🏷️ Basic Information

Make:

Dodge

Model:

Ram 2500 Series

Year:

2005

Vehicle Type:

Heavy Duty Pickup Truck

👋 Introduction

Segment:

Heavy Duty Pickup Truck, designed for towing, hauling, and demanding commercial or personal use.

Competitors:

Ford F-250 Super Duty, Chevrolet Silverado 2500HD, GMC Sierra 2500HD.

Drivetrain Options:

Available in 4x2 and 4x4 configurations.

Body Styles:

Regular Cab, Extended Cab (Club Cab), Crew Cab.

Bed Lengths:

8-foot bed standard for most configurations, shorter beds available on some variants.

Towing Hauling Capacity:

Designed for substantial towing and payload capacities, exceeding that of light-duty trucks.

📋 Manual Details

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital (likely PDF, implied by typical workshop manual distribution)

📖 Manual Coverage

Engine Mechanical:

Detailed disassembly, assembly, diagnosis, and repair of all engine components, including cylinder head, block, pistons, crankshaft, camshaft, valvetrain, lubrication, cooling, and exhaust systems.

Engine Management:

Engine control module (ECM) operation, fuel injection systems (MPI, common rail diesel), ignition systems, emissions control, sensor diagnostics, and actuator testing.

Transmission Manual:

Repair and overhaul procedures for NV5600 (6-speed manual) and G56 (6-speed manual) transmissions, including clutch system.

Transmission Automatic:

Diagnosis, service, and repair of the 48RE (4-speed automatic) transmission, including torque converter, valve body, and electronic controls.

Drivetrain:

Front and rear axle servicing, differential repair, transfer case (NV271, NV273) operation and repair, driveshaft maintenance, and U-joint replacement.

Suspension:

Front and rear suspension component identification, diagnosis, replacement of springs (leaf and coil), shocks, struts, control arms, ball joints, and sway bars.

Steering:

Power steering system diagnosis and repair, steering gear replacement, tie rod ends, and steering column components.

Brakes:

Front and rear brake system servicing (disc/drum), ABS diagnosis and repair, brake fluid flushing, caliper and rotor replacement, parking brake system.

Electrical System:

Comprehensive wiring diagrams, fuse and relay locations, battery, charging system (alternator), starting system (starter motor), lighting systems, and accessory circuits.

Body Exterior:

Door panel removal, body panel alignment, tailgate repair, glass replacement, exterior trim, bumper repair and replacement.

Body Interior:

Dashboard removal, seat removal and repair, HVAC system components, interior trim, sound deadening, and carpet replacement.

HVAC:

Air conditioning system service, refrigerant charging, blower motor, evaporator, condenser, and heater core replacement.

Diagnostics Troubleshooting:

Systematic diagnostic procedures, common fault identification, use of diagnostic scan tools (OBD-II), and symptom-based troubleshooting charts.

Preventative Maintenance:

Detailed service intervals, oil change procedures, fluid level checks and top-offs, filter replacements, and general inspection routines.

Repair Procedures:

Step-by-step repair instructions for virtually all mechanical and electrical components, including torque specifications for critical fasteners.

Rebuild Procedures:

Comprehensive instructions for complete engine and transmission overhauls, including clearances, tolerances, and assembly sequences.

Diagnostic Procedures:

Systematic troubleshooting guides, fault code interpretations, and procedures for testing sensors, actuators, and electronic control units.

Depth Level:

Comprehensive, covering everything from basic maintenance to advanced engine and transmission rebuilds, electrical system diagnostics, and chassis component repair.

📊 Manual Specifications

File Type:

Likely PDF. Searchable text and high-resolution diagrams are standard for quality digital manuals.

Diagram Resolution:

High-resolution, enabling clear viewing of intricate mechanical and electrical diagrams.

Binding Type:

Not applicable for digital format. If a physical copy, likely spiral-bound or perfect-bound for lay-flat usability.

Paper Quality:

Not applicable for digital format. Physical copies typically use durable paper to withstand workshop conditions.

⚙️ Engine Specifications

Gas Engine Options:

8.0L V10 Triton (420 lb-ft torque, 305 hp) - Less common in 2005, often phased out for the Hemi.

Diesel Engine Options:

5.9L Cummins ISB I6 Turbo Diesel (555 lb-ft torque, 305 hp for standard output, higher torque versions available) - Highly regarded for durability and performance.

Horsepower Range:

Approximately 305-310 hp depending on engine and configuration.

Torque Range:

Approximately 420 lb-ft (V10) to 555+ lb-ft (Cummins).

Gas Fuel System:

Multi-point fuel injection (MPI) for the V10.

