🏷️ Basic Information

Make:

Dodge

Model:

Ram 1500, 2500, 3500

Years Covered:

2003, 2004, 2005, 2006

Chassis Code:

DR (2nd Generation Ram Truck)

👋 Introduction

Vehicle Segment:

Full-size Pickup Truck

Target Audience:

Heavy-duty users, fleet operators, DIY mechanics, and truck enthusiasts seeking in-depth repair knowledge.

Key Competitors:

Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD.

Manual Advantage:

Provides dealership-level repair information, empowering users to perform complex diagnostics and repairs efficiently, saving time and money.

Vehicle Strengths:

Renowned for robust powertrains, towing capacity, and durable construction, making them popular for work and recreational use.

📋 Manual Details

Coverage Scope:

All models (1500, 2500, 3500) and all repair topics A-Z

Estimated Page Count:

Extensive, often exceeding 2000 pages for this generation and range

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Powertrain:

Engine mechanical (including assembly, disassembly, inspection, repair for all engine variants), Fuel & Emissions, Cooling System, Lubrication System, Exhaust System, Engine Control System (ECM/PCM, sensors, actuators).

Transmission Drivetrain:

Manual Transmission (NV4500, G56), Automatic Transmission (48RE, 47RE, 42RE - depending on model/engine), Transfer Case (New Process/BorgWarner 4406, 4410, etc.), Drivelines, Axles (Front and Rear, Dana 44, Dana 60, Chrysler 9.25, etc.), Wheel Bearings, Drive Shafts.

Chassis Suspension Steering:

Front Suspension (Independent Front Suspension for 1500, Solid Front Axle for 2500/3500), Rear Suspension (Leaf Springs, Suspension components), Steering System (Power Steering Pump, Gearbox/Rack and Pinion, Linkages), Power Steering Cooler.

Brakes:

Brake System (Hydraulic lines, Master Cylinder, Brake Booster, ABS Control Module, Wheel Speed Sensors, Calipers, Rotors, Brake Pads, Rear Drums/Shoes), Parking Brake.

Electrical Electronics:

Battery, Charging System (Alternator), Starting System (Starter Motor), Ignition System, Lighting System (Headlights, Taillights, Interior), Power Accessories (Windows, Locks, Mirrors), Wiper/Washer System, Horn, Gauges, Instrument Cluster, Body Control Module (BCM), Powertrain Control Module (PCM), Anti-theft System, Remote Keyless Entry, Trailer Towing Harness and Connectors.

Body Interior:

Exterior Body Panels (Doors, Hood, Tailgate, Fenders), Interior Trim, Seating Systems, HVAC (Heating, Ventilation, Air Conditioning - including Compressor, Condenser, Evaporator, Blower Motor, Controls), Body Sealing, Door Hardware, Bumpers, Mirrors, Glass Replacement, Sunroof (if equipped).

Routine Maintenance:

Oil and Filter Changes, Air Filter Replacement, Fuel Filter Replacement, Spark Plug Replacement, Tire Rotation, Brake Pad and Rotor Inspection/Replacement, Fluid Level Checks and Top-offs, Wiper Blade Replacement.

Troubleshooting Diagnostics:

System-specific diagnostic charts, DTC (Diagnostic Trouble Code) interpretation and resolution, component testing procedures, wiring diagrams for electrical diagnosis, performance anomaly troubleshooting.

Major Repairs Rebuilds:

Engine overhaul (short block, long block, complete), Cylinder Head Reconditioning/Replacement, Transmission Rebuilds (automatic and manual), Differential Rebuilds, Suspension Component Replacement (shocks, struts, ball joints, tie rods, control arms), Brake System Overhaul, Steering Gearbox/Pump Replacement, HVAC System Component Replacement, Body Panel Repair and Replacement.

Electrical Diagnostics Repair:

Wiring harness repair, component replacement (sensors, actuators, modules), diagnostic connector access and use, charging and starting system troubleshooting, power accessory repair, lighting system diagnosis.

Depth Of Information:

Comprehensive. Covers detailed step-by-step repair instructions, torque specifications, component clearances, diagnostic strategies, electrical schematics, and exploded views for parts identification and assembly.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Readability:

High resolution for clear text and diagrams, ensuring professional readability.

Binding Method:

N/A (Digital PDF format)

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Options:

4.7L Magnum V8 (P-Code), 5.9L Cummins I6 Turbo Diesel (ISB), 5.7L HEMI V8 (often introduced late in the generation/model years).

4.7L Magnum V8:

Displacement: 4.7L (287 cu in), Configuration: V8, Fuel System: MPI (Multi-Point Injection), Horsepower: ~235-245 hp, Torque: ~300-315 lb-ft.

5.9L Cummins I6 Turbo Diesel:

Displacement: 5.9L (359 cu in), Configuration: Inline 6-Cylinder Turbo Diesel, Fuel System: Bosch VP44 or Common Rail (depending on specific year/emission updates), Horsepower: ~250-330 hp, Torque: ~460-555 lb-ft.

5.7L Hemi V8:

Displacement: 5.7L (345 cu in), Configuration: V8 with HEMI head design, Fuel System: MDS (Multi-Displacement System) with VVT (Variable Valve Timing) on later models, Horsepower: ~345-370 hp, Torque: ~375-395 lb-ft.

