🏷️ Basic Information

Make:

Dodge

Model:

Ram 1500, 2500, 3500

Model Generation:

Third Generation (DR/DH/D2)

Model Years Covered:

2004-2005

Chassis Code:

DR/DH/D2

👋 Introduction

Market Position:

The Dodge Ram trucks of this generation were positioned as capable, full-size pickup trucks offering a balance of towing/hauling capacity, comfort, and a range of powertrain options to suit various work and lifestyle needs. They competed directly with Ford F-Series, Chevrolet Silverado/GMC Sierra, and Toyota Tundra.

Competitive Analysis:

The Ram 1500, 2500, and 3500 were known for their distinctive styling, comfortable ride (especially compared to some competitors), and strong HEMI V8 engine options. The 2500 and 3500 series offered heavy-duty capabilities with higher payload and towing capacities, often featuring the Cummins turbodiesel.

Key Features:

Robust chassis, coil-spring rear suspension (on many 1500 models for improved ride), powerful engine options including HEMI V8 and Cummins turbodiesel, versatile bed configurations, and a durable interior.

📋 Manual Details

Coverage Areas:

Complete factory service and repair for Dodge Ram 1500, 2500, and 3500 trucks.

Page Count:

Estimated 2000+ pages (typical for full factory service manuals of this era and scope)

Manual Type:

Factory Service Manual / Workshop Manual / Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered:

Engine Mechanical, Engine Performance, Fuel System, Ignition System, Cooling System, Exhaust System, Clutch, Transmission (Manual & Automatic), Driveline, Axles, Suspension (Front & Rear), Steering System, Brakes (Front & Rear, ABS), Body (Interior & Exterior), Electrical System (Wiring Diagrams, Components), HVAC, Emissions Control, Diagnostic Procedures, Troubleshooting.

Drivetrain Coverage:

Detailed diagnosis and repair for 4x2 and 4x4 transfer cases, front and rear axles, differentials, CV joints, driveshafts, and U-joints.

Electrical System Coverage:

Comprehensive wiring diagrams for all major systems, fuse and relay identification, power distribution, lighting systems, instrument cluster, charging system (alternator, battery), starting system, interior and exterior electronics.

Body And Chassis Coverage:

Frame inspection and repair, body panel removal/installation, door and window mechanisms, tailgate, bumpers, interior trim, seat removal, dashboard disassembly, weatherstripping.

HVAC System Coverage:

Air conditioning system service (refrigerant charging, component replacement), heater core replacement, blower motor service, climate control panel diagnostics.

Fuel And Emissions Coverage:

Fuel pump, fuel filter, fuel injectors, evaporative emission control system (EVAP), catalytic converter, oxygen sensors, EGR system (if applicable), emission control related sensors and actuators.

Procedures Included:

Routine maintenance, detailed repair procedures, component replacement, disassembly and reassembly, diagnostic flowcharts, troubleshooting guides, specifications for torque, clearances, and adjustments, wiring diagrams, component testing, system overhauls, specific procedures for different engine and transmission configurations.

Brake System Procedures:

Front and rear disc brake inspection, pad/rotor replacement, caliper service, ABS system diagnostics (wheel speed sensors, ABS module, hydraulic control unit), parking brake adjustment and repair.

Suspension Steering Procedures:

Front and rear suspension component replacement (shocks, struts, ball joints, control arms, bushings, springs), power steering system service (pump, rack/gearbox, hoses), wheel alignment specifications.

Technical Depth:

Comprehensive, from basic fluid changes and inspections to full engine and transmission rebuilds, complex electrical diagnostics, and body repair.

Diagnostic Tools:

Information on using OBD-II scanners, specific diagnostic trouble codes (DTCs), and procedures for using specialized Chrysler/Dodge diagnostic equipment (like DRBIII, if applicable for the era).

Engine Rebuild Procedures:

Detailed steps for engine disassembly, inspection of internal components (pistons, rings, bearings, valves, camshaft), cylinder head service, crankshaft and connecting rod procedures, piston ring end gap, bearing clearances, torque specifications for all critical fasteners.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High-resolution scans, designed for clarity and readability when printed. Includes detailed diagrams and illustrations.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine 1500:

4.7L Magnum V8 (P-Code) - SOHC, 16-valve

Primary Engine 1500 Hemi:

5.7L HEMI V8 (D-Code) - OHV, 16-valve, Multi-Displacement System (MDS)

Primary Engine 2500 3500:

5.7L HEMI V8 (D-Code) - OHV, 16-valve, MDS

Primary Engine Diesel:

5.9L Cummins Turbo Diesel (ISB) I6 - OHV, 24-valve (for 2500/3500 Heavy Duty)

Engine 4.7L V8 Horsepower:

Approx. 235-240 hp @ 4800-5000 rpm

Engine 4.7L V8 Torque:

Approx. 295-300 lb-ft @ 3200-3400 rpm

Engine 5.7L Hemi V8 Horsepower:

Approx. 345-360 hp @ 5400-5600 rpm

Engine 5.7L Hemi V8 Torque:

Approx. 375-395 lb-ft @ 4000-4200 rpm

Engine 5.9L Cummins Hp:

