🏷️ Basic Information

Make:

Dodge

Model:

Ram Truck

Model Generation:

Third Generation (DR/DH/D1/DC/DM)

Platform Code:

DR/DH

👋 Introduction

Positioning:

The Dodge Ram Truck of this era was a dominant player in the full-size pickup truck segment, known for its robust performance, towing capabilities, and distinctive styling. This manual targets owners and mechanics who need in-depth technical information for maintenance and repair.

Competitors:

Competed directly with the Ford F-Series and Chevrolet Silverado/GMC Sierra. Key differentiators included its unique coil spring rear suspension (on some models) and the powerful HEMI V8 option.

Manual Advantage:

Provides factory-authorized procedures and specifications, ensuring accuracy and completeness for all service and repair tasks, which is crucial for maintaining vehicle integrity and performance.

Vehicle Strengths:

Known for strong powertrain options (especially HEMI and Cummins), comfortable ride (compared to some competitors), and a wide range of configurations to suit various needs.

📋 Manual Details

Vehicle Years:

2002, 2003, 2004, 2005, 2006, 2007, 2008

Engine Variants:

Petrol (HEMI V8, Magnum V8, Magnum V6), Diesel (Cummins Turbo Diesel)

Chassis Configurations:

1500, 2500, 3500, Heavy Duty (HD)

Cab Types:

Regular Cab, Quad Cab, Mega Cab

Drivetrain Types:

2WD (Rear-Wheel Drive), 4WD (Four-Wheel Drive)

Estimated Pages:

Over 2000 pages (typical for comprehensive factory manuals)

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, inspection, repair, timing, cooling system, lubrication system, fuel system (mechanical components), emissions control system (mechanical components).

Engine Performance:

Engine control modules (ECM/PCM) operation, sensor inputs/outputs, actuator controls, diagnostic trouble codes (DTCs) related to engine performance, fuel injection system (electronic controls).

Transmission Manual:

Manual transmission disassembly, assembly, inspection, repair, clutch system, shift linkage.

Transmission Automatic:

Automatic transmission disassembly, assembly, inspection, repair, valve body operation, torque converter, electronic controls, transmission fluid (ATF) service.

Drivetrain:

Front axle, rear axle, differentials, transfer case (4WD), driveshafts, universal joints, CV joints, wheel bearings, axle seals.

Suspension:

Front suspension (independent or solid axle depending on model), rear suspension (leaf springs, coil springs), shock absorbers, struts, ball joints, control arms, bushings, sway bars, steering knuckles.

Steering:

Power steering system, steering gear/rack and pinion, steering column, steering linkage, alignment specifications, power steering pump and reservoir.

Brakes:

Front and rear disc brakes, brake calipers, brake pads, brake rotors, brake fluid, ABS (Anti-lock Braking System) components and diagnostics, parking brake system.

Electrical System:

Battery, charging system (alternator, starter), ignition system, lighting (headlights, taillights, interior), wiring diagrams, fuses, relays, power distribution.

Body And Chassis:

Body panel removal/installation, door mechanisms, interior trim, glass, bumpers, frame repair (where applicable), rust prevention and repair guidance.

Climate Control:

Air conditioning system (compressor, condenser, evaporator), heater core, blower motor, HVAC controls, refrigerant handling and charging.

Interior Systems:

Seats, seat belts, airbags (SRS system components and safety precautions), dashboard, instrument cluster, audio system, power windows, power locks.

Diagnostics:

OBD-II (On-Board Diagnostics) system, diagnostic trouble code (DTC) lookup and interpretation, scan tool usage, sensor data interpretation, troubleshooting flowcharts.

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), fluid level checks and top-offs, tire rotation and pressure checks, brake inspections, battery service.

Major Repairs:

Engine overhaul, transmission rebuilds, differential repair, suspension component replacement, brake system overhauls, steering system repairs, electrical component diagnosis and replacement.

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon faults, electrical circuit testing, mechanical component testing, fuel system diagnosis, cooling system leak detection.

Component Replacement:

Detailed instructions for replacing specific components such as spark plugs, ignition coils, fuel injectors, water pump, alternator, starter motor, brake pads, rotors, shock absorbers, ball joints, sensors, etc.

Specifications And Tolerances:

Torque specifications for all fasteners, critical component clearances, alignment angles, engine timing settings, fluid capacities and types.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair procedures.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all major systems, including power distribution, engine control, chassis electronics, lighting, and comfort systems.

Depth:

Comprehensive factory-level coverage, suitable for professional technicians and advanced DIY enthusiasts. Includes detailed disassembly, assembly, diagnostic procedures, and specifications.

📊 Manual Specifications

Format:

PDF

Searchability:

Likely searchable text within the PDF for quick information retrieval.

