Segment:
Compact/Mid-size Pickup Truck
Target Audience:
DIY mechanics, independent repair shops, fleet maintenance.
Competitors 2003:
Ford Ranger, Chevrolet S-10, Toyota Tacoma, Nissan Frontier.
Vehicle Strengths:
Available V8 engine option, stronger chassis than some competitors, comfortable ride for a truck.
Manual Value Proposition:
Provides dealer-level expertise for owners and technicians, saving on repair costs and ensuring accurate maintenance.
Primary Coverage:
Complete workshop procedures for all systems.
Diagnostic Coverage:
Detailed electrical diagnostics and troubleshooting.
Maintenance Coverage:
Routine maintenance, fluid changes, filter replacements, tune-ups.
Repair Coverage:
Engine, transmission, drivetrain, suspension, brakes, steering, body, HVAC, emissions.
Estimated Page Count:
Likely over 2000 pages (typical for comprehensive factory service manuals).
Type:
Factory Service Repair Manual
Origin:
Official dealer workshop documentation.
Format:
Digital (likely PDF, indicated by .zip)
Engine:
All aspects: diagnostics, repair, overhaul, specifications for 3.7L Magnum V6 and 4.7L Magnum V8 engines.
Transmission:
Automatic and Manual transmissions: repair, diagnostics, fluid specifications, overhaul procedures for NV3500, 42RE, 45RFE/545RFE.
Drivetrain:
Front and Rear Axles, Transfer Case (4WD models), Driveshafts, CV Joints, Differentials: maintenance, repair, lubrication.
Suspension:
Front Independent Suspension (Torsion Bar), Rear Leaf Spring Suspension: alignment, component replacement, troubleshooting.
Brakes:
Front Disc Brakes, Rear Drum/Disc Brakes (depending on configuration): service, bleeding, component replacement, ABS diagnostics.
Steering:
Power Steering System, Steering Gear, Tie Rods, Steering Column: maintenance, repair, fluid specifications.
Electrical:
Complete wiring diagrams, component location, diagnostic procedures for all electrical systems including engine control, lighting, accessories, comfort systems.
Body:
Body panel removal/installation, interior trim, glass replacement, door mechanisms, structural repair guidance.
HVAC:
Air Conditioning and Heating System: service, refrigerant handling, component replacement, diagnostics.
Emissions:
Emissions Control Systems: diagnostics, repair, catalytic converter, O2 sensors, EVAP system.
Engine Repair:
Complete engine rebuilds, head gasket replacement, timing chain service, piston and ring replacement.
Transmission Overhaul:
Detailed step-by-step instructions for complete transmission disassembly, inspection, repair, and reassembly.
Brake System Service:
Pad and rotor replacement, caliper service, brake line repair, ABS modulator replacement.
Electrical Troubleshooting:
Systematic approach to diagnosing electrical faults using wiring diagrams and diagnostic trouble codes (DTCs).
Fuel System Service:
Fuel pump replacement, fuel injector cleaning and replacement, fuel pressure testing.
Cooling System Service:
Radiator replacement, water pump service, thermostat replacement, coolant flush and fill.
Wheel Alignment:
Specifications and procedures for front and rear wheel alignment.
Diagnostic Codes:
List and explanation of all Diagnostic Trouble Codes (DTCs) and their associated repair procedures.
Depth:
Comprehensive, covering everything from basic maintenance to complex component overhauls and in-depth diagnostics.
Diagrams:
Detailed, step-by-step diagrams and illustrations for all procedures.
Specifications:
Includes all necessary torque specifications, clearances, fluid types, and capacities.