Approx. 305-325 hp @ 2600-3000 rpm

Engine 5.9L Cummins Torque:

Approx. 555-610 lb-ft @ 1400-1600 rpm

Fuel System Gasoline:

Sequential Electronic Fuel Injection (SEFI)

Fuel System Diesel:

High-Pressure Common Rail (HPCR) Fuel Injection

Fuel Type:

Unleaded Gasoline (Octane 87 recommended), Diesel Fuel (ULSD for Cummins)

🔧 Transmission

Transmission 1500 Std:

4-Speed Automatic (42RE)

Transmission 2500 3500 Std:

4-Speed Automatic (48RE)

Transmission 1500 Opt:

5-Speed Manual (NV3500) on some 4.7L models; 4-Speed Automatic (45RFE/545RFE) with 5.7L HEMI

Transmission 2500 3500 Opt:

6-Speed Manual (G56) with Cummins Diesel; 4-Speed Automatic (47RE) previously, replaced by 48RE

Transmission Features:

Overdrive gearing, electronic controls, Tow/Haul mode on automatics, PTO provision on some manual transmissions.

📐 Dimensions

Wheelbase 1500:

134.5 inches (Standard Cab), 140.5 inches (Quad Cab)

Wheelbase 2500 3500:

134.5 inches (Standard Cab), 140.5 inches (Quad Cab), 160.5 inches (Mega Cab), 164.5 inches (Mega Cab Long Bed)

Bed Length Options:

6.3 ft (Standard), 8.0 ft (Long Bed)

Curb Weight 1500:

Approx. 4,700 - 5,300 lbs

Gvw 2500:

Approx. 8,510 - 8,800 lbs

Gvw 3500:

Approx. 9,750 - 11,500 lbs

🛡️ Safety Features

NHTSA Front Impact:

Likely 4-star driver, 5-star passenger (based on similar era Dodge trucks, manual will have specifics)

IIHS Side Impact:

Good (for models equipped with side airbags, if applicable)

Active Features:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Traction Control System (TCS) on some models.

Passive Features:

Driver and Passenger front airbags. Optional side curtain airbags on some higher trims/later models.

💡 Technology Features

Infotainment Options:

Factory AM/FM/CD player, optional premium audio systems, optional satellite radio, Uconnect hands-free communication system available on some later models within this generation.

Driver Assistance Features:

ABS, Traction Control System (TCS), Trailer Brake Controller (factory option for heavy-duty models).

Connectivity Features:

Auxiliary input for audio devices on some models, Uconnect system integrated phone connectivity.

🔧 Maintenance

Oil Change Interval:

Every 3,000-6,000 miles or 3-6 months, depending on driving conditions (refer to manual for exact specifications based on oil type and engine).

Tire Rotation Interval:

Every 5,000-7,500 miles

Engine Air Filter Replacement:

Every 15,000-30,000 miles or as needed based on inspection.

Spark Plug Replacement Hemi:

Approx. 100,000 miles (if using long-life plugs)

Engine Oil 1500 4.7L:

SAE 5W-30, API Certified (e.g., Chrysler Material Standard MS-6395)

Engine Oil 1500 5.7L Hemi:

SAE 5W-20, API Certified (e.g., Chrysler Material Standard MS-6395). MDS requires specific oil formulation.

Engine Oil 2500 3500 Diesel:

API CJ-4 or CK-4 rated, SAE 15W-40 (check manual for specific viscosity based on temperature).

Transmission Fluid Auto Gas:

ATF+4 (MS-9602)

Transmission Fluid Auto Diesel:

ATF+4 (MS-9602) or equivalent heavy-duty ATF for 48RE

Coolant:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, Pink (MS-90032)

Brake Fluid:

DOT 3

Known Issues Gas:

Exhaust manifold leaks (cracked manifolds), front suspension wear (ball joints, tie rods), PCM failures, rust on the rear quarter panels and cab corners, potential for Lifter Tick in HEMI engines.

Known Issues Diesel:

VP44 injection pump failure (early models), injector issues, potential for turbocharger problems, cracking of engine blocks (rare but documented), water in fuel issues, potential for camshaft lobe wear.

📚 Vehicle History

Brand Heritage:

Dodge has a long history of producing rugged and capable trucks, with the Ram line becoming a distinct identity and a major player in the American pickup truck market for decades.

Model Evolution:

The 2002-2008 third generation Ram (DS/DR/DH/D2) represented a significant redesign from the previous generation, featuring a larger, more aggressive exterior design, a more refined interior, and the introduction of the 5.7L HEMI V8. This generation also saw the introduction of the Mega Cab configuration.

Production Locations:

Saltillo, Mexico; Warren, Michigan, USA

Production Years:

2002-2008 (Third Generation)

🏆 Awards & Recognition

Recognized Awards:

The Dodge Ram pickup consistently received praise for its ride quality, powerful HEMI engine, and the capability of the Cummins diesel in the heavy-duty models. Awards might include 'MotorTrend Truck of the Year' nominations or specific segment awards from automotive publications for its class.

Owner Satisfaction:

Mixed to positive, with strong loyalty from owners who appreciate the powertrain and towing capabilities, especially the Cummins diesel variants. Some reported issues impacted overall satisfaction scores for certain components.