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Dodge Ram 1500 2500 3500 2009-2012 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 1500, 2500, 3500 Model Years Covered: 2009, 2010, 2011, 2012 Codes Platform Code: DS/DJ (for 1500), HB/HC (for 2500/3500) Generation Generation Designation:...
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Dodge Ram 1500 2500 3500 2009-2012 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram 1500, 2500, 3500
Model Years Covered:
2009, 2010, 2011, 2012
Codes
Platform Code:
DS/DJ (for 1500), HB/HC (for 2500/3500)
Generation
Generation Designation:
Fourth Generation Ram Truck (2009-2018)
👋 Introduction
Market Position
Vehicle Segment:
Full-size pickup truck.
Competitive Analysis
Key Competitors:
Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra, Nissan Titan.
Key Features
Vehicle Strengths:
Robust build, powerful engine options, towing and hauling capability, customizable trims, comfortable ride for a truck.
Manual Value Proposition:
Enables owners and technicians to perform a wide range of maintenance and repair tasks, saving on labor costs and ensuring proper vehicle upkeep.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service, repair, maintenance, and diagnostics for Dodge Ram 1500, 2500, and 3500 trucks.
Page Count
Total Pages:
17,570
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (Printable, Copyable to Hard Drive)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, inspection, component replacement, timing, cooling system, lubrication system.
Fuel System:
Fuel injection, fuel pump, fuel filter, fuel lines, evaporative emissions control (EVAP).
Emission Control:
Catalytic converter, oxygen sensors, EGR system, PCV system.
Exhaust System:
Exhaust manifolds, pipes, mufflers, catalytic converters, mounting hardware.
Transmission Manual:
Manual transmission disassembly, repair, clutch system, gear shifting mechanisms.
Transmission Automatic:
Automatic transmission repair, valve body, torque converter, transmission control module (TCM).
Transfer Case:
Transfer case operation, disassembly, repair, 4WD system components.
Drivetrain:
Driveshafts, U-joints, axle shafts, differentials, hub assemblies.
Suspension Front:
Independent front suspension, control arms, ball joints, coil springs, shocks, steering knuckles.
Suspension Rear:
Multi-link solid rear axle, leaf springs, shocks, control arms.
Steering:
Power steering system, steering gear, steering column, tie rods, alignment procedures.
Brakes Front:
Front brake rotor, caliper, pad replacement, brake bleeding, ABS components.
Brakes Rear:
Rear brake rotor, caliper, pad replacement (or drum brake for some models/trims), ABS components.
Brake Control System:
ABS (Anti-lock Braking System), ESC (Electronic Stability Control), Brake assist, Trailer Brake Controller integration.
Wheels And Tires:
Tire pressure monitoring system (TPMS), wheel alignment, tire rotation, wheel bearing replacement.
Body And Frame:
Body panel repair, corrosion protection, frame straightening, door, hood, tailgate service.
Interior:
Seat removal, dashboard disassembly, HVAC controls, interior trim, airbags.
Exterior:
Exterior trim, mirrors, bumpers, lighting systems, sunroof.
HVAC:
Heating, Ventilation, and Air Conditioning system, compressor, refrigerant, evaporator, heater core.
Electrical System General:
Battery, charging system, starter, lighting circuits, fuses, relays.
Instrument Panel:
Instrument cluster, gauges, warning lights, driver information center.
Infotainment Audio:
Radio, speakers, Uconnect system, navigation, auxiliary inputs.
Safety Restraints:
Airbag system operation, SRS module, seat belts, airbag deployment procedures.
Cruise Control:
Cruise control module, switches, operation.
Diagnostics And Troubleshooting:
OBD-II (On-Board Diagnostics II) system, diagnostic trouble codes (DTCs), diagnostic procedures, scan tool usage.
Procedures Included
Preventive Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, inspections.
Basic Repairs:
Component replacement (e.g., spark plugs, belts, hoses, brake pads).
Advanced Repairs:
Engine rebuild, transmission overhaul, suspension component overhaul, complex electrical system repairs.
Troubleshooting Guides:
System-specific diagnostic trees and fault isolation procedures.
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems.
Torque Specifications:
Precise torque values for all fasteners and critical components.
Specifications And Tolerances:
Engine, transmission, brake, suspension, and steering system specifications and acceptable wear tolerances.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Technical Depth
Depth Of Coverage:
Extremely comprehensive, covering everything from routine maintenance to complete vehicle overhauls and advanced diagnostics.
Diagnostic Capabilities:
Detailed diagnostic information for all electronic control modules (ECMs), sensors, and actuators.
📊 Manual Specifications
File Format
Digital Format:
Likely PDF, optimized for viewing, searching, and printing.