ECM Control:

Engine Control Module (ECM) / Powertrain Control Module (PCM) manages fuel delivery, ignition timing, emissions, and more.

Diesel Fuel Injection:

High-pressure injection systems, including potential lift pump and injection pump diagnostics for Cummins engines.

🔧 Transmission

Standard Transmission Options:

Manual transmission (e.g., NV4500 5-speed for heavy-duty applications) and Automatic transmissions (e.g., 48RE 4-speed heavy-duty automatic).

Optional Transmission Options:

A wider range of automatics and potentially different manual options depending on the specific sub-model and year.

Automatic Transmission Cooling:

Emphasis on auxiliary transmission coolers for towing applications, crucial for preventing overheating.

Transfer Case Operation:

Information on 2WD/4WD engagement, electronic 4WD controls, and transfer case maintenance.

📐 Dimensions

Wheelbase:

Varies by cab configuration (e.g., Regular Cab, Quad Cab, Crew Cab) and bed length (e.g., 6.3 ft, 8.0 ft). Typically ranges from 135.1 inches to 166.5 inches.

Overall Length:

Varies based on wheelbase and cab configuration.

Curb Weight:

Ranges significantly based on configuration and engine, often from 5,000 lbs for a 2WD Regular Cab to over 7,000 lbs for a 4WD Crew Cab Long Bed Diesel.

Gross Vehicle Weight Rating Gvwr:

Class 2a and 2b for 1500/2500, Class 3 for 3500. GVWRs can range from approximately 6,000 lbs to over 10,000 lbs.

🛡️ Safety Features

NHTSA Crash Test Results:

Generally good for the era, with potential for 4 or 5-star ratings in frontal and side impact tests depending on configuration and specific testing year.

ABS:

Anti-lock Braking System (ABS) is standard, with variations in sensor placement and control module logic for different models.

Airbags:

Driver and Passenger Frontal Airbags are standard. Side curtain airbags may be optional or standard on higher trims.

💡 Technology Features

Audio System:

Factory AM/FM/CD players, optional Infinity premium audio systems. Cassette player availability on base models.

Navigation:

Optional factory navigation systems were available on higher trim levels.

Parking Assist:

Rear parking assist sensors were an option on some models.

Trailer Brake Controller:

Provisions and optional integrated trailer brake controllers for heavy-duty towing.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-7,500 miles or 3-6 months, depending on engine type (gas vs. diesel) and driving conditions (severe vs. normal).

Transmission Fluid Change:

Automatic: Every 30,000-60,000 miles. Manual: Every 50,000-100,000 miles, or as specified for specific units.

Diesel Maintenance:

Includes fuel filter replacement (critical for Cummins), coolant service, and air filter replacement at specified intervals (often more frequent than gasoline).

Engine Oil Gas:

SAE 5W-30 or 10W-30 (depending on temperature and specific engine variant) meeting Chrysler MS-6395 or API specifications.

Engine Oil Diesel Cummins:

API CJ-4 or CK-4 rated heavy-duty diesel engine oil, typically SAE 15W-40.

Automatic Transmission Fluid:

ATF+4 (Chrysler MS-9602) for most automatic transmissions.

Manual Transmission Fluid:

Varies by transmission, often GL-3 or GL-4 gear oil for older units, or specific manual transmission fluids for newer ones.

Coolant:

HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar OAT (Organic Additive Technology) or equivalent, P-S-COOL1 (Purple) or P-S-COOL2 (Pink).

Common Concerns Gas:

Lifter tick on 4.7L, occasional intake manifold gasket leaks, throttle body issues.

Common Concerns Diesel Cummins:

Lift pump failure (especially in earlier VP44 systems), injection pump issues, potential for injector problems, exhaust manifold cracking, turbocharger issues. Regular fuel filter changes are critical to prevent lift pump failure.

Common Concerns Transmission:

Overheating on heavy towing, potential for torque converter shudder on automatics, worn clutch components on manuals.

Common Concerns Suspension Steering:

Worn ball joints and tie rod ends, especially on 4x4 models; steering gear play.

📚 Vehicle History

Dodge Truck Legacy:

Dodge has a long history in the truck market, with the Ram brand evolving from Dodge trucks in the mid-1980s.

Second Generation Ram:

This 2003-2006 period represents the latter half of the second-generation Ram truck platform (DN/DR), known for its bold styling and significant powertrain upgrades, including the introduction of the HEMI V8 and further refinement of the Cummins diesel.

Manufacturing Locations:

Primarily produced at Chrysler's Sterling Heights Assembly Plant (SHAP) in Michigan and Saltillo Truck Assembly Plant in Mexico.

🏆 Awards & Recognition

Editorial Awards:

Ram trucks from this era, particularly diesel variants, were often praised for their towing prowess and durability, earning accolades in various truck-focused publications.

Towing Hauling:

Consistently strong towing and payload capacities across the 1500, 2500, and 3500 lineups, making them a top choice for work applications.

Emissions Compliance:

Compliance with EPA emissions standards for gasoline and diesel engines of the respective model years.