> i ... i
UGHTtR
J95IN-23
FASTENER IDENTIFICATION
THREAD IDENTIFICATION
SAE andmetricbolt/nut threads arenotthe same.
ThedifferenceisdescribedintheThreadNotation
chart(Fig.5).
GRADE/CLASS IDENTIFICATION
TheSAE bolt strength grades range from grade2
to grade8.Thehigherthegradenumber,thegreater
the bolt strength. Identification isdeterminedbythe
line marksonthetopofeach bolt head.Theactual
bolt strengthgradecorrespondstothenumberof line
marksplus2.Themostcommonlyusedmetric bolt
strength classes are9.8and12.9.Themetric
strength class identification numberis imprinted on
theheadofthe bolt. Thehigherthe class number,
INCH
5/16-18
METRIC
M8 X 1.25
THREAD
MAJOR
DIAMETER
ININCHES
NUMBER
OF
THREADS
PER INCH
THREADDISTANCE
MAJORBETWEEN
DIAMETER IN THREADS IN
MILLIMETERSMILLIMETERS
PR606B
Fig. 5 Thread Notation—SAE and Metric
thegreaterthe bolt strength.Somemetricnutsare
imprinted with a single-digitstrength class onthe
nut face.Refertothe Fastener Identification and
Fastener StrengthCharts.

8INTRODUCTION _
GENERALINFORMATION (Continued)
FASTENER IDENTIFICATION
bolt MarkingsandTorque- Metric
Commercial Steel Class
8.8 10.912.9
Body
Size TorqueTorqueTorque
Diam.
Cast Iron
Aluminum
CastIron Aluminum CastIron
Aluminum
mm N»m
ft-lb ft-lb ft-lb N®m
ft-lb ft-lb
N»mft-lb
6 9
5 7 4 14 9
11 7 14
9
117
7 14 9 11 7 18 14 14 11 23 18 1814
8 25 18 18 14 32 23 25 18 36 27 2821
10 40 30 30 25 60 45 45 35 70 50 5540
12 70 55 55 40 105 75 80 60 125 95 10075
14 115 85 90 65 160 120 125 95 195 145 150110
16 180 130 140 100 240 175 190 135 290 210 220165
18 230 170 180 135 320 240 250 185 400 290 310230
Bolt MarkingsandTorqueValues- U.S.Customary
SAEGradeNumber 5 8
BoltHeadMarkings
TheseareallSAEGrade 5 (3) line
BoltTorque - Grade 5 BoltBoltTorque - Grade 8 Bolt
BodySize CastIron
Al
uminum CastIron Aluminum
ft-lb
N®m
1Mb
ft-lb ft-lb
1/4-20 9 7 8 6 15 11 12 9
- 28 12 9 9 7 18 13 14 10
5/16- 18 20 15 16 12 30 22 24 18
- 24 23 17 19 14 33 24 25 19
3/8- 16 40 30 25 20 55 40 40 30
- 24 40 30 35 25 60 45 45 35
7/16- 14 60 45 45 35 90 65 65 50
-20 65 50 55 40 95 70 75 55
1/2- 13 95 70 75 55 130 95 100 75
-20 100 75 80 60 150 110 120 90
9/16- 12 135 100 110 80 190 140 150 110
- 18 150 110 115 85 210 155 170 125
5/8-11 180 135 150 no 255 190 205 150
- 18 210 155 160 120 290 215 230 170
3/4- 10 325 240 255 190 460 340 365 270
- 16 365 270 285 210 515 380 410 300
7/8-9 490 360 380 280 745 550 600 440
- 14 530 390 420 310 825 610 660 490
1-8 720 530 570 420 1100 820 890 660
- 14 800 590 650 480 1200 890 960 710
95IN-6

BR INTRODUCTION9
GENERAL INFORMATION(Continued)
FASTENER STRENGTH
HOWTODETERMINEBOLTSTRENGTH
Mark Class Mark Class
Hexagon
headbolt
A —
5—
/\Bolt6 —
jfY^^headNo. 7 —
lO-
ll—
4T
5T
6T
7T
8T
9T
10T
1 IT
Studbolt
Nomark
y 4T
Hexagon
headbolt
j^^^^j Nomark 4T
Studbolt
Nomark
y 4T
Hexagon
headbolt
j^^^^j Nomark 4T
Studbolt
61
Hexagon
flangebolt
w/washer
hexagonbolt
((^^j) Nomark
4T
Studbolt
Grooved
61
Hexagon
headbolt TWO
j1 protruding
lines
51
Studbolt
Grooved
61
Hexagon
flangebolt
w/washer
hexagonbolt
Twoj.
