DODGE RAM 1500 2500 3500 2003 Service-Reparaturhandbuch

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🏷️ Basic Information Identification Make: Dodge Model: Ram 1500 / 2500 / 3500 Year: 2003 Generation Generation Code: Third Generation (DR/DH/D2) Generation Years: 2002-2008 👋 Introduction Market Position Vehicle Segment:...

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Art.-Nr: 584598

Stichworte: 2003 Cars Dodge RAM 1500 RAM 2500 RAM 3500 Ram Models Truck

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Beschreibung

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram 1500 / 2500 / 3500

Year:

Generation

Generation Code:

Third Generation (DR/DH/D2)

Generation Years:

2002-2008

👋 Introduction

Market Position

Vehicle Segment:

Full-size pickup truck, renowned for its towing and hauling capabilities.

Target Audience:

DIY mechanics, professional technicians, fleet maintenance, and truck enthusiasts.

Competitive Analysis

Competitors 2003:

Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra.

Key Features

Powertrain Options:

Choice of robust V6 and V8 engines, including the introduction of the highly acclaimed 5.7L HEMI.

Chassis Design:

Body-on-frame construction, solid rear axle with leaf springs, and independent front suspension offering a balance of capability and ride comfort.

Towing Hauling:

Class-leading towing and payload capacities across the 1500, 2500, and 3500 series.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Digital (PDF)

Coverage Scope:

Comprehensive repair and maintenance for all Dodge Ram 1500, 2500, and 3500 models of the 2003 model year.

Page Count

Page Count:

Approximately 1000+ pages (estimated for comprehensive coverage)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed diagnostics, disassembly, assembly, and repair procedures for all engines offered in 2003 Ram trucks, including 3.7L Magnum V6, 4.7L Magnum V8, and 5.7L HEMI V8.

Engine Performance:

Engine tuning, performance diagnostics, emissions controls, fuel injection system, ignition system, and cooling system.

Transmission Manual:

Service and repair for manual transmissions (NV3500, NV4500, NV5600) including clutch system, gear sets, synchronizers, and shifter mechanisms.

Transmission Automatic:

Service and repair for automatic transmissions (42RE, 44RE, 45RFE, 47RE, 48RE) including torque converter, valve body, internal components, and electronic controls.

Drivetrain:

Front and rear axle service, differentials, driveshafts, CV joints, transfer case (manual and electronic shift), and wheel bearings.

Brakes:

Hydraulic brake system (front disc, rear drum/disc depending on model), ABS system, parking brake, and brake fluid specifications.

Suspension:

Front independent suspension (double wishbone) and rear solid axle (leaf springs). Includes ball joints, control arms, shock absorbers, torsion bars (if applicable), sway bars, and steering components.

Steering:

Power steering system, steering gear box/rack and pinion, steering column, and tie rod ends.

Electrical System:

Wiring diagrams, battery, alternator, starter motor, fuses, relays, lighting systems, instrument cluster, power windows, power locks, and body control modules.

HVAC:

Air conditioning system, heating system, blower motor, controls, and refrigerant specifications.

Body And Trim:

Exterior body panels, doors, hood, tailgate, bumpers, interior trim, seats, and glass replacement.

Diagnostics:

On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), scan tool usage, and troubleshooting guides for various systems.

Procedures Included

Scheduled Maintenance:

Detailed procedures for oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement, and brake inspections.

Repair Procedures:

Step-by-step instructions for overhauling engines, rebuilding transmissions, replacing suspension components, repairing brake systems, and electrical diagnostics.

Troubleshooting:

Systematic approaches to identify and resolve common and uncommon issues, including diagnostic flowcharts and symptom-based troubleshooting.

Specifications And Tolerances:

Torque specifications for all fasteners, engine clearances, bearing preloads, and other critical dimensions.

Wiring Diagrams:

Complete and detailed electrical wiring diagrams for all major systems, including powertrain control, body electronics, lighting, and comfort systems.

