🏷️ Basic Information

Make:

Dodge

Model:

Ram Pickup 2500

Year:

2005

Product Type:

Full Service Repair Manual

Platform:

Third Generation Ram (DR/DH/D2)

Chassis Code:

DR/DH/D2

👋 Introduction

Vehicle Segment:

Heavy-Duty Pickup Truck

Target Audience:

Commercial users, fleet operators, serious DIY mechanics, and owners requiring in-depth repair and maintenance knowledge.

Key Competitors:

Ford F-250 Super Duty, Chevrolet Silverado 2500HD, GMC Sierra 2500HD.

Vehicle Attributes:

Robust construction, strong towing and payload capacities, powerful engine options (particularly the Cummins diesel), and a reputation for durability.

Manual Value Proposition:

Provides detailed, factory-level repair and maintenance information essential for keeping these heavy-duty trucks in optimal working condition.

📋 Manual Details

Engine Coverage:

5.7L HEMI V8 (16-Valve OHV) and 5.9L Cummins Turbo Diesel (24-Valve ISB)

Transmission Coverage:

4-Speed Automatic (45RFE/48RE), 6-Speed Manual (NV5600)

Drivetrain Coverage:

2WD and 4WD configurations

Suspension Coverage:

Front: Solid Live Axle with Leaf Springs, Rear: Solid Live Axle with Leaf Springs

Braking Coverage:

Front: Vented Disc Brakes, Rear: Solid Disc Brakes (ABS equipped)

Estimated Pages:

~2000+

Type:

Comprehensive Service and Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, turbocharging (Cummins), emissions control.

Transmission Drivetrain:

Automatic and manual transmission repair, transfer case operation and service, driveline components (U-joints, CV joints, driveshafts), axle assemblies (Dana 60/70).

Suspension Steering Brakes:

Front and rear suspension components, steering system (rack and pinion, power steering), brake system diagnosis and repair (ABS, parking brake).

Electrical Electronic:

Wiring diagrams, fuse box layouts, lighting systems, power windows, power locks, instrument cluster, body control modules (BCM), engine control modules (ECM/PCM), diagnostics for electronic systems.

Body Chassis:

Body panel repair, interior trim removal and installation, doors, windows, HVAC system service, frame and chassis components, towing specifications.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations, brake inspections, battery maintenance, belt and hose inspections.

Repair Rebuild:

Engine overhaul, transmission overhaul, differential service, brake caliper replacement, suspension component replacement, electrical component repair.

Diagnostics Troubleshooting:

Diagnostic Trouble Codes (DTCs) explanation and troubleshooting strategies, symptoms-based troubleshooting, circuit testing, component testing.

Technical Specifications:

Torque specifications for all fasteners, fluid capacities and types, diagnostic data, component specifications, clearances.

Depth:

Comprehensive, covering everything from basic scheduled maintenance and fluid changes to complete engine and transmission overhauls, detailed electrical system diagnostics, and body repair procedures.

📊 Manual Specifications

Digital Format:

PDF

Searchability:

Searchable text for quick information retrieval.

Image Resolution:

High-resolution images and diagrams for clarity.

Digital Accessibility:

Accessible on computers, tablets, and smartphones.

Digital Layers:

May include interactive links or layered diagrams (dependent on source quality).

⚙️ Engine Specifications

Engine 1 Name:

5.7L HEMI Magnum V8

Engine 1 Displacement:

5.7 Liters (345 cubic inches)

Engine 1 Configuration:

V8 (90-degree)

Engine 1 Valvetrain:

OHV (Overhead Valve), 2 valves per cylinder

Engine 1 Horsepower:

~345-350 hp @ 5400 rpm

Engine 1 Torque:

~375-380 lb-ft @ 4000 rpm

Engine 1 Fuel System:

Sequential Multiport Fuel Injection (MPI)

Engine 1 Block Material:

Cast Iron

Engine 1 Head Material:

Aluminum

Engine 2 Name:

5.9L Cummins Turbo Diesel (ISB)

Engine 2 Displacement:

5.9 Liters (359 cubic inches)

Engine 2 Configuration:

Inline-6 (Straight-6)

Engine 2 Valvetrain:

OHV (Overhead Valve), 4 valves per cylinder

Engine 2 Horsepower:

~305-325 hp @ 2900-3000 rpm

Engine 2 Torque:

~555-610 lb-ft @ 1400-1600 rpm

Engine 2 Fuel System:

High-pressure direct injection with electronic unit pumps (Cummins PT)

Engine 2 Block Material:

Cast Iron

Engine 2 Head Material:

Cast Iron

Diesel Transmission Compatibility:

Primarily mated to the 48RE automatic transmission for optimal torque management.