1J protruding
lines
61
Studbolt
61
Hexagon
flangebolt
w/washer
hexagonbolt
Twoj.
1J protruding
lines
61 Weldedbolt
41
Hexagon
headbolt f^f% Three
IL?^jjprotruding
lines 71
Weldedbolt
41
Hexagon
headbolt ff^l
F°Ur
|L>JJprotruding
lines 8T
Weldedbolt
41
95IN-4

10INTRODUCTION
BR
GENERAL INFORMATION(Continued)
METRIC SYSTEM
WARNING;USEOFANINCORRECTFASTENER
MAYRESULTINCOMPONENTDAMAGEORPER-
SONALINJURY.
Figure art, specifications and torque references in
this Service Manual areidentifiedin metric andSAE
format.
Duringany maintenance or repair procedures, itis
important to salvage metric fasteners (nuts, bolts,
etc.)for reassembly. Ifthe fastener isnot salvage-
able, a fastener of equivalent specification should be
used.
The metric system is based on quantities ofone,
ten,one hundred, one thousand andonemillion(Fig.
6).
Thefollowing chart will assist in converting metric
units to equivalent English andSAE units, or vise
versa.
Mega
(M) Million Deci (D)Tenth
Kilo
(K) Thousand Centi
(C) Hundreth
Milli
(m)Thousandth
J901N-2
Fig, 6 Metric Prefixes
Refer tothe Conversion Chart to convert torque
values listedin metric Newton- meters (N-m).Also,
usethe chart to convert between millimeters (mm)
and inches (in.)
CONVERSION FORMULAS AND EQUIVALENT VALUES
Multiply By ToGaf Multiply
By
ToGet
in-lbs
x 0.11298
Newton-Meters(N*m) x8.851 = in-lbs
ft-lbs x
1.3558
Newton-Meters(N*m) N*m x
0.7376
= ft-lbs
Inches Hg(60°F) x
3.377
Kilopascafs (kPa) kPa
x 0.2961
= Inches Hg
psi x6.895
=
Kilopascals (kPa)
kPa
x0.145 -psi
Inches
x25.4 Millimeters(mm) mm x
0.03937
= Inches
Feet
x 0.3048
Meters(M) M x3.281
= Feet
Yards
x 0.9144
Meters(M) M x
1.0936
= Yards
Miles x
1.6093
=
Kilometers (Km) Km x
0.6214
= Miles
mph x
1.6093
ss
Kilometers/Hr.(Km/h)
Km/h
x 0.6214
= mph
Feet/Sec.
x 0.3048
ss
Meters/Sec. (M/S) M/S x3.281
= Feet/Sec.
Kilometers/Hr. x
0.27778
SB
Meters/Sec. (M/S) M/S x
3.600
= Kilometers/Hr.