Technical Depth

Depth Level:

Expert-level, covering complete engine and transmission overhauls, advanced electrical diagnostics, and chassis component rebuilds.

Detail Level:

Includes detailed exploded views, assembly sequences, special tool requirements, and factory-recommended procedures.

📊 Manual Specifications

File Format

File Format:

Searchable:

Yes, text-searchable for quick information retrieval.

Printable:

Yes, designed for printing specific sections or the entire manual.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding Type:

Digital (N/A for physical binding)

Paper Type

Paper Type:

Digital (N/A for physical paper type)

⚙️ Engine Specifications

Primary Engine

Engine 1:

3.7L Magnum V6 (e.g., 3.7L SOHC)

Engine 1 Displacement:

3701 cc

Engine 1 Bore X Stroke:

93.0 mm x 90.9 mm

Engine 1 Compression Ratio:

9.9:1

Engine 1 Horsepower:

215 hp @ 5200 rpm (approximate)

Engine 1 Torque:

235 lb-ft @ 4000 rpm (approximate)

Engine 2:

4.7L Magnum V8 (e.g., 4.7L SOHC)

Engine 2 Displacement:

4701 cc

Engine 2 Bore X Stroke:

93.0 mm x 86.0 mm

Engine 2 Compression Ratio:

9.1:1

Engine 2 Horsepower:

240 hp @ 4800 rpm (approximate)

Engine 2 Torque:

300 lb-ft @ 3200 rpm (approximate)

Engine 3:

5.7L HEMI V8

Engine 3 Displacement:

5654 cc

Engine 3 Bore X Stroke:

99.5 mm x 93.0 mm

Engine 3 Compression Ratio:

9.6:1

Engine 3 Horsepower:

345 hp @ 5000 rpm (approximate)

Engine 3 Torque:

375 lb-ft @ 4000 rpm (approximate)

Performance

Fuel Type:

Unleaded gasoline

Ignition System:

Distributorless Ignition System (DIS) with coil-on-plug (COP) technology for 5.7L HEMI; distributor-based for Magnum engines.

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Pump Type:

In-tank electric fuel pump

🔧 Transmission

Standard

Transmission 1500 Standard:

4-speed automatic (45RFE or 48RE)

Transmission 1500 Manual Option:

5-speed manual (NV3500)

Transmission 2500 3500 Standard:

4-speed automatic (47RE or 48RE)

Transmission 2500 3500 Manual Option:

5-speed manual (NV4500) or 6-speed manual (NV5600) for heavy-duty models.

Features

Overdrive:

All automatic transmissions feature overdrive gear.

Transfer Case 4X4:

Manual shift transfer case (NP241DHD) or electronic shift transfer case (NV244/NV271D/NV273D depending on trim and configuration).

Transmission Fluid Type Auto:

ATF+4 (Chrysler specification)

Transmission Fluid Type Manual:

Manual transmission fluid (specific grade varies by transmission model, consult manual).

📐 Dimensions

Exterior

Wheelbase 1500:

Approximately 140.5 inches (Quad Cab) / 139.0 inches (Regular Cab)

Wheelbase 2500 3500:

Approximately 140.5 inches (Quad Cab) / 139.0 inches (Regular Cab) for 1500HD and 2500; 154.5 inches for 2500/3500 Crew Cab/Long Bed.

Overall Length:

Varies by cab and bed configuration, typically between 229 to 259 inches.

Overall Width:

Approximately 79.1 inches (excluding mirrors)

Overall Height:

Varies by configuration, typically between 74.4 to 78.0 inches.