Quality:

High-resolution scans ensuring clarity of text and diagrams.

Binding:

N/A (Digital download format)

Paper Type:

N/A (Digital download format)

⚙️ Engine Specifications

Petrol V8 Hemi:

5.7L (345 cu in) V8 HEMI. Power output typically around 345-360 hp and 375-400 lb-ft of torque. Features include variable valve timing (VVT) and cylinder deactivation (MDS).

Petrol V8 Magnum:

4.7L (287 cu in) V8 Magnum. Power output typically around 230-250 hp and 300-330 lb-ft of torque. Also a 5.9L (360 cu in) V8 Magnum with higher outputs.

Petrol V6:

3.7L (226 cu in) V6 Magnum. Power output typically around 215 hp and 235 lb-ft of torque.

Diesel:

5.9L (359 cu in) Cummins Turbo Diesel I6. Power output varied by year and tune, generally from 250-330 hp and 470-610 lb-ft of torque. Known for durability and towing power.

Tuning Potential:

HEMI and Cummins engines are well-regarded for aftermarket tuning and performance upgrades.

Petrol:

Multi-point Fuel Injection (MPI) for Magnum engines, Sequential Fuel Injection (SFI) and VVT for HEMI engines.

Diesel:

High-pressure common rail fuel injection system for the 5.9L Cummins.

🔧 Transmission

Manual:

NV3500 (5-speed manual) often found on V6 and smaller V8 models. NV4500 (5-speed heavy-duty manual) on some V8 and Cummins diesel models.

Automatic:

45RFE/545RFE (4-speed automatic) for V6 and 4.7L V8. 48RE (4-speed automatic) for 5.9L Magnum V8 and 5.9L Cummins diesel. Some later models may have received the 68RFE 6-speed automatic.

Transfer Case:

Part-time 4WD system with electronic shift-on-the-fly (NV244, NV271, NV273) or full-time 4WD options depending on model and year.

📐 Dimensions

Length:

Varies significantly by cab and bed configuration (e.g., ~228 inches to ~260 inches for crew cab long bed).

Width:

~79.1 inches (excluding mirrors).

Height:

Varies by configuration, typically ~75-78 inches.

Curb Weight:

Ranges from approximately 4,500 lbs to over 6,000 lbs depending on configuration and powertrain.

Payload Capacity:

Varies by Gross Vehicle Weight Rating (GVWR), typically from 1,500 lbs to over 4,000 lbs.

Towing Capacity:

Up to 8,000 lbs for 1500 series, and significantly higher (over 10,000 lbs, sometimes up to 12,000+ lbs for properly equipped 3500 HD) for 2500/3500 series.

🛡️ Safety Features

NHTSA Front Impact:

Generally rated well in frontal impact tests for its era, but specific star ratings can vary by year and test methodology. (Refer to NHTSA archives for exact figures).

IIHS Crash Test:

Received 'Good' ratings in some IIHS frontal offset tests, indicating good occupant protection. (Refer to IIHS archives for exact figures).

ABS:

Standard Anti-lock Braking System (ABS) on most models, with specific configurations for 2WD and 4WD.

Traction Control:

Available traction control system on some models, particularly those with electronic stability control (ESC) which was introduced later in the generation.

Airbags:

Driver and front passenger airbags. Side curtain airbags became available on some later models or higher trim levels.

Seatbelts:

Three-point seatbelts for all seating positions, pre-tensioners on front seatbelts.

Rollover Sensing:

Available supplemental side curtain airbags may incorporate rollover sensing technology.

💡 Technology Features

Radio Options:

Base AM/FM radios, AM/FM/CD players, and premium Infinity sound systems were available. Uconnect hands-free communication system was introduced later in the generation.

Navigation:

Optional factory navigation systems were available on higher trim levels.

Parking Sensors:

Rear parking assist sensors were an optional feature.

Trailer Brake Controller:

Integrated trailer brake controller was available on some models, particularly heavy-duty versions.

Auxiliary Input:

Auxiliary audio input jacks became more common later in the generation.

Bluetooth:

Bluetooth connectivity (Uconnect) was an optional feature, becoming more prevalent in later years (post-2005/2006).

🔧 Maintenance

Oil Change Petrol:

Typically every 3,000-7,500 miles or 6-12 months, depending on oil type (conventional vs. synthetic) and driving conditions (severe vs. normal). Refer to manual for precise intervals based on engine and oil spec.

Oil Change Diesel:

Cummins diesel typically requires oil changes every 5,000-7,500 miles or 6 months, utilizing specific heavy-duty diesel engine oil. Consult the manual for specific recommendations.

