Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECM/PCM).
Transmission:
Manual transmission (NV4500, NV5600) and automatic transmission (48RE, NV246 transfer case) overhaul, diagnostics, and service.
Drivetrain:
Front and rear axle assemblies, propeller shafts, U-joints, differentials, 4WD system operation and repair.
Braking System:
Front and rear brake systems (disc/drum), hydraulic system, ABS operation, service, and troubleshooting.
Suspension:
Front and rear suspension components (leaf springs, shocks, ball joints, steering linkage), alignment procedures, troubleshooting.
Steering:
Power steering system, steering gear, tie rods, steering column, troubleshooting.
Electrical System:
Battery, charging system, starting system, lighting, instrumentation, power accessories, body control modules (BCM), wiring diagrams.
HVAC System:
Heating, ventilation, and air conditioning system diagnosis and repair, component replacement.
Body And Frame:
Body panels, doors, interior trim, glass, frame repair, payload and towing information.
Diagnostics And Troubleshooting:
Fault code interpretation (OBD-II), diagnostic procedures for various systems, symptom-based troubleshooting guides.
Maintenance Procedures:
Routine maintenance tasks such as oil changes, filter replacements, fluid checks, tire rotations, and brake inspections.
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair for all major vehicle systems.
Overhaul Procedures:
Detailed guides for the complete disassembly, inspection, and reassembly of engines, transmissions, and differentials.
Diagnostic Procedures:
Systematic approaches to identifying and resolving mechanical and electrical issues, including wiring harness testing and sensor diagnostics.
Specifications And Tolerances:
Precise measurements, torque specifications, clearances, and other critical parameters for proper assembly and adjustment.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle circuits, facilitating troubleshooting and repair of electrical components.
Depth Level:
In-depth technical information suitable for professional mechanics and experienced DIY enthusiasts.
Diagnostic Capabilities:
Advanced diagnostic strategies, including interpretation of diagnostic trouble codes (DTCs) and use of scan tools.
Rebuild Instructions:
Detailed instructions for complete engine, transmission, and axle rebuilds, including component specifications and procedures.
Engine Options:
5.7L Magnum V8 (360 ci), 8.0L V10 Triton (488 ci), 5.9L Cummins Turbo Diesel I6.
5.7L Magnum V8:
Approx. 245-250 hp, 330-335 lb-ft torque (specific output varied slightly by year/trim).
8.0L V10 Triton:
Approx. 305-310 hp, 450-455 lb-ft torque.
5.9L Cummins Turbo Diesel:
Approx. 235-250 hp, 460-505 lb-ft torque (HP increased in 2003/2004 models).
Fuel System Type:
Multi-port fuel injection (MPI) for V8 and V10; Direct injection (common rail for 2003+ Cummins) for diesel.
488 V10:
TBA (Engine specific code often associated with trim/package)
5.9L Cummins:
ISB (Engine family), specific variant codes apply based on HP/torque.
Body Styles:
Regular Cab, Club Cab (Quad Cab), Mega Cab (introduced later in the generation, check specific year).
Bed Lengths:
Short Bed (approx. 6.3 ft), Long Bed (approx. 8 ft).
Curb Weight:
Varies significantly by configuration (e.g., approx. 5,500 - 7,500+ lbs).
Gross Vehicle Weight Rating Gvwr:
Exceeds 8,500 lbs, often in the 8,800 lbs to 9,500+ lbs range depending on configuration.
Oil Change Interval:
Typically 3,000-5,000 miles for gasoline engines, 5,000-7,500 miles for Cummins diesel (refer to manual for exact specifications).
Transmission Fluid Change:
Refer to manual for specific intervals, generally around 30,000-60,000 miles depending on usage (towing).
Engine Oil Gasoline:
SAE 5W-30 or 10W-30 (check manual for specific engine and temperature range, API classification SN or earlier).
Engine Oil Diesel Cummins:
CJ-4 or CK-4 rated diesel engine oil, viscosity typically 15W-40 or 5W-40 for cold weather (consult manual and oil manufacturer).
Transmission Fluid 48Re:
ATF+4 (Mopar Part Number: 68083383AA or equivalent).
Manual Transmission Fluid:
NV4500: GL-3 or GL-4 rated manual transmission fluid (e.g., Castrol Syntrans, Mopar Manual Transmission Lubricant).
Coolant:
Mopar Antifreeze/Coolant (HOAT) or equivalent HOAT coolant, typically a 50/50 mix with distilled water.
Cummins Injectors:
Early 5.9L Common Rail (2003+) injectors can be prone to failure due to water contamination or wear; the manual will guide on diagnostics and replacement.
Transmission Issues:
NV4500 5th gear nut issues (requiring updated retainer), 48RE 'clunk' or delayed engagement can occur. Manual provides troubleshooting.
Front Suspension/Steering:
Ball joints and steering linkage components can wear prematurely due to the heavy nature of the truck; regular inspection is recommended.
Electrical Gremlins:
Like many vehicles of this era, intermittent electrical issues can arise; the comprehensive wiring diagrams in the manual are crucial for diagnosis.