Print Quality
Illustrations And Diagrams:
Loaded with illustrations, instructions, photos, and diagrams for clear understanding.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format - printable on various paper types)
⚙️ Engine Specifications
Primary Engine
Engine Options:
3.7L V6, 4.7L V8, 5.7L HEMI V8, 6.7L Cummins Turbo Diesel (2500/3500)
Performance
Horsepower Range:
Approx. 215 hp (3.7L) to 390 hp (5.7L HEMI) and 350 hp (6.7L Cummins)
Torque Range:
Approx. 235 lb-ft (3.7L) to 410 lb-ft (5.7L HEMI) and 650 lb-ft (6.7L Cummins)
Fuel System
Injection Type:
Multi-point fuel injection (MPI) for gasoline engines; High-pressure common rail (HPCR) for diesel.
🔧 Transmission
Standard
Transmission Options Standard:
4-speed automatic (early models/lower trims), 5-speed automatic, 6-speed automatic (later models/higher trims), 6-speed manual (available on select models).
Optional
Transmission Options Optional:
Refer to specific engine and trim level for transmission availability. Heavy-duty trucks primarily featured automatic or manual transmissions suited for towing.
Features
Transmission Features:
Tow/Haul mode, manual shift capability on some automatic transmissions.
📐 Dimensions
Exterior
Body Styles:
Regular Cab, Extended Cab (Quad Cab), Crew Cab.
Bed Lengths:
5'7" (Short Bed), 6'4" (Standard Bed), 8' (Long Bed).
Weights
Gross Vehicle Weight Rating Gvwr:
Varies significantly by model (e.g., 1500: 6,500-7,400 lbs; 2500: 8,500-9,900 lbs; 3500: 9,900-14,000+ lbs)
Curb Weight:
Varies by configuration, typically ranging from 4,800 lbs to over 7,000 lbs.
🛡️ Safety Features
Ratings
NHTSA Crash Test Ratings:
Ratings vary by specific model year and configuration, but generally good for the era. Refer to NHTSA database for specifics.
Active Features
Active Safety Features:
ABS, Traction Control, Electronic Stability Control (ESC), Trailer Sway Control.
Passive Features
Passive Safety Features:
Front airbags, side curtain airbags (available/standard on some trims), advanced seat belt systems.
💡 Technology Features
Infotainment
Infotainment System:
Uconnect infotainment system offering touchscreens, navigation, Bluetooth, voice control, satellite radio, and media inputs.
Driver Assistance
Driver Assistance Features:
ParkView rear backup camera, ParkSense front/rear park assist (optional).
Connectivity
Connectivity Options:
Bluetooth connectivity for hands-free calling and audio streaming, USB ports, auxiliary input jack.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-7,500 miles or 6 months, depending on driving conditions and oil type (consult manual for specific engine).
Transmission Fluid Change:
Around 30,000-60,000 miles for automatic transmissions (heavy-duty use may require more frequent changes). Manual transmission fluid varies.
Coolant Flush:
Typically every 30,000-100,000 miles or 5 years, depending on coolant type (e.g., HOAT).
Fluid Specifications
Engine Oil Recommendation:
SAE 5W-20 or 5W-30 for gasoline engines; SAE 15W-40 for 6.7L Cummins diesel. Consult manual for exact specifications and API classifications (e.g., API SP, CK-4).
Transmission Fluid Recommendation:
ATF+4 for most automatic transmissions; Manual transmission fluid specific to the transmission type (e.g., gear oil).
Coolant Recommendation:
Mopar Antifreeze/Coolant (HOAT - Hybrid Organic Additive Technology) or equivalent. Typically a 50/50 mix with distilled water.
Known Issues
Common Wear Items:
Ball joints, tie rod ends, exhaust components, front end bushings, brake wear items, catalytic converters (on some gasoline models).
Powertrain Common Concerns:
Lifter issues in some HEMI engines, occasional transmission issues (particularly with heavy towing if maintenance is neglected), EGR cooler failures on diesel models.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long-standing reputation for producing durable and capable trucks, evolving from the Power Wagon to the modern Ram trucks.
Model Evolution
Fourth Gen Ram Introduction:
The fourth generation, launched for 2009, introduced a significant redesign with a more imposing grille, updated interior, and new powertrains, including the introduction of the 6.7L Cummins for heavy-duty models and the HEMI V8 as a potent option.
Production
Manufacturing Locations:
Primarily manufactured in North America (e.g., Warren Truck Assembly Plant, Michigan).
🏆 Awards & Recognition
Recognitions
Truck Of The Year Awards:
While specific awards for the 2009-2012 model years vary, the Ram truck line has consistently received accolades from automotive publications for its capability, design, and powertrain options.
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