DIY Ram repair notes

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1994+ Dodge Ram DIY Repair Page
Info from various sources

[Brake, suspension, steering, wheels] [transmission, transfer case] [axle, driveshaft]

[engine] [wiring, gauges] [body] [HVAC] [tools] [other sites]

Visit Geno's Garage
for Truck accessories.

Modifications have moved to a new index

These are not a substitute for the service manual. They are intended more as a supplement to the manual. Before attempting any repair, obtain a factory repair manual from your dealer. Although they cost $75 to over $120 (depending on the model year), the service manual is indispensable if you plan to do your own mechanical work. The manuals are available at the dealership or on the web at Tech Authority.

There is also an excellent Haynes manual for 1994-1998 Rams. It contains numerous photos and covers some things that my '94 service manual left untouched. The Haynes 94-98 Ram manual is number 30041 and only set me back $12 at Advance Auto.

BRAKES, STEERING, WHEELS AND SUSPENSION

Brakes
- Brake Job Description
  - see also TSB 05-04-97 for 2500HD and 3500 brake instructions.
- Brake job for a 1500 2WD = photos and tips on The Benner RAM Page
- ABS Brake Bleed Procedure - service manual revision from TSB 05-03-94
- Rotor Replacement and wheel bearing replacement/adjustment - 1500 2WD Recall 778
- Parking Brake Pedal Mechanism Replacement - photos and hints
- Brake switch Replacement - procedure from TSB 08-67-93
- Brake caliper replacement = photos and tips on the PavementSucks.com site
- Build a Brake Pressure Bleeder = photos and instructions on the Bay Area 02 site for BMWs
Steering
- Steering Clunk Fix - using tie wraps to eliminate steering slop and clunk
- steering shaft rebuild for 89 to 93 models - part numbers and procedure
- Steering damper
  - Replace damper - hints posted to RTML, DiRT
  - Replace damper, install aux damper - TSB 19-05-96
  - install tips - for 99 models from the Star Center News
- Power Steering Pump Replacement - R&R comments
- Power Steering Gear Adjustment procedure:
  - from 94 shop manual - replace gear, adjust with gear on bench
  - from TSB 19-10-97 - adjust without removing gear from truck
Suspension System
- Replace Shocks & Steering damper - hints posted to RTML, DiRT
- Wheel Alignment tips = posted to Alt.autos.dodge.trucks
Replacing Wheel Studs = photos, instructions on Jason B's pavementsucks.com site

TRANSMISSION / TRANSFER CASE / CLUTCH

Automatic Transmission
- Band Adjustment
- Fluid, filter, and gasket replacement notes
- Change Transmission Fluid & Filter = photos, instructions from the Pavementsucks.com site
  - Includes instructions for adding a transmission drain plug

shift problem diagnosis
shift linkage adjustment - TSB 21-24-94
Throttle Position Sensor adjustment
Throttle Lever Adjustment
Line Pressure Adjustment Tips = on Bill Kondolay's Diesel Transmission Technology page
Line Pressure & Transmission Longevity - on Bill Kondolay's Diesel Transmission Technology page
Transmission tech questions - forum on Bill Kondolay's Diesel Transmission Technology page
noise - what is normal / what is not.
disassembly and reassembly - useful info in TSB 21-11-97A
cooling lines - TSB 21-15-96 quick connect procedure
- Replace the plastic couplings with steel versions.

Transfer Case
- Shifter Adjustment - simple procedure to adjust the shift mechanism
- Shifter Noise fixes - homebrew mods that work
- Replacing the front driveshaft output seal - TSB 21-21-94
- Rebuilding the 241 = photos & tips from Old Army Bake's page
Manual Transmission
- Hydraulic clutch service tips - from the Star Center News
- Installation notes: NV5600 swap into a 98 Ram 12 Valve
Locating an oil leak - using talcum powder to find the source of a leak.
Repairing a porosity leak - TSB 21-15-99 for cars uses an air hammer to peen the case

AXLE / DRIVESHAFT RELATED

Differential Fluid Change = photos, instructions on Pavementsucks.com site
Axle Ring And Pinion Setup - notes from RTML, DiRT
9.25" Axle rebuild = from the www.offroad.com technical pages
Diagnosing 4X4 engagement problems - how 4X4 engagement works, troubleshooting
LockRight installation notes - comments and tips from RTML
TSB 03-02-98 - axle lubes and sealing requirements for the 8 1/4 and 9 1/2 axles
Replacing Driveshaft U-Joints - DIY instructions and photos
Diagnosing Axle Noises - TSB 03-05-99 Cherokee TSB has much general information
Diagnosing Axle Noises - Procedures from Oct 99 MasterTech
Dana 44 Hub & U-joint repair = instructions and photos on the Pavementsucks.com site
Front Axle repairs - U-joint, seal, and shaft repair notes
Front Axle Assembly Remove/Install - Recall 861 has complete R&R instructions for 2500 and 3500 4X4
Front Axle u-joint replacement = photos and instructions at pirate4x4.com
Dana 60 service manual = Complete manual scanned at gohumvee.com
Replacing Front Axle oil seals and cross joints = photos & tips from Old Army Bake's page
Repairing an ARB Air Locker = 4 Wheel & Off Road article

ENGINE RELATED

General for all engines:

Head Gasket Installation Notes
Locating an oil leak - using talcum powder to find the source of a leak.
Temporary repair for throttle cable ball/socket that keeps popping off
Understanding, selecting, and testing thermostats = on the Aluminium Radiators & Engineering site

