1986 Dodge D150 Service Manual PDF

The 1986 Dodge D150 Service Manual provides comprehensive technical information for maintaining and repairing the Dodge D150 pickup truck. This manual covers engine systems, transmission, brakes, suspension, electrical systems, and routine maintenance procedures for the 1986 model year. Below are key sections for specifications, maintenance schedules, troubleshooting, and service procedures.

1. Vehicle Specifications 2. Maintenance Schedule 3. Engine Systems 4. Transmission & Drivetrain 5. Brake System 6. Suspension & Steering 7. Electrical System 8. Fuel System 9. Cooling System 10. Troubleshooting Guide 11. Service Procedures

Vehicle Specifications

Technical specifications for the 1986 Dodge D150 pickup truck including engine options, dimensions, and capacities.

Specification	Details
Engine Options	3.7L Slant-6, 5.2L V8, 5.9L V8
Transmission	3-speed automatic, 4-speed manual
Wheelbase	115 inches
Payload Capacity	1,500 lbs
Fuel Capacity	20 gallons
Oil Capacity	5 quarts (with filter)
Coolant Capacity	15 quarts
Brake System	Front disc, rear drum
Tire Size	P215/75R15
GVWR	5,100 lbs

Maintenance Schedule

Recommended maintenance intervals for optimal vehicle performance and longevity.

Oil Change: Every 3,000 miles or 3 months
Oil Filter: Replace with every oil change
Air Filter: Inspect every 12,000 miles, replace as needed
Spark Plugs: Replace every 30,000 miles
Coolant Flush: Every 30,000 miles or 2 years
Brake Fluid: Check every 15,000 miles, replace every 30,000 miles
Transmission Fluid: Check every 15,000 miles, replace every 60,000 miles

WARNING! Always use recommended fluids and follow torque specifications to prevent damage.

Engine Systems

Detailed service procedures for engine components and systems.

Engine Removal: Disconnect battery, drain fluids, remove accessories
Cylinder Head: Torque sequence and specifications
Timing Chain/Belt: Inspection and replacement procedures
Valve Adjustment: Clearance specifications and adjustment method
Compression Test: Normal range 125-150 psi, variation max 25 psi

CAUTION! Allow engine to cool before performing service work to prevent burns.

Transmission & Drivetrain

Automatic Transmission: A904 3-speed, fluid type ATF+4
Manual Transmission: NP435 4-speed, gear oil 80W-90
Transfer Case: NP205 (4WD models), fluid type ATF+4
Rear Axle: 8.25-inch ring gear, gear oil 80W-90
U-Joints: Grease with NLGI #2 lithium grease
Clutch: 11-inch diameter, adjustment specifications

Brake System

Service procedures for hydraulic brake system components.

Front Disc Brakes: Rotor minimum thickness 1.230 inches, pad replacement procedure. Rear Drum Brakes: Drum maximum diameter 11.090 inches, shoe adjustment. Master Cylinder: Bench bleeding procedure, torque specifications. Brake Lines: Steel and rubber hose inspection criteria.

Suspension & Steering

Front torsion bar and rear leaf spring suspension service.

Front Suspension: Torsion bar adjustment, ball joint inspection
Rear Suspension: Leaf spring U-bolt torque, shackle inspection
Steering Gear: Manual steering box adjustment procedure
Alignment Specifications: Camber, caster, and toe settings
Shock Absorbers: Replacement and torque specifications

Tip: Always support vehicle properly with jack stands when working under vehicle.

Electrical System

Wiring diagrams and component service procedures.

Battery: Group 24, 12V 60Ah, maintenance procedures
Alternator: 60-amp output, testing and replacement
Starter: Direct drive type, solenoid testing
Ignition System: Electronic ignition, timing specifications
Lighting: Headlight aiming, bulb replacement procedures
Fuses: Fusible link locations and amperage ratings

WARNING! Disconnect battery before performing electrical work to prevent shorts.

Fuel System

Carburetor and fuel delivery system service.

Carburetor: Carter BBD 2-barrel, adjustment specifications. Fuel Pump: Mechanical type, pressure 4-6 psi. Fuel Filter: Replace every 15,000 miles. Fuel Tank: 20-gallon capacity, removal procedure. Emissions: PCV system, EGR valve service procedures.

Cooling System

Radiator, thermostat, and water pump service.

Radiator: Down-flow type, cap pressure 16 psi. Thermostat: 195°F opening temperature. Water Pump: Cast iron housing, replacement procedure. Hoses: Inspection and replacement criteria. Fan Clutch: Viscous type, testing procedure.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression issue	Check fuel delivery, spark plugs, compression test
Poor fuel economy	Carburetor adjustment, timing	Adjust carburetor mixture, check ignition timing
Brake pedal soft	Air in system, worn components	Bleed brake system, inspect master cylinder
Steering wander	Alignment, worn components	Check alignment, inspect tie rods and ball joints
Electrical issues	Ground connections, alternator	Clean battery terminals, test alternator output

Diagnostic Tools: Multimeter, compression tester, vacuum gauge required for proper diagnosis.

Service Procedures

Step-by-step instructions for common service tasks.

Oil Change: Drain plug torque 25 ft-lbs, filter hand-tight plus 3/4 turn
Spark Plug Replacement: Gap 0.035 inches, torque 20 ft-lbs
Brake Service: Bleed sequence RR-LR-RF-LF, fluid type DOT 3
Timing Adjustment: Set at 5° BTDC at idle, vacuum advance disconnected
Carburetor Adjustment: Idle mixture screws 1.5 turns out from seated

Service Support: For technical assistance, contact Dodge service department or authorized repair facilities.