mph x
0.4470
=
Meters/Sec. (M/S) M/S x2.237
s mph
COMMONMETRICEQUIVALENTS
1Inch= 25Millimeters1 Cubic Inch= 16 Cubic Centimeters
1Foot= 0.3 Meter 1 Cubic Foot= 0.03 Cubic Meter
1Yard= 0.9 Meter 1 Cubic Yard= 0.8 Cubic Meter
1 Mile =1.6Kilometers
J91IN-1

BR — ——_____ INTRODUCTION 11
GENERAL INFORMATION (Continued)
METRIC CONVERSION
in-lbstoN»mN»mtoin-lbs
in- lb N«m
in-lb
N®m
in-lb
N»m in-lb
N®m
in-lb N®m N0m
in-lb
N©m in-lb
N®m
in-lb
N®m
in-lb
N°m in-lb
2
.2260
42
4.7453
82
9.2646
122
13.7839
162
18.3032
.2
1.7702
4.2
37.1747
8.2 72.5792
12.2
107.9837
16.2
143.3882
4 .4519 44
4.9713
84
9.4906
124
14.0099
164
18.5292
.4
3.5404 4.4
38.9449
8.4 74.3494
12.4
109.7539 16.4 145.1584
6
.6779
46
5.1972
86 9.7165
126
14.2359
166
18.7552
.6
5.3107 4.6
40.7152
8.6
76.1197
12.6
111.5242
16.6 146.9287
8
.9039
48
5.4232
88
9.9425
128
14.4618
168
18.9811
.8
7.0809
4.8 42.4854 8.8 77.8899
12.8 113.2944
16.8 148.6989
10
1.1298
50
5.6492
90
10.1685
130 14.6878
170 19.2071
1 8.8511 5
44.2556
9 79.6601
13
115.0646
17 150.4691
12
1.3558
52
5.8751
92
10.3944
132
14.9138
172 19.4331
1.2
10.6213
5.2
46.0258
9.2 81.4303
13.2 116.8348
17.2 152.2393
14
1.5818
54
6.1011
94
10.6204
134
15.1397
174
19.6590
1.4
12.3916
5.4
47.7961
9.4
83.2006
13.4
118.6051
17.4 154.0096
16
1.8077
56
6.3270
96
10.8464
136
15.3657
176
19.8850
1.6 14.1618 5.6
49.5663
9.6 84.9708
13.6
120.3753
17.6 155.7798
18
2.0337
58
6.5530
98
11.0723
138
15.5917
178
20.1110
1.8 15.9320
5.8
51.3365
9.8
86.7410
13.8
122.1455
17.8 157.5500
20
2.2597
60
6.7790
100 11.2983
140 15.8176
180 20.3369
2 17.7022 6 53.1067 10 88.5112
14
123.9157 18 159.3202
22
2.4856
62
7.0049
102
11.5243
142 16.0436
182
20.5629
2.2
19.4725
6.2
54.8770
10.2 90.2815
14.2
125.6860
18.5 163.7458
24
2.7116
64
7.2309
104
11.7502
144
16.2696
184
20.7889
2.4 21.2427 6.4 56.6472 10.4 92.0517
14.4
127.4562
19 168.1714
26
2.9376
66
7.4569
106 11.9762
146
16.4955
186
21.0148
2.6 23.0129 6.6 58.4174 10.6 93.8219
14.6
129.2264 19.5 172.5970
28
3.1635
68
7.6828
108 12.2022
148
16.7215
188
21.2408
2.8 24.7831 6.8
60.1876
10.8 95.5921
14.8
130.9966
20
177.0225
30
3.3895
70
7.9088
110 12.4281
150 16.9475
190
21.4668
3 26.5534 7
61.9579 11
97.3624
15
132.7669 20.5 181.4480
32
3.6155
72
8.1348
112 12.6541
152
17.1734
192
21.6927
3.2
28.3236
7.2
63.7281
11.2 99.1326
15.2
134.5371
21 185.8736
34
3.8414
74
8.3607
114
12.8801
154 17.3994
194
21.9187
3.4
30.0938
7.4
65.4983
11.4 100.9028
15.4
136.3073
22 194.7247
36
4.0674
76
8.5867
116
13.1060
156 17.6253
196 22.1447
3.6
31.8640
7.6
67.2685
11.6 102.6730
15.6 138.0775
23 203.5759
38
4.2934
78
8.8127 118 13.3320
158
