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Dodge Durango 2003 Factory Service Repair Manual.zip

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🏷️ Basic Information Identification Make: Dodge Model: Durango Year: 2003 Codes Vehicle Generation: Second Generation (2004-2009) - Although the manual is for the 2003 model, it's important to note this...
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Dodge Durango 2003 Factory Service Repair Manual.zipDodge Durango 2003 Factory Service Repair Manual.zipDodge Durango 2003 Factory Service Repair Manual.zipDodge Durango 2003 Factory Service Repair Manual.zip
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Durango
Year:
2003
Codes
Vehicle Generation:
Second Generation (2004-2009) - Although the manual is for the 2003 model, it's important to note this model represents the end of the first generation, with the second generation launching for the 2004 model year. This manual covers the final iteration of the first generation platform.
👋 Introduction
Market Position
Vehicle Segment:
Full-size SUV
Target Audience:
Families, individuals needing towing capacity and cargo space, those seeking a robust SUV.
Competitive Analysis
Key Competitors:
Ford Explorer, Chevrolet TrailBlazer, Toyota 4Runner, Jeep Grand Cherokee.
Key Features
Durability:
Known for its body-on-frame construction, providing robust towing and off-road capabilities, though less refined ride than unibody competitors.
Engine Options:
Offered with powerful V8 engines, enhancing its towing and performance credentials.
Interior Versatility:
Available with a third-row seating option, increasing passenger capacity, though the third row is typically tight for adults.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Manual / Repair Manual
Language:
English
Format:
Digital (ZIP archive, likely containing PDF files)
Page Count:
Estimated 1500-2000+ pages (typical for a comprehensive factory service manual of this era)
Format
File Format:
Digital Archive (ZIP), likely containing PDF documents
Print Quality:
High resolution, suitable for printing individual sections or the entire manual.
Binding Type:
Not applicable (digital format)
Paper Type:
Not applicable (digital format)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, engine control systems (PCM), transmission (automatic).
Chassis:
Suspension (front and rear), steering, brakes (hydraulic and ABS), driveline (4WD system, axles, driveshafts, differentials).
Body And Electrical:
Body structure, exterior components, interior trim, HVAC system, power accessories (windows, locks, seats), lighting, instrumentation, audio system, body control module (BCM), wiring diagrams, diagnostic connectors.
Procedures Included
General Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, lubrication points, belt inspections and tensioning, spark plug replacement.
Engine Repair:
Cylinder head removal/installation, piston and connecting rod service, crankshaft and bearing service, timing chain/belt replacement, valve train service, oil pump and pan service.
Transmission Service:
Fluid and filter changes, transmission removal/installation, internal component diagnosis and repair (for automatic transmissions).
Brake System Service:
Brake pad and rotor replacement, brake caliper service, brake line and hose inspection/replacement, bleeding procedures, ABS component diagnosis and replacement.
Suspension And Steering:
Component replacement (shocks, struts, ball joints, tie rod ends, control arms), wheel alignment procedures, steering gear service, power steering system diagnosis and repair.
Electrical And Diagnostics:
Wiring diagram interpretation, fuse and relay identification, component testing (sensors, actuators, motors), diagnostic trouble code (DTC) interpretation and troubleshooting, module programming (where applicable).
Technical Depth
Diagnostic Procedures:
Detailed diagnostic flowcharts for common symptoms, troubleshooting steps for electrical and mechanical issues, use of scan tools and specialized equipment.
Component Rebuilding:
Instructions for the disassembly, inspection, repair, and reassembly of major components like engines and transmissions.
Torque Specifications:
Precise torque values for all critical fasteners throughout the vehicle.
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
4.7L Magnum V8 (265 ci) - P-code
Bore X Stroke:
3.66 in x 3.57 in (93.0 mm x 90.7 mm)
Compression Ratio:
9.0:1
Horsepower:
230-235 hp @ 4500-4900 rpm (depending on specific tuning for 2003)
Torque:
295-300 lb-ft @ 3200-3400 rpm (depending on specific tuning for 2003)
Valvetrain:
SOHC (Single Overhead Cam), 16 valves (2 valves per cylinder)
Secondary Engine
Engine Code And Type:
4.7L High Output Magnum V8 (265 ci) - Y-code (optional)
Horsepower:
260-265 hp @ 5000-5200 rpm
Torque:
320-330 lb-ft @ 3600-3800 rpm
Valvetrain:
SOHC (Single Overhead Cam), 16 valves (2 valves per cylinder)
Tertiary Engine
Engine Code And Type:
4.7L Magnum V8 (265 ci) - G-code (for specific configurations, e.g., some Canadian models)
Horsepower:
220-230 hp
Torque:
290-300 lb-ft
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (SEFI)
Fuel Type:
87 octane regular unleaded gasoline (minimum)
Fuel Tank Capacity:
25 U.S. gallons (94.6 L)
🔧 Transmission
Standard
Transmission Type:
45RFE (4-Speed Automatic)
Gear Ratios:
1st: 3.12, 2nd: 1.66, 3rd: 1.00, 4th: 0.72, Reverse: 2.20
Transmission Fluid Type:
ATF+4 (Automatic Transmission Fluid Type 9602)
Optional
Transmission Type:
NV3500 (5-Speed Manual) - Available on some V6 models (not typically on V8s for 2003)
Features
Transfer Case:
Part-time 4WD system (NV244 transfer case) or 2WD available. Some models may have a full-time 4WD option.
