🏷️ Basic Information

Make:

Dodge

Model:

Ram 1500, 2500, 3500

Model Years Covered:

2002, 2003, 2004, 2005, 2006, 2007, 2008

Primary Engine Covered In Product Name:

3.7L

Additional Engines Covered In Description:

4.7L, 5.7L HEMI, 5.9L Cummins Diesel

Chassis Types Covered:

1500, 2500, 3500

Manual Origin:

OEM Factory Service Repair Information

Product Type:

Service Repair Manual

👋 Introduction

Target Audience:

Professional automotive technicians, DIY mechanics, and owners seeking in-depth knowledge of their Dodge Ram trucks.

Value Proposition:

Provides OEM-level technical information, enabling accurate diagnosis, repair, and maintenance, saving time and money compared to guesswork or less comprehensive guides.

Advantage:

Directly sourced from Dodge (OEM), ensuring accuracy and completeness, unlike aftermarket Haynes or Chilton manuals which may offer less detail on specific components or diagnostic procedures.

Feature 1:

Authoritative OEM factory repair data for accuracy.

Feature 2:

Detailed illustrations, diagrams, and exploded views for visual clarity.

Feature 3:

Comprehensive coverage across multiple model years and engine options.

Feature 4:

Searchable PDF format for efficient information retrieval.

Feature 5:

Print-on-demand capability for specific repair tasks.

📋 Manual Details

General Coverage:

Comprehensive coverage for all major systems and components of the Dodge Ram 1500, 2500, and 3500 trucks from 2002-2008.

Engine Coverage:

3.7L Magnum V6, 4.7L Magnum V8, 5.7L HEMI V8, 5.9L Cummins Turbo Diesel I6.

Transmission Coverage:

Manual and automatic transmissions for the specified engines.

Chassis And Body Coverage:

Suspension, steering, brakes, frame, body panels, interior trim, HVAC, and electrical systems.

Estimated Page Count:

Likely several thousand pages when printed, typical for OEM service manuals covering multiple years and configurations.

Type:

Factory Service Repair Manual (FSM)

Language:

English

Format:

Digital (PDF)

Delivery Medium:

Standard Disc (CD/DVD)

📖 Manual Coverage

Engine Mechanical:

Engine assembly/disassembly, internal components, cylinder heads, block, crankshaft, pistons, connecting rods, timing.

Engine Performance:

Fuel system, ignition system, lubrication system, cooling system, exhaust system.

Transmission Drivetrain:

Manual transmission (NV3500, NV4500, G56), Automatic transmissions (42RLE, 48RE, 47RE, 68RFE potentially), transfer case, differentials, driveshafts, axles.

Suspension Steering:

Front and rear suspension components (coil springs, leaf springs, shocks, control arms), steering gear, power steering system, steering linkage.

Brakes:

Front and rear brake systems (disc, drum), ABS system, parking brake.

Electrical:

Battery, charging system, starting system, lighting, instrument cluster, power distribution, body control modules (BCM), engine control modules (ECM).

Body Interior:

Body panel removal and installation, interior trim, seats, glass, doors, tailgate, bumpers, HVAC (heating, ventilation, air conditioning).

Diagnostic And Testing:

Diagnostic trouble codes (DTCs), troubleshooting procedures, component testing, circuit testing.

Maintenance:

Routine maintenance procedures, fluid checks and changes, filter replacements, lubrication.

Removal And Installation:

Step-by-step procedures for removing and installing all major components and systems.

Assembly Disassembly:

Detailed instructions for taking apart and putting back together various assemblies.

Tune Ups:

Procedures for engine tune-ups, ignition system adjustments, and emissions control.

Diagnostics Troubleshooting:

Systematic approaches to identifying and resolving common and complex issues.

Depth:

Extensive, covering everything from basic maintenance to complex component overhaul and electrical diagnostics.

Detail Level:

High-resolution images, detailed illustrations, exploded views, wiring diagrams, and step-by-step instructions.

Diagnostic Capability:

Advanced diagnostic procedures, including symptom-based troubleshooting and electrical circuit analysis.

📊 Manual Specifications

Software Requirement:

Adobe Reader (or compatible PDF viewer)

Compatibility:

Windows and MAC operating systems

Image Resolution:

High-resolution images for clear viewing of details ('Hi-Res images for zooming and viewing every nut & bolt clearly').

Printability:

Printable pages (allows users to 'print only the pages you need').

Binding:

Not applicable (digital format on disc)

Paper Quality:

Not applicable (digital format on disc)

Navigation:

Searchability, navigation links, table of contents.

⚙️ Engine Specifications

Engine 1:

3.7L Magnum V6

Engine 1 Displacement Liters:

3.7

Engine 1 Configuration:

Overhead Valve (OHV) V6

Engine 1 Approx Horsepower 2002-2003:

215 hp @ 5200 rpm (varies slightly by year)

Engine 1 Approx Torque 2002-2003:

235 lb-ft @ 4000 rpm (varies slightly by year)

Engine 2:

4.7L Magnum V8

Engine 2 Displacement Liters:

4.7

Engine 2 Configuration:

Single Overhead Cam (SOHC) V8

Engine 2 Approx Horsepower 2002-2003:

235 hp @ 4800 rpm (varies slightly by year)

Engine 2 Approx Torque 2002-2003:

295 lb-ft @ 3200 rpm (varies slightly by year)

Engine 3:

5.7L HEMI V8

Engine 3 Displacement Liters:

5.7

Engine 3 Configuration:

Overhead Valve (OHV) V8 with HEMI cylinder heads and Multi-Displacement System (MDS) introduced later in the generation.