Cargo

Bed Length Short:

6.3 ft (Standard Bed)

Bed Length Long:

8.0 ft (Long Bed)

Weights

Curb Weight 1500:

Approximately 4,600 - 5,200 lbs

Gvwr 1500:

Approximately 6,000 - 7,500 lbs

Gvwr 2500:

Approximately 8,500 - 9,000 lbs

Gvwr 3500:

Approximately 9,600 - 10,500 lbs

Towing Capacity:

Up to 10,000+ lbs (varies significantly by configuration and axle ratio)

Payload Capacity:

Up to 3,000+ lbs (varies significantly by configuration)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

Good (for 2003 model year, as per available data for similar models)

NHTSA Frontal Passenger:

Good (for 2003 model year, as per available data for similar models)

IIHS Frontal Offset:

Acceptable (for 2003 model year, as per available data for similar models)

Active Features

Standard Anti-lock Braking System (ABS) on all wheels.

Traction Control:

Optional on some models, or integrated into ABS system.

Passive Features

Airbags Front:

Driver and passenger front airbags.

Seat Belts:

Three-point front and rear seat belts.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Audio System Options:

Factory AM/FM/CD player, cassette player (optional), and premium Infinity sound system.

Navigation:

Optional factory navigation system available on higher trims.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Parking Assist:

Rear parking assist sensors available as an option on some models.

Connectivity

Power Outlets:

12V auxiliary power outlets.

Remote Keyless Entry:

Available as an option.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles or 3-6 months, depending on driving conditions and oil type (synthetic recommended for longer intervals).

Air Filter Replacement:

Every 15,000-30,000 miles or annually, or sooner if driving in dusty conditions.

Spark Plug Replacement:

Platinum-tipped spark plugs typically rated for 100,000 miles (HEMI) or copper plugs for Magnum engines (e.g., 30,000-60,000 miles).

Coolant Flush:

Every 30,000-50,000 miles or 2-3 years, using HOAT (Hybrid Organic Acid Technology) coolant.

Transmission Fluid Service:

Automatic: Every 30,000-60,000 miles. Manual: Inspect annually, change as needed (refer to manual for specific intervals).

Fluid Specifications

Engine Oil Spec 3.7L:

SAE 5W-30 API SN (or equivalent, synthetic blend recommended).

Engine Oil Spec 4.7L:

SAE 5W-30 API SN (or equivalent, synthetic blend recommended).

Engine Oil Spec 5.7L:

SAE 5W-20 API SN (or equivalent, synthetic recommended; consult manual for specific viscosity requirements).

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) or equivalent, typically pink or orange.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Heater Core Leaks:

Common issue on some third-gen Rams, often related to the heater core material or installation.

Transmission Hard Shifting:

Can occur with automatic transmissions due to valve body issues or solenoid problems.

Wheel Speed Sensor Failure:

Can trigger ABS and traction control warning lights.

Intermediate Shaft Failure 4X4:

On 4x4 models, wear or failure of the intermediate shaft can lead to drivetrain noise or failure.

Exhaust Manifold Cracks:

Can occur on HEMI engines, leading to ticking noises and potential exhaust leaks.

📚 Vehicle History

Brand Heritage

Dodge Truck Legacy:

Dodge has a long history of building rugged and capable trucks, dating back to the 1930s.

Model Evolution

Ram Introduction Year:

The 'Ram' nameplate was introduced in 1981.

Third Generation Launch:

The third generation (DB/DH/D2) launched for the 2002 model year, representing a significant redesign with improved styling, interior, and powertrains.

Key Enhancements 2003:

The 5.7L HEMI V8 engine was introduced for the 2003 model year, a major development that significantly boosted performance and market appeal.

Production

Manufacturing Locations:

Primary assembly plants included Warren Truck Assembly (Michigan) and Saltillo Truck Assembly (Mexico).

🏆 Awards & Recognition

Recognitions

Motor Trend Truck Of The Year Nominee:

The Ram trucks are consistently strong contenders and often nominated for awards like MotorTrend's Truck of the Year.

Hemitransplant Popularity:

The 5.7L HEMI engine became highly sought after, leading to its widespread adoption and positive reputation in the performance truck segment.

Ratings

Towing Hauling Leadership:

The Ram 2500 and 3500 series were recognized for their robust chassis and powerful powertrains, making them leaders in their heavy-duty segments.