17.8513
198
22.3706
3.8 33.6342 7.8
69.0388
11.8 104.4433
15.8 139.8478
24 212.4270
40
4.5193
80
9.0386
120
13.5580
160
18.0773
200 22.5966
4
35.4045 8
70.80%
12 106.2135
16 141.6180
25 221.2781
ft-lbs toN®mN®mto ft-lbs
ft-lb N©m
ft-lb
N«m ft-lb N«m
ft-lb
Nem
ft-lb N®m N»m
ft-lb
N®m
ft-lb
N®m ft-lb N«m
ft-lb
N®m
ft-lb
1
1.3558
21 28.4722 41
55.5885
61
82.7049
81
109.8212
1
.7376
21
15.9888
41 30.2400
61 44.9913
81
59.7425
2
2.7116
22
29.8280 42
56.9444 62
84.0607
82
111.1770
2
1.4751
22
16.2264
42 30.9776
62
45.7289
82
60.4801
3
4.0675
23 31.1838 43
58.3002 63
85.4165
83
112.5328
3
2.2127
23
16.9639 43
31.7152
63
46.4664
83
61.2177
4
5.4233
24
32.5396
44
59.6560
64
86.7723
84
113.8888
4
2.9502
24
17.7015
44 32.4527
64
47.2040
84
61.9552
5 6.7791
25 33.8954
45
61.0118
65
88.1281
85
115.2446
5
3.6878
25
18.4391
45 33.1903
65 47.9415
85 62.6928
6 8.1349
26
35.2513
46
62.3676
66 89.4840
86
116.6004 6
4.4254 26
19.1766
46
33.9279
66 48.6791
86
63.4303
7
9.4907
27
36.6071
47
63.7234
67
90.8398
87
117.9562
7
5.1629
27
19.9142
47
34.6654
67
49.4167
87
64.1679
8
10.8465
28
37.9629
48
65.0793
68
92.1956
88
119.3120 8
5.9005
28
20.6517
48 35.4030
68
50.1542
88
64.9545
9 12.2024
29
39.3187
49
66.4351
69
93.5514
89
120.6678
9
6.6381
29
21.3893
49
36.1405
69
50.8918
89
65.6430
10
13.5582
30
40.6745
50
67.7909 70
94.9073
90 122.0236 10
7.3756
30
22.1269
50 36.8781
70 51.6293
90 65.38%
11
14.9140
31
42.0304 51
69.1467
71
96.2631
91
123.3794
11
8.1132
31
22.8644
51
37.6157
71
52.3669
91
67.1181
12 16.2698
32
43.3862
52
70.5025
72
97.6189
92
124.7352
12
8.8507
32
23.6020
52
38.3532
72 53.1045
92 67.8557
13
17.6256
33
44.7420
53
71.8583
73 98.9747
93
126.0910 .13
9.5883
33
24.3395
53 39.0908
73 53.8420
93 68.5933
14
18.9815
34
46.0978
54
73.2142 74
100.3316
94
127.4468 14
10.3259
34
25.0771
54
39.8284
74
54.5720
94
69.3308
15
20.3373
35
47.4536
55
74.5700 75
101.6862
95
128.8026
15
11.0634
35
25.8147 55
40.5659
75 55.3172
95
70.0684
16
21.6931
36 48.8094 56
75.9258 76
103.0422
96
130.1586
16
11.8010
36
26.5522
56
41.3035
76
56.0547
96 70.8060
17 23.0489
37
50.1653
57
77.2816
77
104.3980
97
131.5144
17
12.5386
37
27.2898
57
42.0410
77 56.7923
97
71.5435
18 24.4047
38
51.5211
58 78.6374 78
105.7538
98
132.8702
18
13.2761
38
28.0274
58 42.7786
78 57.5298
98 72.2811
19 25.7605
39
52.8769
59
79.9933
79
107.1196
99
134.2260 19
14.0137
39
28.7649
59 43.5162
79
58.2674
99
73.0187
20
27.1164
40
54.2327
60
81.3491
80 106.4654
100
135.5820
20
14.7512
40
29.5025
60
44.2537
80 59.0050
100
73.7562
in.
tomm mmtoin.
in.
mm
in.
mm
in.
mm
in.
mm
in.
mm mm
in.
mm
in.
mm
in. mm in.
mm
in.
