Segment:
Full-size pickup truck
Target Audience:
OEM technicians, independent repair shops, DIY enthusiasts
Competitors:
Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra
Vehicle Highlight:
Renowned for its robust construction, powerful engine options (especially the HEMI V8 and Cummins turbodiesel), and towing/hauling capability.
Manual Value:
Provides comprehensive, accurate, and detailed information essential for maintaining and repairing the vehicle effectively, crucial for a generation known for its durability and capability.
Vehicle Years Covered:
2002, 2003, 2004, 2005, 2006, 2007, 2008
Vehicle Models Covered:
Dodge Ram 1500, 2500, 3500
Estimated Page Count:
Extensive, typically over 1500 pages for full coverage across models/years
Type:
Factory Authorized Service Manual
Format:
Digital Download (PDF)
Engine:
Complete engine repair, diagnostics, overhaul for all gasoline and diesel variants. Includes specific sections for V6, V8 (HEMI), and Cummins Turbo Diesel.
Transmission:
Manual and automatic transmission service, repair, overhaul, including NV3500, NV4500, NV5600, G56 (manual) and 45RFE, 48RE, 68RFE (automatic) with detailed hydraulic and electronic controls.
Drivetrain:
Front and rear axle service, differential repair, driveline components, 4WD system engagement and maintenance (NV244, NV271, NV273 transfer cases).
Brakes:
Hydraulic brake system, ABS diagnostics and repair, rotor and pad replacement, caliper service, parking brake system.
Suspension:
Front and rear suspension component diagnosis, replacement (ball joints, control arms, shocks, springs), alignment specifications.
Steering:
Power steering system diagnosis, pump and gear replacement, steering linkage components.
Electrical:
Complete wiring diagrams, fuse and relay information, lighting systems, power windows, locks, mirrors, instrument cluster, body control modules (BCM), Powertrain Control Module (PCM) diagnostics.
HVAC:
Air conditioning system service, refrigerant handling, climate control system diagnostics, heater core replacement.
Body:
Body panel repair, interior trim removal and installation, door hardware, glass replacement, tailgate service, corrosion prevention.
Emissions:
Emission control systems, diagnostic trouble codes (DTCs) related to emissions, catalytic converter information, EGR system.
Maintenance:
Routine maintenance procedures, oil changes, filter replacements, fluid checks and changes, lubrication points.
Troubleshooting:
Comprehensive diagnostic flowcharts and symptom-based troubleshooting guides for all major systems.
Repair:
Detailed step-by-step repair instructions for virtually every component and system on the vehicle.
Diagnostics:
Diagnostic procedures using OBD-II scanner, specific component testing, wiring harness continuity checks.
Depth:
Factory-level technical detail, including torque specifications, diagnostic trouble codes (DTCs), repair times, and component specifications.
Coverage Level:
Full vehicle service and repair, from basic maintenance to complete engine and transmission rebuilds.
Engine Options:
3.7L Magnum V6, 4.7L Magnum V8, 5.7L HEMI V8, 8.3L V10 (Viper engine for Ram SRT-10), 5.9L Cummins I6 Turbo Diesel (early models), 6.7L Cummins I6 Turbo Diesel (later models).
Horsepower Range:
Approx. 215 hp (3.7L V6) to 500 hp (V10 SRT-10), 325-350 hp (Cummins Diesel)
Torque Range:
Approx. 235 lb-ft (3.7L V6) to 525 lb-ft (Cummins Diesel) and 525 lb-ft (V10 SRT-10)
Fuel Delivery:
Multi-point Fuel Injection (MPI) for gasoline engines, Common Rail Diesel Injection (CRDI) for Cummins engines.
Fuel Type:
Unleaded gasoline (87 octane recommended for most V8s, 89 for HEMI), Diesel fuel (ULSD for 6.7L Cummins).
Coolant Type:
Mopar Antifreeze/Coolant (MS-7170 or MS-9769) or equivalent HOAT (Hybrid Organic Acid Technology) coolant, typically orange or pink.
Oil Type:
5W-20 or 5W-30 synthetic blend (V6/V8 gasoline), 15W-40 or 5W-40 synthetic (Cummins Diesel - consult manual for specific viscosity based on temperature).
Oil Capacity:
Approx. 6 quarts (V6/V8 gasoline), 12 quarts (Cummins Diesel - filter included). Check manual for exact capacity by engine.
Manual Transmission:
NV3500 (5-speed), NV4500 (5-speed heavy-duty), NV5600 (6-speed heavy-duty, diesel only), G56 (6-speed heavy-duty, diesel only).
Automatic Transmission:
45RFE (4-speed, gasoline V6/V8), 48RE (4-speed, heavy-duty gasoline V8/V10 and diesel), 68RFE (6-speed, heavy-duty diesel, introduced later in the generation).
Transfer Case:
Electronic Shift-On-Demand 4WD (NV244), Part-Time 4WD (NV271, NV273) with manual or electronic shift options.