Diesel Fuel System:

Common Rail Fuel Injection (CRFI) for the Cummins, known for efficiency and power delivery.

Coolant Type:

Chrysler's HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar OAT 50/50 mix (or equivalent).

Engine Oil Capacity Gas:

Approx. 7 quarts (6.6 liters) for the V10.

Engine Oil Capacity Diesel:

Approx. 11 quarts (10.4 liters) for the 5.9L Cummins.

Engine Oil Spec Gas:

SAE 10W-30 or 10W-40, API SN or higher (refer to manual for exact specification).

Engine Oil Spec Diesel:

API CJ-4 or CI-4 PLUS (or previous C-category designations suitable for heavy-duty diesel engines), typically SAE 15W-40.

🔧 Transmission

Manual Transmission:

NV5600 6-speed manual transmission.

Automatic Transmission:

48RE 4-speed automatic transmission.

Transmission Fluid Spec Auto:

ATF+4 (Chrysler spec). Capacity approx. 12-13 quarts with converter.

Transmission Fluid Spec Manual:

Refer to manual for specific NV5600 fluid type (typically GL-3 or GL-4 rated gear oil).

📐 Dimensions

Wheelbase:

Varies by cab and bed configuration (e.g., 140.5 inches for Regular Cab, 160.5 inches for Crew Cab Long Bed).

Overall Length:

Varies by cab and bed configuration (e.g., 231 inches for Regular Cab, 259 inches for Crew Cab Long Bed).

Curb Weight:

Typically ranges from 6,000 to 7,500 lbs depending on configuration and engine.

Gross Vehicle Weight Rating Gvw:

Typically 8,800 lbs to 9,500 lbs for the 2500 series.

Max Towing Capacity:

Can exceed 10,000 lbs to over 12,000 lbs depending on configuration and factory options.

Standard Tire Size:

Commonly 235/80R17 or 265/70R17.

Wheel Bolt Pattern:

8x165.1 mm (8x6.5 inches).

🛡️ Safety Features

NHTSA Frontal Crash Rating:

Varies by model year and specific tests, typically good for its class.

IIHS Crash Test Ratings:

Varies by model year and specific tests, refer to IIHS for detailed ratings.

ABS:

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

Trailer Brake Controller Provision:

Often equipped with or provision for an integrated trailer brake controller.

Airbags:

Driver and front passenger airbags. Side curtain airbags may be optional on Crew Cab models.

Seatbelts:

Three-point height-adjustable seat belts with pretensioners for front occupants.

💡 Technology Features

Audio System:

Factory AM/FM stereo with CD player, optional premium audio systems, and SiriusXM satellite radio.

Cruise Control:

Standard cruise control.

Towing Features:

Integrated trailer brake controller wiring, trailer tow mirrors (optional/available).

Power Outlets:

12V auxiliary power outlets.

🔧 Maintenance

Oil Change Interval Gas:

Typically every 3,000-7,500 miles depending on driving conditions and oil type (consult manual).

Oil Change Interval Diesel:

Typically every 7,500-15,000 miles or 12 months, especially with synthetic oils and in severe service (consult manual and specific oil manufacturer recommendations).

Fuel Filter Replacement Diesel:

Recommended every 15,000-30,000 miles, or more frequently in dusty conditions. Critical for Cummins longevity.

Transmission Service Interval Auto:

Fluid and filter change typically every 30,000-60,000 miles depending on towing and driving conditions.

Power Steering Fluid:

ATF+4 or Chrysler power steering fluid.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Cummins Injectors:

Early common rail injectors (03-04.5) had some issues, but 2005 generally uses improved versions. Water contamination is a major concern.

48Re Transmission:

Can be prone to overheating and wear with heavy towing without proper upgrades or maintenance. Torque converter issues can occur.

Suspension Components:

Ball joints and tie rod ends can wear prematurely due to the weight and work of these trucks.

Heater Control Valve:

Known to fail, leading to improper HVAC temperature control.

📚 Vehicle History

Dodge Trucks:

Dodge has a long history of producing robust and capable trucks, with the Ram line evolving into a distinct brand later on.

Third Generation Ram:

The 2005 model falls within the third generation of Dodge Ram trucks (2002-2008), characterized by a significantly redesigned exterior and interior, improved powertrains, and increased capability.

Manufacturing Location:

Assembly predominantly in North America, often in plants like Warren Truck Assembly Plant in Michigan.

🏆 Awards & Recognition

Powertrain Recognition:

The 5.9L Cummins engine is consistently recognized for its durability, longevity, and performance by automotive publications and owners.

Truck Of The Year Contenders:

While specific awards vary, the Ram 2500 Series was a strong contender in the heavy-duty pickup truck segment during its production years.