Filter Replacement:

Air filter: 15,000-30,000 miles. Fuel filter (petrol): 30,000-60,000 miles. Fuel filter (diesel): Typically 15,000-30,000 miles. Cabin air filter: 15,000-30,000 miles or annually.

Transmission Fluid:

Automatic transmission fluid and filter change: 30,000-60,000 miles. Manual transmission fluid: 60,000-100,000 miles. Transfer case fluid: 60,000-100,000 miles.

Engine Oil Petrol Hemi:

SAE 5W-20 (preferred for fuel economy and VVT). Some earlier models or specific conditions may recommend SAE 5W-30. API SN or later certification. Capacity: ~7.0 quarts.

Engine Oil Petrol Magnum:

SAE 5W-30 or 10W-30 depending on temperature. API SN or later certification. Capacity: ~4.75 quarts (4.7L), ~5.0 quarts (5.9L).

Engine Oil Diesel Cummins:

Heavy-duty diesel engine oil, API CJ-4 or CK-4 (or equivalent for the era), SAE 15W-40 is most common. Capacity: ~11.0 quarts.

Transmission Fluid Automatic:

Chrysler ATF+4 (MS-9602) is specified for 45RFE/545RFE and 48RE transmissions. Capacity: Varies by model, typically 4-6 quarts for a fluid change, 12-15 quarts for a full rebuild/flush.

Transmission Fluid Manual:

NV3500: SAE 75W-90 synthetic gear lubricant. NV4500: SAE 75W-90 synthetic gear lubricant, often with a specific additive for the earlier generations. Check manual for exact specs.

Transfer Case Fluid:

NV244 (full-time): ATF+4. NV271/NV273 (part-time): SAE 75W-90 or specific transfer case fluid. Capacity: ~2.0-2.5 quarts.

Coolant:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, Orange color (MS-9803). Typically a 50/50 mix with distilled water. Capacity: ~13-15 quarts depending on engine.

Brake Fluid:

DOT 3 or DOT 4. Always use fresh, sealed fluid. Capacity: ~1 quart (for a flush and fill).

Death Wobble:

A common issue on solid front axle Ram trucks (especially 2500/3500 4WD) involving worn steering and suspension components (e.g., track bar, ball joints, tie rod ends) causing shimmy or violent shaking at speed. This manual will detail inspection and replacement.

Hemi Oil Consumption:

Some early 5.7L HEMI engines experienced higher-than-normal oil consumption, potentially due to valve seal or piston ring issues. The manual covers diagnostic procedures.

Transmission Filter Clogging:

Some automatic transmissions (especially 48RE) can suffer from filter clogging due to wear, necessitating timely fluid and filter changes.

Cummins Injectors:

While robust, the 5.9L Cummins can experience injector issues or fuel system problems, which are covered in detail within the manual.

Rust:

Like many trucks of this era, rust can affect fenders, cab corners, rocker panels, and the frame, especially in regions with salt exposure. Manual may offer some guidance on body repair.

Oil Filter Hemi:

Mopar: MO-349 / Wix: 57318 / Fram: PH16 / K&N: HP-3001 (Note: Part numbers can vary; always verify with your specific vehicle's VIN).

Air Filter Hemi:

Mopar: 68164759AA / Wix: 49423 / Fram: CA9916 (Note: Part numbers can vary).

📚 Vehicle History

Dodge Trucks:

Dodge has a long history of producing robust and capable trucks, dating back to the early 20th century. The Ram nameplate was established in 1981.

Third Gen Introduction:

The third generation of the Dodge Ram Truck was introduced for the 2002 model year, representing a significant redesign over the previous generation (second gen, '94-'01).

Key Changes 2002:

New interior and exterior styling, introduction of the 5.7L HEMI V8, improved chassis and suspension, introduction of the Quad Cab and later the Mega Cab.

Updates:

The third generation received a facelift for the 2006 model year, featuring revised styling, an updated interior, and improved powertrain options, including the introduction of the 6.1L HEMI for the performance SRT-10 model (though not typically covered in standard manuals).

Manufacturing Locations:

Primary assembly plants included Warren Truck Assembly Plant in Michigan and St. Louis Assembly Plant in Missouri (until its closure in 2006).

🏆 Awards & Recognition

Jdp Power Initial Quality:

The Ram truck often received mixed to average ratings in J.D. Power Initial Quality Studies during this period, reflecting typical challenges for large, complex vehicles.

Truck Of The Year:

Various automotive publications and organizations have recognized different Ram configurations over the years, though specific 'Truck of the Year' awards for this exact generation might be less prominent than some competitors.

Cummins Engine Reputation:

The 5.9L Cummins Turbo Diesel engine itself is highly regarded for its durability and performance, often receiving accolades within the diesel enthusiast community.