Engine Code:
3.7L Magnum V6 (PowerTech)
Displacement V6:
3701 cc (226 cu in)
Bore Stroke V6:
93.0 mm x 90.9 mm
Compression Ratio V6:
9.1:1
Horsepower V6:
210 hp @ 5200 rpm
Torque V6:
235 lb-ft @ 4000 rpm
Engine Code:
4.7L Magnum V8 (PowerTech)
Displacement V8:
4701 cc (287 cu in)
Bore Stroke V8:
94.5 mm x 85.7 mm
Compression Ratio V8:
8.7:1
Horsepower V8:
235 hp @ 4800 rpm
Torque V8:
300 lb-ft @ 3200 rpm
Induction:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
ECU:
Commonly NGC (Next Generation Controller) or similar Chrysler/Dodge ECU.
Oil Type V6:
SAE 5W-30 (API Service SJ or SL)
Oil Capacity V6:
5.0 Quarts (4.7 Liters) with filter
Oil Type V8:
SAE 5W-30 (API Service SJ or SL)
Oil Capacity V8:
5.0 Quarts (4.7 Liters) with filter
Transmission Type:
Getrag NV3500 5-Speed Manual (standard on some models)
Transmission Type:
Chrysler 45RFE/545RFE 4-Speed Automatic (with 4.7L V8)
Fluid Type Auto:
ATF+4 (Mopar)
Fluid Capacity 42Re:
Approx. 9.5 Quarts (9.0 Liters) for a fill
Fluid Capacity 45Rfe 545Rfe:
Approx. 10.5 Quarts (9.9 Liters) for a fill
Fluid Type Manual:
MS-9224 specification manual transmission fluid (check manual for specific viscosity, typically 75W-80 or 75W-90 GL-4/GL-5)
Fluid Capacity Nv3500:
Approx. 2.5 Quarts (2.4 Liters)
Wheelbase:
124.8 inches (3170 mm)
Length:
204.6 inches (5200 mm)
Width:
71.7 inches (1821 mm)
Height:
65.4 inches (1661 mm)
Curb Weight V6 2Wd:
Approx. 4,000 lbs (1814 kg)
Curb Weight V8 4Wd:
Approx. 4,400 lbs (1996 kg)
Towing Capacity:
Up to 6,400 lbs (2903 kg) depending on configuration and engine.
Payload Capacity:
Up to 1,500 lbs (680 kg) depending on configuration.
Pattern:
5 x 4.5 inches (114.3 mm)
Standard Tire:
P235/75R15 (common for base models)
Optional Tire:
P255/65R17 (common for higher trims/Sport models)
NHTSA Driver Front 2003:
Not rated or 4 stars (NHTSA ratings can vary by year and specific test; consult official NHTSA records for definitive data).
NHTSA Passenger Front 2003:
Not rated or 4 stars (NHTSA ratings can vary by year and specific test; consult official NHTSA records for definitive data).
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Traction Control:
Optional Traction Control System (TCS) available on some models.
Airbags:
Standard driver and passenger front airbags.
Seatbelts:
Three-point height-adjustable front seat belts, three-point rear seat belts.
Oil Change Interval:
Every 3,000 - 6,000 miles or 6 months, depending on driving conditions and oil type used. Refer to manual for specific recommendations.
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on inspection.
Spark Plug Replacement V6:
Typically 100,000 miles for recommended platinum or iridium plugs.
Spark Plug Replacement V8:
Typically 100,000 miles for recommended platinum or iridium plugs.
Coolant Flush:
Every 30,000 - 50,000 miles or 2-3 years.
Power Steering Fluid:
ATF+4 (Mopar) or equivalent power steering fluid.
Coolant:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, 5/150 (Orange)
Intake Manifold Gaskets:
Potential vacuum leaks due to deteriorating intake manifold gaskets, especially on the 4.7L V8.
Crankshaft Position Sensor:
Failure of the crankshaft position sensor can lead to no-start or stalling issues.
Water Pump:
The water pump on the 4.7L V8 can be a point of failure, often leading to coolant leaks.
Radiator End Tanks:
Cracking or leaking plastic end tanks on the radiator.
Transmission Control Module Tcm:
Intermittent transmission shifting issues, sometimes related to TCM or solenoid pack failures.