📐 Dimensions
Exterior
Length:
193.7 inches (4919 mm)
Width:
71.9 inches (1826 mm) (excluding mirrors)
Height:
70.3 inches (1786 mm)
Wheelbase:
116.1 inches (2950 mm)
Front Track:
61.0 inches (1549 mm)
Rear Track:
61.0 inches (1549 mm)
Ground Clearance:
Approximately 8.3 inches (211 mm) (Varies slightly by configuration)
Interior
Seating Capacity:
5 or 7 passengers (with optional third row)
Front Headroom:
39.5 inches (1003 mm)
Front Legroom:
40.3 inches (1024 mm)
Second Row Headroom:
39.8 inches (1011 mm)
Second Row Legroom:
36.4 inches (925 mm)
Third Row Headroom:
36.9 inches (937 mm) (estimated)
Third Row Legroom:
30.0 inches (762 mm) (estimated)
Cargo
Cargo Volume Behind 1St Row:
88.8 cu ft (2515 L)
Cargo Volume Behind 2Nd Row:
42.7 cu ft (1209 L)
Cargo Volume Behind 3Rd Row:
16.9 cu ft (478 L) (estimated for 7-passenger models)
Weights
Curb Weight:
4,457 lbs - 4,900 lbs (2021 kg - 2223 kg) (depending on engine and drivetrain)
Gross Vehicle Weight Rating Gvwr:
Approximately 6,300 lbs - 6,500 lbs (2858 kg - 2948 kg)
Towing Capacity:
Up to 8,950 lbs (4059 kg) (with proper equipment and V8 engine)
🛡️ Safety Features
Ratings
NHTSA Front Driver Impact:
4 stars (for 2003 model year)
NHTSA Front Passenger Impact:
4 stars (for 2003 model year)
NHTSA Side Driver Impact:
4 stars (for 2003 model year)
NHTSA Side Rear Passenger Impact:
4 stars (for 2003 model year)
IIHS Frontal Offset:
Good (for the first generation Durango, including 2003)
Active Features
ABS:
Standard 4-wheel Anti-lock Braking System (ABS)
Traction Control:
Available (often tied to 4WD system or specific trim levels)
Passive Features
Airbags Front:
Standard front driver and passenger airbags
Airbags Side:
Optional side curtain airbags (covering front and second-row occupants in many configurations)
Seatbelts:
3-point seatbelts for all occupants, pretensioners for front seats.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system in second-row seating positions.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional Infinity premium sound system with subwoofer, cassette player still common.
Navigation:
Rarely offered as factory navigation on this generation; aftermarket solutions were more common.
Driver Assistance
Parking Sensors:
Optional rear parking assist sensors.
Connectivity
Power Outlets:
Standard 12V power outlets for accessories.
Remote Keyless Entry:
Standard or optional, depending on trim level.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions and oil type used (refer to owner's manual for specifics).
Engine Oil Filter Replacement:
With every oil change.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Approximately every 100,000 miles (160,000 km) for platinum or iridium tipped plugs (OEM recommendations may vary).
Transmission Fluid Change:
Every 30,000-60,000 miles (48,000-96,000 km), especially for towing or severe use.
Coolant Flush And Replacement:
Every 30,000-60,000 miles (48,000-96,000 km) or 2-4 years.
Fluid Specifications
Engine Oil:
SAE 5W-30 or 10W-30 (depending on temperature range and engine variant, consult manual for exact spec). API Certified.
Engine Coolant:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant (50/50 mix with distilled water). Mopar part number 05010885AA or equivalent HOAT coolant.
Power Steering Fluid:
Mopar Power Steering Fluid or equivalent Pentosin CHF 11S (check specific system requirements).
Brake Fluid:
DOT 3 or DOT 4 (check reservoir cap or manual for exact specification).
Known Issues
Radiator Leaks:
Common for the plastic end tanks of the radiator to crack and leak, especially with age.
Water Pump Failure:
Water pump bearing failure or seal leaks can occur, leading to coolant loss.
Ignition Coil Failure:
Individual ignition coils can fail, leading to misfires and rough running, particularly in V8 engines.
Ball Joint Wear:
Upper and lower ball joints can wear prematurely, leading to steering looseness and potential safety issues.
Heater Core Leaks:
Heater core leaks can cause coolant to enter the cabin, creating a sweet smell and fogged windows.
Transmission Hard Shifting:
The 45RFE transmission can sometimes develop hard shifting or delayed engagement issues, often related to solenoid issues or fluid condition.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge has a long history of producing trucks and SUVs known for their ruggedness and performance, building on brands like Ram and Ramcharger.
Model Evolution
First Generation Introduction:
The Dodge Durango was introduced for the 1998 model year as a mid-size SUV, based on the Dodge Ram pickup truck platform. It was designed to offer more space and utility than smaller SUVs.
First Generation Updates:
The 2003 model year represents the final iteration of the first-generation Durango, receiving minor updates but largely retaining its established platform and features.
Transition To Second Gen:
The Durango underwent a significant redesign for the 2004 model year, moving to a unibody platform shared with the Dodge Ram 1500, offering improved ride comfort but sacrificing some of the rugged, truck-like feel of the first generation.
Production
Manufacturing Location:
Newark, Delaware, USA
🏆 Awards & Recognition
Recognitions
Tow Vehicle Awards:
Often recognized for its towing capabilities in its class during its production run, making it a popular choice for those with trailers or boats.
Segment Performance:
Well-regarded for its spacious interior and V8 power, contributing to its sales success in the competitive SUV market.
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