Market Segment:
Full-size pickup truck, known for its robust build, towing capacity, and versatility for work and personal use.
Competitors:
Ford F-Series (F-150, F-250, F-350), Chevrolet Silverado/GMC Sierra (1500, 2500HD, 3500HD), Toyota Tundra, Nissan Titan.
Vehicle Strengths:
Strong V8 and Turbo Diesel engine options, heavy-duty capabilities (especially 2500/3500 models), spacious and durable interiors, class-leading towing and payload capacities.
Professional Equivalence:
This manual is the equivalent of what professional technicians use in dealerships and independent repair shops, providing the depth and accuracy needed for any repair task.
Engine:
Detailed diagnostic, repair, and overhaul procedures for all gasoline and diesel engines, including 3.7L V6 Magnum, 4.7L V8 Magnum, 5.7L V8 HEMI, 8.0L V10 Magnum, and 5.9L Cummins Turbo Diesel.
Transmission:
Complete coverage for automatic transmissions (45RFE, 48RE, 545RFE) and manual transmissions (NV3500, NV4500, NV5600), including diagnosis, repair, and overhaul.
Drivetrain:
Four-wheel drive (4WD) systems, transfer cases (NV241DHD, NV271D, NV273D), front and rear axles, differentials, drive shafts, and CV joints.
Brakes:
ABS, hydraulic system, disc and drum brake components, parking brake, and related diagnostics.
Suspension Steering:
Front and rear suspension (solid front axle, independent front suspension on some models), steering system, power steering, wheel alignment specifications.
Electrical Electronics:
Full wiring diagrams, component testing, diagnostic procedures for ignition, charging, starting systems, lighting, instruments, body control modules (BCM), power distribution, and entertainment systems.
HVAC:
Air conditioning, heating, ventilation system diagnosis, repair, and component replacement.
Body Chassis:
Body panel removal/installation, interior trim, exterior components, frame inspection and repair, collision repair information.
Maintenance:
Scheduled maintenance intervals, fluid changes, filter replacements, lubrication, belt and hose inspection/replacement.
Diagnostics:
System-specific diagnostic flowcharts, symptom-based troubleshooting guides, OBD-II diagnostic trouble codes (DTCs) and their resolutions.
Repair Rebuild:
Step-by-step instructions for component removal, installation, overhaul, and adjustment for virtually all mechanical and electrical systems.
Technical Specifications:
Torque specifications, clearances, tolerances, fluid capacities, and electrical data.
Depth:
Comprehensive, covering everything from basic fluid checks and tire rotations to complex engine and transmission rebuilds, advanced electrical diagnostics, and frame straightening procedures.
3.7L Magnum V6:
Displacement: 3.7L (226 cu in), Bore x Stroke: 3.66 x 3.57 in, Compression Ratio: 9.1:1, Horsepower: 215 hp @ 5200 rpm, Torque: 235 lb-ft @ 4000 rpm.
4.7L Magnum V8:
Displacement: 4.7L (285 cu in), Bore x Stroke: 3.43 x 3.19 in, Compression Ratio: 9.1:1, Horsepower: 235-260 hp @ 4800-5200 rpm, Torque: 290-335 lb-ft @ 3200-3600 rpm (varies by year/tune).
5.7L Hemi V8:
Displacement: 5.7L (345 cu in), Bore x Stroke: 3.92 x 3.58 in, Compression Ratio: 9.6:1, Horsepower: 345-350 hp @ 5000-5400 rpm, Torque: 375-375 lb-ft @ 4000-4200 rpm.
8.0L Magnum V10:
Displacement: 8.0L (488 cu in), Bore x Stroke: 4.00 x 3.88 in, Compression Ratio: 9.1:1, Horsepower: 305 hp @ 4800 rpm, Torque: 450 lb-ft @ 3200 rpm.
5.9L Cummins Turbo Diesel I6:
Displacement: 5.9L (359 cu in), Bore x Stroke: 4.02 x 4.72 in, Compression Ratio: 16.3:1, Horsepower: 250-325 hp @ 2800-2900 rpm, Torque: 460-555 lb-ft @ 1400-1600 rpm (varies significantly by year/pump calibration).
Fuel Delivery:
Multi-port Fuel Injection (MPI) for gasoline engines; High-pressure common rail (HPCR) injection for 5.9L Cummins Turbo Diesel.
Cooling System:
Pressurized, multi-channel cooling system with thermostat control. Specific capacities and thermostat ratings provided for each engine.
Standard Transmission:
Varies by model and trim. Examples: 4-speed automatic (45RFE, 48RE) for gasoline engines, 6-speed manual (NV5600) for high-output diesel models.