Gasoline Engines: Moved to a new page

Diesel Engines: Moving to a new page

Oil Filter change tips = photos and tips on Murdock's page
IAT replacement = Marco's notes and R&R instructions for the Intake Air Temp sensor.
P7100 Timing adjustment procedure - from TSB 18-10-94A
Holset Turbo Bearing Replacement - Hints and part numbers
Throttle Cable Replacement - procedure for 94-98 12 Valve engines
Cooling system flush - Diesel
Fuel Filter Change - 94-96 12 valve diesel
Clean/Replace the fuel filter strainer - 94-98 12V photos and description
Fuel Filter Change - 97-98 12 valve diesel
Fuel Filter Change - 98-99 24 valve diesel
Fuel Filter Change - 00-01 24 valve diesel
Diesel Injector Pump Overflow Valve Troubleshooting
TSB 18-07-98 Diesel dash tach is not accurate enough for idle speed adjustments
Installing injectors on a 1st gen - Tips from the TDR forums and mail lists
Installing injectors on a 24V ISB - Tips from the TDR forums and mail lists
PacBrake solenoid cleaning (pdf file) - disassemble and clean a sticking vacuum solenoid

WIRING, SWITCH, AND GAUGE RELATED

Brake switch Replacement - procedure from TSB 08-67-93
Compass Recalibration - hints posted to DiRT
- TSB 08-51-98 includes complete instructions for compass recalibration.
Fuel Gauge Sending Unit Repair
- Photos and instructions CJ Johansson's instructions
  - Photos and instructions same information on Will Rosenberry's page
- Photos and instructions from Huey Conway
  - additional details text only posted to mail list by Huey Conway
- Fuel level sender replacement - tips from the mail lists and Chrysler
Heater motor relay diagnostics - TSB 08-32-96
Ignition switch replacement - instructions and tips
Instrument Panel Self Test 1998+ - using ign key and odometer reset to self-test the IP
Keyless entry programming
Lights
- Headlamp Switch replacement - Instructions in Recall #819
Radio / Speakers
- Radio connector wiring diagrams - from the Install Doctor website
- 94-97 Radio R&R = on the carstereohelp.com site
- 94-97 Front Door Panel / Speaker Removal = on the carstereohelp.com site
- 98-01 Radio R&R = on the carstereohelp.com site
- 02 1500 Radio R&R = on the carstereohelp.com site
Starter repair = replacing the starter solenoid contacts (on the Foster Truck accessory page)
Trailer Connector Wiring - connector pins and color codes, etc
Wire Splicing Techniques - from TSB 08-05-00

BODY RELATED

Door Panel and Body Side Molding Removal
- see also TSB 23-35-98, TSB 08-09-98, TSB 08-54-98
Door window glass replacement - how to replace a broken window
Windshield wiper replacement - R&R instructions found in TSB 23-22-97
Instrument Panel / Dash Disassembly notes
- Cluster Bezel Removal 98 Ram - R&R instructions found in TSB 08-35-98
- Glove box door removal procedure - Instructions in TSB 23-02-96
Paint blemish Repair

HVAC, Etc

Ram AC drain extension - to prevent condensation from blowing back into the cab.
Removing AC odor - how to get rid of that musty smell.
- TSB 24-11-97 has instructions
Heater motor relay diagnostics - TSB 08-32-96

TOOLS

Harbor Freight Torque Wrench Review

Other DIY Repair/Tech sites:

Saturday Mechanic series - from the Popular Mechanics magazine site
Engine Pages
- Degreeing a Cam = from the Crain Cams pages
- Valve Timing Tutorial - From the comp cams page
- OBD-II - helping the home and independent technician understand OBD-II technology
- Champion spark Plug Handbook - selecting, installing, and reading spark plugs (archived at dodgeram.info)
- Adjusting the valve train = from the Crain Cams pages
- 1967 Dodge LA-318 Engine rebuild - photos and tips from the '61-'71 Dodge Truck Website link dead http://www2.dana.com/expert/wc.dll?DSD~deabill~3~ will attempt to locate new URL
Transmission Pages
- Bill Konolday's Diesel Transmission Technology - forums, tips, more
Driveshaft, Axle and Differential pages
- Dana Axle Bill of Materials - look up parts for your OEM Dana axle link dead http://www.wsu.edu/~moparman/tech/engine5.html will attempt to locate new URL
- The Dana Expert Site - identify parts and part numbers
- Front Dana 60 bible = everything you want to know about the D60 Front from pirate4x4.com
- Driveshaft 401 = detailed look at all you need to know about driveshaft tech and maintenence from pirate4x4.com
- Rebuilding Dana 60 Front Axle Kingpins (instruction for Chevy, but useful tips apply to pre '94 Ram axles) = from pirate4x4.com
- Ball joint installation = Moog bulletin posted at pirate4x4.com
- Moog's front axle ball joint adjustment tech bulletin = posted at pirate4x4.com
- Speedi Sleeve repair for leaking axle spindle seal (14 bolt axle, but Ram would be similar) = pirate4x4.com
- Manuals for Axles, hubs, lockers, and bearings, bolt specs, more = pirate4x4.com library
4X4 Related - Lifts, mud flaps, winches,
- Warn 8274 Winch Rebuild = photos and instructions on Bill's Tech Article on the pirate4x4.com site
- See the very large Large collection of tech articles at the pirate4x4.com site
Wiring Pages
- The Headlamps FAQ - high wattage, types of lights, wiring, etc from Stern Lighting
- The Car Battery FAQ - on Roy Schmaus' pages. Links to other battery FAQ pages. link down http://nyquist.ee.ualberta.ca/~schmaus/batfaq.html
Wheels and Tires

none

Aftermarket installation, maintenance

K&N Air Filter cleaning instructions - from the K&N site

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This page last updated on September 8, 2004