1986 Dodge 3500 Van Factory Service Manual

The 1986 Dodge 3500 Van Factory Service Manual provides comprehensive technical information for maintaining and repairing the Dodge 3500 van series. This manual covers engine systems, transmission, chassis, electrical systems, body components, and routine maintenance procedures for the 1986 model year. Below are key sections for specifications, maintenance schedules, troubleshooting, and repair procedures.

1. Vehicle Specifications 2. Maintenance Schedule 3. Engine Systems 4. Transmission & Drivetrain 5. Brake System 6. Suspension & Steering 7. Electrical System 8. Body & Interior 9. Troubleshooting Guide 10. Wiring Diagrams 11. Technical Service Bulletins

Vehicle Specifications

Complete technical specifications for the 1986 Dodge 3500 Van series.

SpecificationDetails
Engine Options5.2L V8, 5.9L V8, 6.6L Diesel
Transmission3-speed automatic, 4-speed manual
Wheelbase109", 127", 146"
GVWR8,500 - 10,000 lbs
Fuel Capacity30-35 gallons
Brake SystemFront disc, rear drum
Electrical System12-volt, 60-amp alternator
Tire SizeLT225/75R16
Payload Capacity3,500 - 5,000 lbs
Towing CapacityUp to 10,000 lbs

Maintenance Schedule

Recommended maintenance intervals for optimal vehicle performance.

  1. Oil Change: Every 3,000 miles or 3 months
  2. Filter Replacement: Air filter every 12,000 miles, fuel filter every 15,000 miles
  3. Tire Rotation: Every 6,000 miles
  4. Brake Inspection: Every 12,000 miles
  5. Coolant Flush: Every 30,000 miles or 24 months
  6. Transmission Service: Every 30,000 miles

WARNING! Always use manufacturer-recommended fluids and follow torque specifications.

Engine Systems

Detailed service procedures for engine components and systems.

Transmission & Drivetrain

Service procedures for transmission, driveshaft, and differential.

  1. Automatic Transmission: Fluid change and band adjustment
  2. Manual Transmission: Clutch replacement and shift linkage adjustment
  3. Drive Shaft: U-joint replacement and balancing procedures
  4. Differential: Gear oil change and bearing replacement
  5. Transfer Case: Service procedures for 4WD models

CAUTION! Use proper lifting equipment when working under vehicle.

Brake System

Complete brake system service and repair procedures.

ComponentService Procedure
Master CylinderBench bleeding and replacement
Brake CalipersPiston service and seal replacement
Brake DrumsAdjustment and resurfacing specifications
Brake LinesFlaring and routing procedures
Parking BrakeCable adjustment and service

Suspension & Steering

Front and rear suspension service with alignment specifications.

  1. Front Suspension: Ball joint replacement and wheel bearing adjustment
  2. Rear Suspension: Leaf spring service and shackle replacement
  3. Steering Gear: Adjustment and replacement procedures
  4. Power Steering: Pump service and hose replacement
  5. Alignment: Camber, caster, and toe specifications

Electrical System

Complete electrical system diagnosis and repair.

Body & Interior

Body panel replacement and interior component service.

  1. Door Service: Hinge adjustment and window regulator replacement
  2. Seat Service: Track repair and upholstery replacement
  3. Dash Components: Instrument panel and control head service
  4. Exterior Trim: Moldings and emblems replacement
  5. Glass Service: Windshield and door glass replacement

Troubleshooting Guide

Diagnostic procedures for common vehicle problems.

SymptomPossible CauseCorrective Action
Engine won't startFuel delivery, ignition failureCheck fuel pressure, test spark, verify timing
Poor fuel economyCarburetor adjustment, timingAdjust air/fuel mixture, check ignition timing
Brake pullCaliper seizure, fluid contaminationInspect calipers, flush brake fluid
Electrical drainShort circuit, faulty componentPerform parasitic draw test, inspect wiring
Transmission slippageLow fluid, band adjustmentCheck fluid level, adjust bands

Wiring Diagrams

Complete electrical schematics for all vehicle systems.

Includes: Starting/charging circuits, lighting systems, instrument panel, engine management, and accessory circuits. All diagrams include wire colors, connector locations, and component identification.

Technical Service Bulletins

Manufacturer-issued updates and service procedures.

Service Support: Contact Dodge technical support for additional information.

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