Optional Transmission:
Manual transmissions (NV3500, NV4500) for lighter duty models; 4-speed automatic (545RFE) for newer gasoline engines; 48RE automatic for diesel engines.
Automatic Transmission Features:
Electronic controls, overdrive gears, torque converter lock-up for improved efficiency. Specific control strategies detailed for each transmission type.
Manual Transmission Specifications
Clutch Type:
Hydraulically actuated single dry-plate clutch (for manual transmissions). Specifications for clutch disc, pressure plate, and release bearing.
Wheelbase:
Ranges from 135.5 inches (standard cab, short bed) to 160.5 inches (crew cab, long bed).
Overall Length:
Varies by cab and bed configuration, up to approximately 260 inches for crew cab, long bed.
Bed Lengths:
Available in 6.3 ft (standard) and 8.0 ft (long) bed lengths.
Curb Weight:
Ranges from approximately 4,800 lbs (1500, regular cab) to over 7,000 lbs (2500/3500, crew cab, long bed diesel).
Gross Vehicle Weight Rating Gvwr:
GVMWRs range from 6,500 lbs for 1500 models to over 11,500 lbs for 3500 models, depending on configuration.
NHTSA Ratings:
Frontal crash test ratings from NHTSA (National Highway Traffic Safety Administration) for these years typically range from 4 to 5 stars, though specific model year and configuration dependent. Side impact and rollover ratings are also detailed.
ABS:
Anti-lock Braking System (ABS) is standard on all models, with specific diagnostic and repair procedures for the system.
Airbags:
Frontal airbags for driver and passenger are standard. Side curtain airbags were optional or not available on all models within this generation, with detailed system coverage.
Seatbelts:
Pretensioner seatbelts for front occupants, with detailed inspection and replacement procedures for the seatbelt system.
Audio Systems:
Factory-installed AM/FM radio with CD player, cassette player (early models), optional Infinity premium audio systems, and Sirius Satellite Radio compatibility.
Cruise Control:
Standard cruise control system with detailed testing and repair procedures.
Trailer Towing Features:
Integrated trailer wiring harnesses, trailer brake controller options, and specific towing capacity charts based on engine and drivetrain configuration.
Oil Change Interval:
Typically 3,000-7,500 miles for gasoline engines, depending on oil type and driving conditions (severe vs. normal). Diesel engines often have longer intervals, 7,500-15,000 miles, with specific recommendations for oil type.
Transmission Fluid Change:
Recommended every 30,000-60,000 miles for automatic transmissions, depending on load and driving conditions. Manual transmission fluid changes usually at 60,000-100,000 miles.
Coolant Change:
Initial change often at 100,000 miles or 5 years, then every 50,000 miles or 3 years thereafter, using specified antifreeze. Diesel engines may have different recommendations.
Engine Oil Gasoline:
SAE 5W-30 (API SG/SH/SJ/SL) recommended for most gasoline engines. Specific viscosity may vary based on temperature. HEMI engines may have specific oil requirements.
Engine Oil Diesel:
CJ-4 or CK-4 rated diesel engine oil, typically SAE 15W-40, with specific Cummins-approved oils recommended for optimal performance and longevity.
Transmission Fluid Automatic:
ATF+4 (Automatic Transmission Fluid Type 9602) is the specified fluid for all automatic transmissions (45RFE, 48RE, 545RFE).
Transmission Fluid Manual:
GL-3 or GL-4 gear oil for manual transmissions, with specific weight recommendations (e.g., 75W-90). Cummins transmissions may use specific GL-4 or GL-5 fluids.
Coolant:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, typically pink in color. Mixing with other coolant types can cause damage.
Common Wear Items:
Ball joints, tie rod ends, sway bar links (due to vehicle weight and usage), alternator, water pump, and potentially transmission solenoid issues.
Diesel Specific Concerns:
Lift pump failures, injector issues (especially older models), VP44 injection pump failures (pre-2003), and possible turbocharger wear.
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, with the Ram line evolving into a distinct and highly regarded brand.
Third Generation Ram:
This generation (2002-2008, with 2002-2006 being the initial phase) represented a significant redesign over the previous generation, featuring updated styling, improved interiors, and the introduction of the HEMI V8 and the widely praised Cummins Turbo Diesel.
Manufacturing Locations:
Primarily manufactured in North America, including plants like the Warren Truck Assembly Plant in Michigan.
Segment Accolades:
The Dodge Ram 1500/2500/3500 series has historically received numerous awards and positive reviews for its towing and hauling capabilities, engine power (especially the Cummins diesel), and robust chassis.
Motor Trend Truck Of The Year:
While not every model year won, the Ram truck line has been recognized by MotorTrend as 'Truck of the Year' multiple times in its history, reflecting its competitive standing.