Engine 3 Approx Horsepower 2003:

345 hp @ 5000 rpm

Engine 3 Approx Torque 2003:

375 lb-ft @ 4000 rpm

Engine 4:

5.9L Cummins Turbo Diesel I6

Engine 4 Displacement Liters:

5.9

Engine 4 Configuration:

Inline 6-Cylinder Turbo Diesel with Bosch VP44 injection pump (early models) or common rail (later models).

Engine 4 Approx Horsepower 2002-2003:

250 hp @ 2900 rpm (varies by model year and configuration)

Engine 4 Approx Torque 2002-2003:

460 lb-ft @ 1400 rpm (varies by model year and configuration)

Fuel Delivery Gasoline:

Electronic Fuel Injection (EFI)

Fuel Delivery Diesel:

High-pressure injection system (VP44 or common rail depending on year).

🔧 Transmission

Manual Options:

NV3500 (5-speed) for light-duty, NV4500 (5-speed heavy-duty), G56 (6-speed manual for later models).

Automatic Options:

42RLE (4-speed automatic for 3.7L/4.7L), 47RE/48RE (4-speed automatic for 5.9L Diesel and 4.7L/5.7L V8), potentially 68RFE (6-speed automatic for later Cummins).

Transfer Case:

Part-time 4WD (e.g., BW 4488) or Full-time 4WD options.

Rear Axle:

Various gear ratios depending on engine, transmission, and chassis configuration (e.g., Dana 44, Dana 60, Corporate 9.25).

📐 Dimensions

Body Styles:

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

Bed Lengths:

Short Bed (approx. 6.3 ft), Long Bed (approx. 8 ft).

Gvwr Range:

Ranges from approximately 6,500 lbs (1500) to over 10,500 lbs (3500 Diesel).

Curb Weight Range:

Varies significantly by configuration, typically 4,500 lbs to 7,500 lbs.

🛡️ Safety Features

NHTSA Ratings Typical:

Generally good to acceptable for its era. Frontal crash test ratings often 4-star or 5-star. Side impact and rollover ratings can vary. Consult NHTSA records for specific year/configuration.

ABS:

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

Traction Control:

Optional traction control system on some models, especially later years and 4WD.

Airbags:

Standard front airbags. Optional side curtain airbags or seat-mounted side airbags on some configurations and later model years.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

💡 Technology Features

Audio Systems:

Factory AM/FM/CD players, optional premium audio systems (e.g., Infinity), CD changers, satellite radio preparation.

Navigation:

Optional factory navigation systems became available in later years of this generation.

Cruise Control:

Standard cruise control on most trims.

Parking Assist:

Optional rear parking sensors on some models.

Phone Integration:

Optional Uconnect hands-free communication system introduced in later years.

🔧 Maintenance

Oil Change Gasoline:

Typically every 5,000-7,500 miles or 6 months, depending on driving conditions and oil type used (check manual for specifics).

Oil Change Diesel:

Typically every 7,500-15,000 miles or 6-12 months for the Cummins, depending on usage and oil quality.

Transmission Fluid Change Automatic:

Recommended every 30,000-60,000 miles, depending on load and driving conditions.

Transmission Fluid Change Manual:

Recommended every 50,000-100,000 miles.

Coolant Flush:

Typically every 30,000-50,000 miles or 2-3 years.

Engine Oil Gasoline:

SAE 5W-20 or 5W-30 (API Certified, meets Chrysler MS-6395). Refer to specific engine and owner's manual.

Engine Oil Diesel:

CJ-4 rated diesel engine oil, SAE 15W-40 or 5W-40 (depending on temperature). Refer to Cummins specifications and owner's manual.

Transmission Fluid Automatic:

ATF+4 (Chrysler Material Standard MS-9602).

Transmission Fluid Manual:

GL-3 or GL-4 gear oil (specific weight varies by transmission model, e.g., SAE 75W-90 or 75W-140).

Coolant:

HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar OAT or equivalent, mixed 50/50 with distilled water.

Common Issue Diesel:

VP44 injection pump failures (early 5.9L Cummins), injector issues, potential for head gasket leaks under heavy load if not maintained.

Common Issue Gasoline Engines:

Valve spring issues in early 5.7L HEMI, oil leaks (valve covers, oil pan), coolant leaks (water pump, radiator), occasional transmission hard shifting.

Common Issue Chassis:

Front-end wear (ball joints, tie rods), rear main seal leaks, exhaust manifold leaks, power steering pump noise.

📚 Vehicle History

Dodge Truck Legacy:

Dodge has a long history of producing robust and capable trucks, with the Ram line becoming a distinct brand within Chrysler. Known for their power, towing capacity, and durability.

Third Generation Ram:

This generation (2002-2008, often referred to as 'DR' or 'DN' platform) represented a significant redesign from the previous generation, featuring a bolder styling, improved interior, and the introduction of the HEMI V8 and the renowned Cummins turbodiesel.

Key Updates:

Major update in 2006 included revised styling, interior upgrades, introduction of the 5.7L HEMI as a widespread option, and the move to a common-rail fuel system for the Cummins diesel.

Manufacturing Plant:

Primarily Saltillo, Mexico, and Warren, Michigan.

🏆 Awards & Recognition

Engine Awards:

The 5.7L HEMI engine received significant acclaim for its power and performance, often cited in 'Ward's 10 Best Engines' lists.

Diesel Engine Reputation:

The 5.9L Cummins Turbo Diesel consistently earned a reputation for exceptional durability, reliability, and towing prowess.