🔧 Transmission

Automatic Transmission:

45RFE (for 5.7L HEMI) / 48RE (for 5.9L Cummins Diesel)

Automatic Gears:

4-Speed Electronically Controlled

Manual Transmission:

New Venture Gear NV5600

Manual Gears:

6-Speed Manual

Diesel Clutch Type:

Heavy-duty dual-mass flywheel with organic clutch disc for NV5600.

Automatic Torque Converter:

Lock-up torque converter for improved highway efficiency.

Transfer Case:

New Process Gear (NP) 271 (manual 4WD) or NP273 (electronic shift 4WD).

📐 Dimensions

Wheelbase Options:

130.5" (Regular Cab), 140.5" (Mega Cab), 145.5" (Quad Cab 8ft Bed), 160.5" (Quad Cab 8ft Bed Crew Cab)

Bed Length Options:

6'4" (Mega Cab) and 8'0"

Gvwr Range:

9,000 - 11,500 lbs (depending on configuration)

Curb Weight Range:

~5,500 - 7,000 lbs

🛡️ Safety Features

NHTSA Front Impact Driver:

5-Star (for models with side airbags)

NHTSA Front Impact Passenger:

5-Star (for models with side airbags)

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS)

Airbags:

Standard front airbags; Optional side curtain airbags.

Seatbelts:

Three-point seatbelts with pretensioners.

💡 Technology Features

Audio System:

Factory AM/FM stereo with CD player; optional Infinity premium audio system.

Connectivity:

Limited by modern standards; primarily focused on audio input. No factory Bluetooth or USB ports.

Cruise Control:

Standard cruise control on most trims.

Parking Sensors:

Optional rear parking sensors.

🔧 Maintenance

Oil Change Interval Gas:

Every 3,000-7,500 miles or 6 months (depending on usage and oil type).

Oil Change Interval Diesel:

Every 5,000-7,500 miles or 6 months (severe duty may require more frequent changes).

Transmission Fluid Change Automatic:

Every 30,000-60,000 miles (refer to manual for severe service).

Transmission Fluid Change Manual:

Every 50,000-100,000 miles.

Coolant Flush:

Every 30,000-100,000 miles or 2-5 years (depending on coolant type and condition).

Engine Oil Gas:

SAE 5W-30 (API SN or newer, synthetic recommended for HEMI)

Engine Oil Diesel:

CJ-4 or CK-4 15W-40 (Cummins recommends specific diesel engine oil)

Transmission Fluid Automatic:

ATF+4 (Chrysler Material Standard MS-9602)

Transmission Fluid Manual:

NV5600: SAE 75W-90 GL-4 or GL-5 Gear Oil

Brake Fluid:

DOT 3

Coolant:

Mopar OAT (Orange) Antifreeze/Coolant (5/100,000 mile formula)

Hemi Lifter Tick:

Some HEMI engines may experience lifter tick due to wear or oiling issues, often addressed by specific oil viscosity or lifter replacement.

Cummins Fuel Injector Issues:

Early common rail injection systems could be sensitive to fuel quality; occasional injector issues may arise, though generally robust.

Transmission Hard Shifting Automatic:

The 48RE can sometimes exhibit hard shifting or delayed engagement, often related to solenoid pack wear or TCM calibration.

Rear Main Seal Leaks:

Anecdotal reports of rear main seal leaks on both engine types, particularly with high mileage.

Body Rust:

As with many trucks of this era, rust can be a concern, especially on cab corners, rocker panels, and wheel arches in areas with road salt.

📚 Vehicle History

Dodge Trucks:

Dodge has a long-standing history of producing rugged and capable pickup trucks, with the Ram nameplate signifying strength and utility since its introduction in 1981.

Third Generation:

The 2005 model year falls within the third generation (2002-2008), which introduced significant styling updates, a more refined interior, and enhanced powertrain options, including the introduction of the HEMI engine and the Cummins turbo-diesel's continued availability.

Manufacturing Location:

Saltillo, Mexico; Warren, Michigan, USA

🏆 Awards & Recognition

Truck Of The Year Contender:

While specific 'Truck of the Year' awards for the 2005 model year aren't prominent, the Ram series consistently ranked high in heavy-duty truck segments for its capabilities and HEMI/Cummins powertrains.

Consumer Reports:

Consumer Reports often highlighted the Ram's strong powertrain options, particularly the Cummins diesel, while noting potential concerns with interior build quality and reliability compared to some competitors.