.01 .254 .21
5.334
.41
10.414
.61
15.494
.81
20.574
.01 .00039
.21
.00827
.41
.01614
.61 .02402
.81 .03189
.02 .508 .22
5.588
.42
10.668
.62
15.748
.82
20.828
.02
.00079
.22
.00866
.42 .01654 .62
.02441
.82
.03228
.03 .762 .23
5.842
.43 10.922 .63
16.002
.83
21.082
.03
.00118
.23
.00906 .43
.01693 .63 .02480
.83 .03268
.04 1.016 .24
6.096
.44
11.176
.64
16.256
.84
21.336
.04
.00157
.24
.00945
.44
.01732
.64
.02520
.84 .03307
.05 1.270 .25
6.350
.45 11.430
.65
16.510
.85
21.590 .05
.00197
.25
.00984 .45
.01772 .65 .02559
.85 .03346
.06 1.524 .26
6.604
.46
11.684
.66
16.764
.86 21.844
.06 .00236
.26 .01024
.46
.01811 .66
.02598
.86 .03386
.07 1.778 .27
6.858
.47
11.938
.67
17.018
.87
22.098
.07
.00276
.27
.01063
.47
.01850
.67
.02638
.87
.03425
.08
2.032
.28 7.112 .48
12.192
.68
17.272
.88
22.352
.08
.00315
.28
.01102 .48 .01890 .68
.02677
.88
.03465
.09
2.286
.29
7.366
.49
12.446
.69
17.526
.89
22.606 .09 .00354
.29
.01142
.49
.01929
.69 .02717
.89 .03504
.10
2.540
.30
7.620
.50
12.700
.70
17.780
.90
22.860
.10 .00394
.30
.01181
.50 .01969 .70 .02756
.90
.03543
.11
2.794
.31 7.874
.51
12.954
.71
18.034
.91
23.114
.11
.00433
.31
.01220 .51
.02008
.71
.02795
.91
.03583
.12
3.048
.32 8.128 .52
13.208
.72
18.288
.92
23.368
.12 .00472
.32
.01260
.52 .02047
.72
.02835
.92 .03622
.13 3.302
.33
8.382
.53
13.462 .73
18.542
.93
23.622
.13 .00512
.33
.01299 .53
.02087 .73
.02874
.93
.03661
.14
3.556
.34
8.636
.54
13.716
.74
18.796
.94
23.876
.14
.00551
.34
.01339
.54
.02126
.74
.02913
.94
.03701
.15 3.810 .35
8.890
.55
13.970
.75
19.050
.95
24.130
.15
.00591
.35
.01378
.55
.02165
.75 .02953
.95
.03740
.16
4.064
.36 9.144 .56
14.224
.76 19.304
.96
24.384
.16
.00630
.36
.01417 .56
.02205
.76
.02992
.96 .03780
.17 3.318 .37 9.3% .57
14.478
.77
19.558
.97
24.638
.17
.00669
.37
.01457 .57
.02244
.77
.03032
.97 .03819
.18
4.572 .38
9.652
.58 14.732
.78
19.812
.98
24.892
.18
.00709
.38
.01496
.58
.02283 .78
.03071
.98
.03858
.19
4.826
.39
9.906
.59
14.986
.79
20.066
.99
25.146
.19
.0)748
.39
.01535
.59
.02323
.79 .03110
.99 .03898
.20
5.080 .40
10.160
.60
15.240
.80
20.320
1.00
25.400
.20
.00787
.40
.01575
.60
.02362
.80
.03150
1.00
.03937
J901N-10

BR
LUBRICATION AND MAINTENANCE 0 -1
LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION 1 MAINTENANCE SCHEDULES—LIGHT DUTY
JUMPSTARTING, TOWING AND HOISTING ...21 VEHICLES 4
MAINTENANCE SCHEDULES—DIESEL ENGINEMAINTENANCESCHEDULES—MEDIUMDUTY
VEHICLES 17 VEHICLES 8
MAINTENANCE SCHEDULES—HEAVY DUTY
VEHICLES 12
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CLASSIFICATION OF LUBRICANTS 2
FLUID CAPACITIES 2
INTERNATIONAL SYMBOLS 1
INTRODUCTION 1
PARTS ANDLUBRICANTRECOMMENDATIONS ...1
GENERALINFORMATION
INTRODUCTION
Serviceandmaintenance procedures forcompo-
nents and systems listedinSchedule—AorB canbe
found byusingtheGroupTabLocatorindexatthe
front ofthismanual.Ifitisnotclear which group
containstheinformation needed, refertotheindexat
thebackofthismanual.
Therearetwomaintenance schedules thatshow
properservice based ontheconditionsthatthevehi-
cleissubjectedto.
Schedule—A,listsscheduledmaintenancetobe
performedwhenthevehicleis used forgeneraltrans-
portation.
Schedule—B,listsmaintenanceintervalsforvehi-
cles thatareoperatedundertheconditionslistedat
thebeginningoftheMaintenance Schedule section.
Usethe schedule that best describes your driving
conditions.
Wheretimeandmileagearelisted, follow the
interval thatoccurs first.
PARTS AND LUBRICANTRECOMMENDATIONS
When serviceisrequired,ChryslerCorporation
recommendsthatonlyMopar*brandparts, lubri-
cants andchemicalsbe used. Moparprovidesthe
best engineeredproductsforservicingChryslerCor-
poration vehicles.
