Vehicle Segment:
Heavy-Duty Pickup Truck
Target Audience:
Commercial users, fleet operators, heavy towing/hauling enthusiasts, DIY mechanics
Key Competitors:
Ford F-250/F-350 Super Duty, Chevrolet Silverado 2500HD/3500HD, GMC Sierra 2500HD/3500HD
Vehicle Strengths:
Robust chassis, high towing and payload capacity, powerful engine options, proven durability
Manual Value Proposition:
Comprehensive diagnostic and repair information crucial for maintaining heavy-duty vehicles, saving on professional labor costs
Engine Systems:
Engine mechanical, lubrication, cooling, fuel delivery, ignition, emissions control, exhaust, engine diagnostics, turbocharger (if applicable)
Transmission Systems:
Manual transmission, automatic transmission, transfer case, driveline, clutch, torque converter
Chassis Systems:
Suspension (front and rear), steering system, braking system (ABS, disc/drum), wheels and tires, frame and body mounting
Electrical Systems:
Battery, starting system, charging system, lighting, ignition, instrumentation, power distribution, body control modules, infotainment, comfort and convenience systems, wiring diagrams
Body Systems:
Body panels, doors, windows, interior trim, seats, HVAC system, safety restraints (airbags, seatbelts), glass, exterior trim, paint and body repair basics
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections, belt and hose replacement
Repair Procedures:
Component removal and installation, engine overhauls, transmission rebuilding, brake caliper replacement, suspension component replacement, electrical component diagnosis and repair
Troubleshooting Procedures:
Diagnostic charts, symptom-based troubleshooting, error code interpretation, electrical circuit tracing
Technical Specifications:
Torque specifications, clearances, tolerances, diagnostic parameters, alignment specifications
Diagnostic Capabilities:
In-depth diagnostic procedures, component testing, electrical schematic analysis, OBD-II code interpretation
Rebuild Instructions:
Detailed step-by-step instructions for engine, transmission, and differential rebuilds
Special Tools:
Identification and usage instructions for specialized tools required for specific repairs
Engine Code And Type:
Cummins ISB 5.9L (24-valve) OHV Turbo-Diesel (RVM), V8 5.7L HEMI Magnum (EZB, EZH - Gasoline)
Diesel Horsepower:
Approx. 305-325 hp @ 2900 rpm (depending on tune)
Diesel Torque:
Approx. 555-610 lb-ft @ 1600 rpm (depending on tune)
Gasoline Horsepower:
Approx. 345-360 hp @ 5600 rpm
Gasoline Torque:
Approx. 375-400 lb-ft @ 3600 rpm
Diesel Fuel System:
High-pressure common rail (HPCR) direct injection, Bosch fuel system
Gasoline Fuel System:
Sequential Multi-Point Fuel Injection (MPI)
Diesel Oil Type:
API CJ-4 or CK-4, SAE 15W-40 (check manual for specific approvals)
Gasoline Oil Type:
API SN, SAE 5W-20 or 10W-30 (check manual for specific approvals)
Transmission Type Diesel:
NV5600 6-Speed Manual, G56 6-Speed Manual (later models)
Transmission Type Gasoline:
NV3500 5-Speed Manual (less common on 3500), 48RE 4-Speed Automatic
Transmission Type Diesel Auto:
48RE 4-Speed Automatic
Transmission Type Gasoline Auto:
48RE 4-Speed Automatic (primary auto)
Transfer Case:
New Process NV271 (manual shift) or NV273 (electronic shift) Command-Trac 2-speed transfer case
Auto Trans Fluid Type:
Chrysler ATF+4 (MS-9602)
Manual Trans Fluid Type:
MS-9224 SAE 75W-90 Synthetic Gear Oil
Wheelbase Options:
140.5 inches (Regular Cab), 154.5 inches (Club Cab/Mega Cab), 168.5 inches (Long Bed)
Bed Length Options:
6.3 feet (short bed), 8.0 feet (long bed)
Gvwr Range:
10,500 lbs - 11,500 lbs (depending on configuration)
Curb Weight Range:
Approx. 6,500 - 7,500 lbs
Max Towing Capacity:
Up to 13,000+ lbs (with appropriate configuration and hitch)
Payload Capacity:
Up to 4,500+ lbs
NHTSA Front Impact Rating:
Not rated or varies by year/configuration (heavy-duty trucks often have different testing protocols)
IIHS Crashworthiness Rating:
Generally good for its class, but detailed specific ratings for 2005 3500 may vary
Braking System:
Front disc, rear disc (or disc/drum depending on specific configuration), Anti-lock Braking System (ABS)
Traction Control:
Available (e.g., Electronic Stability Control on some later models, but less common on early 3rd gen HD)
Airbags:
Front airbags, available side curtain airbags
Seatbelts:
Three-point seat belts with pretensioners
Oil And Filter Diesel:
Every 7,500 miles or 6 months (severe service may require more frequent changes)
Oil And Filter Gasoline:
Every 5,000 miles or 6 months
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on conditions
Fuel Filter Replacement Diesel:
Every 15,000 miles
Transmission Fluid Change Auto:
Every 30,000-60,000 miles (depending on towing/load usage)
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) Extended Life Antifreeze/Coolant (or equivalent)
Diesel Common Problems:
Injectors, fuel pump issues (injection pump), EGR valve issues, turbocharger problems, water in fuel issues (due to fuel quality/filter maintenance)
Gasoline Common Problems:
Oil leaks, exhaust manifold cracks (HEMI), lifter noise, catalytic converter issues
Transmission Common Problems:
Automatic transmission solenoid issues (48RE), clutch wear (manual), transfer case actuator issues (electronic shift)
Suspension And Steering:
Ball joint wear, tie rod end wear, steering stabilizer issues, U-joint wear
Dodge Truck Legacy:
Dodge has a long history of producing durable and capable trucks, particularly for commercial and work applications.
Third Gen Ram Introduction:
The third generation (2002-2009) introduced a significant redesign with a larger, more aggressive styling and improved chassis.
Heavy Duty Enhancements:
The 3500 model specifically received upgrades to the frame, suspension, and powertrains to handle increased towing and payload demands compared to the 1500/2500 series.
Manufacturing Plant:
Saltillo Truck Assembly Plant, Saltillo, Mexico; Warren Truck Assembly Plant, Warren, Michigan
