Segment:
Heavy-Duty Pickup Truck
Purpose:
Designed for work, towing, and heavy hauling applications.
Competitors:
Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD.
Frame:
Robust ladder frame construction for superior strength and durability.
Powertrain:
Legendary Cummins Turbo Diesel engines and powerful HEMI V8 options.
Towing Capacity:
Exceptional towing and payload capabilities, a hallmark of the Ram 3500.
Engine Mechanical:
Yes, including disassembly, assembly, diagnostics, and specifications for all available engine variants.
Engine Performance:
Yes, covering fuel delivery, ignition, emissions control, cooling, and lubrication systems.
Transmission Manual:
Yes, including NV4500 and NV5600 manual transmissions, with repair, overhaul, and fluid specifications.
Transmission Automatic:
Yes, including NV3500 automatic transmission, with repair, overhaul, and fluid specifications.
Drivetrain:
Yes, covering transfer case (NV241DHD, NV271D/NV273D), front and rear axles, driveshafts, and differentials.
Brakes:
Yes, covering hydraulic brake systems, ABS, parking brake, and component replacement.
Suspension:
Yes, covering front and rear suspension components, steering system, and alignment specifications.
Electrical System:
Yes, including starter, alternator, battery, lighting, wiring diagrams, and component testing.
Body And Frame:
Yes, covering body panels, doors, windows, interior trim, and frame inspection.
HVAC:
Yes, covering air conditioning, heating, and ventilation system diagnosis and repair.
Diagnostics:
Yes, comprehensive diagnostic procedures, fault codes, and troubleshooting guides.
Routine Maintenance:
Yes, oil changes, filter replacements, fluid checks, and lubrication schedules.
Major Repairs:
Yes, engine rebuilds, transmission overhauls, suspension component replacement, and brake system repairs.
Component Replacement:
Yes, detailed instructions for replacing all major and minor components.
Troubleshooting:
Yes, systematic approaches to diagnose and resolve common and uncommon issues.
Depth:
Full workshop level, suitable for professional mechanics and advanced DIY enthusiasts.
Detail Level:
Extremely detailed with step-by-step instructions, torque specifications, clearances, and diagnostic flowcharts.
Diesel Engine Option 1:
5.9L Cummins Turbo Diesel (ISB), 24-valve OHV, I6
Diesel Engine Option 1 Power:
Approx. 235-250 hp @ 2700-2900 rpm
Diesel Engine Option 1 Torque:
Approx. 460-505 lb-ft @ 1400-1600 rpm
Gas Engine Option 1:
5.7L HEMI Magnum V8, 16-valve OHV
Gas Engine Option 1 Power:
Approx. 325 hp @ 4800 rpm
Gas Engine Option 1 Torque:
Approx. 375 lb-ft @ 3200 rpm
Gas Engine Option 2:
8.0L V10 Magnum, 20-valve OHV
Gas Engine Option 2 Power:
Approx. 310 hp @ 4000 rpm
Gas Engine Option 2 Torque:
Approx. 450 lb-ft @ 2400 rpm
Diesel Fuel System:
High-pressure common rail (HPCR) injection (Cummins ISB)
Gas Fuel System:
Sequential Multi-Port Fuel Injection (MPI)
Transmission Type Standard:
NV4500 5-speed manual transmission (common with Cummins)
Transmission Type Optional 1:
NV5600 6-speed manual transmission (common with Cummins)
Transmission Type Optional 2:
47RE 4-speed automatic transmission (common with V8/V10)
Transmission Type Optional 3:
NV3500 5-speed manual transmission (less common in 3500 models, more in 2500)
4Wd System:
Part-time 4WD with manual or electronic transfer case engagement.
Wheelbase Standard:
134.5 inches (Regular Cab 8' Bed), 160.5 inches (Club Cab 8' Bed), 160.5 inches (Regular Cab Long Bed)
Overall Length Standard:
Varies by cab and bed configuration, approx. 238-259 inches
Bed Length Options:
6.3 ft (75.2 in), 8.0 ft (96.0 in)
Curb Weight Range:
Approx. 6,500 - 7,500 lbs (depending on configuration and engine)
Gvwr Range:
Approx. 10,000 - 11,500 lbs
Oil Change Diesel:
Every 7,500 miles or 6 months (synthetic oil recommended), check manual for specific Cummins recommendations.
Oil Change Gas:
Every 3,000 miles (conventional) or 5,000 miles (synthetic blend/full synthetic) or 6 months.
Fuel Filter Diesel:
Every 15,000 miles or annually (Cummins).
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed or every 30,000 miles depending on operating conditions.
Engine Oil Diesel:
Cummins CES 20081 compliant, API CJ-4 or CK-4 rated (e.g., 15W-40 or 5W-40 synthetic).
Engine Oil Gas:
API SN, SAE 5W-20 or 5W-30 (refer to owner's manual for specific viscosity based on temperature).
Coolant:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, 50/50 mix with distilled water. Equivalent to Chrysler MS-9769.
Transmission Fluid Auto:
ATF+4 (MS-9602).
Transmission Fluid Manual Nv4500:
API GL-3 or GL-4 gear oil, SAE 75W-90 or 75W-140 (check specific manual recommendation for fluid type).
Transfer Case Fluid:
NV241DHD: ATF+4; NV271/273: Mopar NV271/273 transfer case fluid or equivalent.
Rear Axle Fluid:
API GL-5, SAE 75W-140 synthetic gear oil (limited slip additive may be required if equipped).
Cummins Fuel Delivery:
Potential issues with lift pump (1998.5-2002), but less prevalent in 2003+ with improved systems. VP44 injection pump issues (earlier models).
Automatic Transmission 47Re:
Can overheat under heavy towing, may require upgrades for heavy-duty use.
Steering Components:
Worn steering gear, tie rods, and ball joints can be common due to heavy use and load.
Rear Main Seal Leak:
Some Cummins engines could experience rear main seal leaks over time.
Brake Wear:
Front brake pads and rotors may wear faster under heavy braking and towing conditions.
Dodge Trucks:
Dodge has a long history of producing durable and capable trucks, with the Ram nameplate representing their truck division for decades.
Third Generation:
This manual covers the third generation (2003-2009) Dodge Ram, which saw a significant redesign with a larger, more aggressive styling and improved chassis.
Year Specific Updates:
2002 was part of the second generation (BR/BE), while 2003 marked the introduction of the redesigned third generation (DR).
Manufacturing Location:
Saltillo Truck Assembly Plant, Coahuila, Mexico.