INTERNATIONALSYMBOLS
ChryslerCorporation uses internationalsymbolsto
identify enginecompartmentlubricantand fluid
inspectionand fill locations(Fig.1).
^ \
€» CHRYSLER CORPORATION
ENGINE OIL o
BRAKEFLUID
G
AUTOMATIC
TRANSMISSION
FLUID
©
POWER
STEERING
FLUID
b ENGINE
COOLANT WINDSHIELD
WASHERFLUIDy
9500-1
Fig. 1 international Symbols

0 - 2 LUBRICATION AND MAINTENANCE
BR
GENERAL INFORMATION (Continued)
CLASSIFICATION OF LUBRICANTS
Only lubricantsthatareendorsedbythe following
organization shouldbeusedtoservicea Chrysler
Corporation vehicle.
• Societyof Automotive Engineers(SAE)
• AmericanPetroleumInstitute(API)(Fig.2)
• National Lubricating Grease Institute (NLGI)
(Fig. 3)
9400-9
Fig. 2 API Symbol
GASOLINE ENGINE OIL
SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY
An SAEviscositygradeisusedtospecifythe vis-
cosity ofengine oil. SAE30specifiesa singleviscos-
ity engineoil.Engine oils alsohave multiple
viscosities. Thesearespecified with a dualSAE vis-
cosity grade which indicatesthecold-to-hottempera-
ture viscosityrange.
• SAE 30 = singlegradeengineoil.
• SAE10W-30= multiple gradeengineoil.
API QUALITY CLASSIFICATION
The API ServiceGradespecifiesthetypeofperfor-
mancetheengineoilisintendedtoprovide.The API
ServiceGradespecificationsalsoapplytoenergycon-
serving engine oils.
UseengineoilthatisAPIServiceGrade Certified
or anoilthatconformstothe API ServiceGradeSH
or SH/CD. MOPAR engine oils conform toallof these
servicegrades.
Refer toGroup9,Engineforgasolineengineoil
specification.
DIESEL ENGINE OIL
ENGINE OIL QUALITY
Use only oils conforming toAPI Quality CE,or
CE/SG. A sulfatedash limit isspecifiedfor lubrica-
tion oilusedinCumminsengines. Oils with a high
ashcontentmayproducedepositsonvalvesthatcan
progresstogutteringandvalve burning. A maximum
sulfated ashcontentof1.85 mass % isrecommended
for alloilusedintheengine.
Refer toGroup9,Enginefordieselengineoil spec-
ification.
GEAR LUBRICANTS
SAE ratingsalsoapplyto multiple grade gear
lubricants. In addition, APIclassificationdefinesthe
lubricants usage.
LUBRICANTS AND GREASES
Lubricating grease isratedfor quality and usage
by the NLGI. All approvedproductshavethe NLGI
symbol (Fig.3)onthe label. Atthebottom NLGI
symbol isthe usage and quality identification letters.
Wheel bearinglubricantis identified bytheletter
"G". Chassislubricantis identified bythelatter "L".
The letter following the usage letterindicatesthe
quality ofthelubricant.The following symbols indi-
cate thehighest quality.
NLGI
AUTOMOTIVE
WHEEL BEARING & CHASSIS
LUBRICANT
GC
t NATIONAL LUBRICATING
GREASE INSTITUTE
NLGI
AUTOMOTIVE
WHEEL BEARING & CHASSIS
LUBRICANT
Li
WHEEL
BEARINGS
CHASSIS
LUBRICATION
NLGI
AUTOMOTIVE
WHEEL BEARING & CHASSIS
LUBRICANT
GC-LB
CHASSIS AND
WHEEL BEARINGS
9200-7
Fig. 3 NLGI Symbol
FLUID CAPACITIES
FUEL TANK
119 inch wheel base . .98L (26gal.)
135 inch wheel base . .98L (26gal.)
All others132L (35gal.)
ENGINE OIL W/FILTER CHANGE
3.9L 3.8L (4.0qts.)
5.2L & 5.9LGasoline4.7L (5.0qts.)
5.9L Diesel9.5L (10.0qts.)
8.0L 6.6L (7.0qts.)
ENGINE OIL W/O FILTER CHANGE
3.9L. . .3.3L (3.5qts.)
5.2L & 5.9LGasoline.4.3L (4.5qts.)
5.9L Diesel* .
8.0L*
*Oil filter mustbechanged with everyoilchange.