Automatic Transmission Fluid:
ATF+4 (MS-9602) for 45RFE and 48RE. Consult manual for 68RFE fluid type.
Manual Transmission Fluid:
API GL-4 or GL-5 gear oil, viscosity varies by transmission type and temperature (e.g., 75W-90, 75W-140 for heavy-duty units). Check manual for specific recommendations.
Wheelbase:
Varies by cab style (Regular Cab, Quad Cab, Mega Cab) and bed length (6.3 ft, 8.0 ft). Ranges typically from 130.5 inches to 160.5 inches.
Overall Length:
Varies by configuration, typically 227.6 to 247.8 inches.
Curb Weight:
Varies significantly by configuration and engine, typically 4,500 lbs to 6,500+ lbs.
Gross Vehicle Weight Rating Gvw:
Ranges from approximately 6,050 lbs (1500) to over 10,000 lbs (2500/3500 Diesel).
Payload Capacity:
Varies by model and configuration, typically 1,000 lbs to over 5,000 lbs.
Towing Capacity:
Varies significantly, from approximately 4,000 lbs (1500) to over 12,000 lbs (3500 Diesel with proper configuration).
Wheelbase Options:
Standard Wheelbase (SWB), Long Wheelbase (LWB)
Bolt Pattern:
8 x 6.5 inches (8 lug) for 2500/3500, 5 x 5.5 inches (5 lug) for 1500
NHTSA Front Impact:
Generally good ratings for the period, but specific ratings should be verified from official NHTSA archives for individual configurations.
IIHS Front Impact:
Acceptable to Good ratings for frontal impact, depending on year and specific test.
ABS:
Standard Anti-lock Braking System
Traction Control:
Available Traction Control System (TCS) on some models.
Electronic Stability Control:
Available Electronic Stability Control (ESC) on later models, often integrated with brake systems.
Airbags:
Driver and front passenger airbags standard. Optional side curtain airbags available on some configurations.
Seatbelts:
Three-point seat belts with pretensioners for all seating positions.
Radio Options:
AM/FM stereo with CD player, optional satellite radio (SiriusXM), optional in-dash 6-disc CD changer.
Navigation:
Optional factory navigation system available on higher trim levels, typically integrated into a premium infotainment unit.
Parking Sensors:
Optional rear parking assist sensors available on some models.
Trailer Brake Controller:
Integrated trailer brake controller available as an option for towing.
Audio Input:
Auxiliary audio input jack on some models for connecting external devices.
Oil Change Interval:
Generally 3,000-7,500 miles for conventional oil, 7,500-10,000 miles for synthetic oil, depending on driving conditions. Consult manual for specific recommendations based on engine and oil type.
Transmission Fluid Change:
Automatic: 30,000-60,000 miles. Manual: Inspect periodically, change as needed or at higher mileage intervals (e.g., 60,000-100,000 miles).
Coolant Flush:
Every 30,000-50,000 miles or 2-4 years for conventional coolant; extended life coolant may vary.
Spark Plugs:
Varies by engine: 30,000-100,000 miles for conventional spark plugs, up to 100,000+ miles for platinum or iridium plugs. HEMI engines often use unique ignition systems.
Brake Fluid:
DOT 3 or DOT 4 as specified by the manufacturer. Check master cylinder cap or manual.
Power Steering Fluid:
ATF+4 (MS-9602) or specific power steering fluid as per manual.
Differential Fluid:
API GL-5 gear lubricant, viscosity depends on climate (e.g., 75W-90, 75W-140). Limited-slip differentials may require friction modifier.
Engine Crankshaft Position Sensor:
Common failure on V8 gasoline engines, leading to no-start conditions.
Transmission Cooler Lines:
Corrosion and leaks in transmission cooler lines, particularly in rust-belt regions.
Intermediate Steering Shaft:
Wear or looseness can cause steering wheel play and clunking noises.
Radiator Support Cradle:
Corrosion and cracking on the radiator support cradle, especially on earlier models.
Heater Core Leaks:
Can lead to coolant smells in the cabin and evaporator coil contamination.
Cummins Egr Cooler:
EGR cooler failure can lead to coolant loss and white smoke.
Dodge Trucks:
Dodge has a long history of producing rugged and capable trucks, dating back to the 1930s. The Ram nameplate was introduced in 1981.
Third Generation:
The 2002-2008 models represent the third generation of the Dodge Ram, codenamed 'DR'. This generation introduced a significantly redesigned exterior and interior, along with new powertrain options, including the highly acclaimed 5.7L HEMI V8 and the robust 5.9L/6.7L Cummins turbodiesel.
Facelift:
A significant refresh occurred for the 2006 model year, bringing updated styling (grille, headlights, taillights), interior enhancements, and the introduction of the 6.7L Cummins turbodiesel engine.
Manufacturing Locations:
Primarily Saltillo, Mexico, and Warren, Michigan, USA.
