1986 Dodge Truck Repair Manual

The 1986 Dodge Truck Repair Manual provides comprehensive technical information for maintaining and repairing 1986 Dodge truck models including D100, D150, D250, and D350 series. This manual covers engine systems, transmission, brakes, suspension, electrical systems, and routine maintenance procedures for both gasoline and diesel engine variants. Below are key sections for safety, specifications, maintenance schedules, troubleshooting, and repair procedures.

1. Vehicle Specifications 2. Safety Precautions 3. Maintenance Schedule 4. Engine Systems 5. Transmission & Drivetrain 6. Brake Systems 7. Suspension & Steering 8. Electrical Systems 9. Troubleshooting Guide 10. Wiring Diagrams 11. Torque Specifications

Vehicle Specifications

Technical specifications for 1986 Dodge Truck models including engine options, dimensions, and capacities.

Specification	Description
Engine Options	3.7L Slant-6, 5.2L V8, 5.9L V8 gasoline; 6.2L diesel
Transmission	4-speed manual, 3-speed automatic
Wheelbase	115" to 165" depending on model
Payload Capacity	1,500 to 5,000 lbs
Fuel Capacity	20 to 35 gallons
Brake System	Front disc, rear drum with power assist
Suspension	Front independent, rear leaf spring
Electrical	12-volt system, 60-amp alternator
Cooling System	16-20 quart capacity
Oil Capacity	4-6 quarts with filter

Safety Precautions

Essential safety procedures for working on 1986 Dodge trucks.

Always disconnect battery before electrical work.
Use jack stands when working under vehicle.
Wear safety glasses during repairs.
Properly dispose of fluids and batteries.
Ensure proper ventilation when working with fuels.

WARNING! Always use proper lifting equipment and follow torque specifications to prevent injury and damage.

Maintenance Schedule

Recommended maintenance intervals for optimal performance.

Oil and filter change: Every 3,000 miles or 3 months
Air filter replacement: Every 15,000 miles
Spark plugs: Every 30,000 miles
Coolant flush: Every 30,000 miles or 2 years
Brake fluid: Every 30,000 miles or 2 years
Transmission fluid: Every 30,000 miles
Timing belt: Every 60,000 miles (if equipped)

NOTE: Severe service conditions may require more frequent maintenance.

Engine Systems

Engine Identification: VIN codes for engine type identification
Tune-up Procedures: Spark plug gap, timing, carburetor adjustment
Fuel System: Carburetor service, fuel pump replacement
Cooling System: Radiator, water pump, thermostat replacement
Ignition System: Distributor, coil, spark plug wires
Emission Controls: PCV, EGR, catalytic converter service
Engine Removal: Step-by-step procedure for engine replacement

Transmission & Drivetrain

Service procedures for manual and automatic transmissions.

Manual Transmission: Clutch adjustment, linkage repair, fluid change procedures. Automatic Transmission: Band adjustments, fluid and filter service, shift linkage adjustment.

Drivetrain: U-joint replacement, differential service, drive shaft balancing procedures. Transfer case service for 4WD models including fluid changes and seal replacement.

Brake Systems

Brake service including disc and drum brake procedures.

Front disc brakes: Pad replacement, rotor service, caliper rebuild
Rear drum brakes: Shoe replacement, wheel cylinder service
Parking brake: Cable adjustment and replacement
Master cylinder: Bench bleeding and installation
Brake bleeding: Proper procedure for air removal

CAUTION: Always replace brake components in axle sets and test brake operation before road use.

Suspension & Steering

Front end alignment and suspension component replacement.

Ball joint inspection and replacement procedure
Tie rod end replacement and alignment
Shock absorber and spring replacement
Wheel bearing adjustment and repacking
Steering gear box adjustment and repair

Tip: Always check alignment after suspension work and replace worn components in pairs.

Electrical Systems

Diagnosis and repair of electrical components.

Battery testing and replacement procedures
Alternator and regulator testing and replacement
Starter motor service and solenoid replacement
Lighting system: Headlight adjustment, bulb replacement
Instrument cluster: Gauge repair and bulb replacement
Wiring repair: Proper splicing and connector service
Fuse box location and circuit identification

WARNING! Always disconnect battery before electrical repairs to prevent shorts and injury.

Troubleshooting Guide

Common problems and solutions for 1986 Dodge trucks.

Symptom	Possible Cause	Corrective Action
Engine won't start	Battery, ignition, fuel system	Check battery voltage, spark, fuel delivery
Poor fuel economy	Carburetor, timing, filters	Adjust carburetor, check timing, replace filters
Brake pulling	Calipers, hoses, alignment	Inspect calipers, replace hoses, check alignment
Electrical issues	Grounds, alternator, battery	Check grounds, test alternator output
Transmission slipping	Fluid level, bands, linkage	Check fluid, adjust bands, inspect linkage

Wiring Diagrams

Complete electrical schematics for all systems.

Includes engine compartment wiring, dashboard circuits, lighting systems, and accessory wiring. Color-coded diagrams with connector locations and ground points identified.

Torque Specifications

Critical torque values for proper assembly.

Component	Torque Value
Cylinder head bolts	65-75 ft-lbs (sequence required)
Main bearing caps	70-80 ft-lbs
Rod bearing caps	45-50 ft-lbs
Spark plugs	15-20 ft-lbs
Wheel lug nuts	85-110 ft-lbs
Flywheel bolts	55-65 ft-lbs
Pressure plate bolts	20-25 ft-lbs

Service Support: For technical assistance contact Dodge service centers or refer to factory service bulletins.