DODGE 2500 RAM Truck 2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 2500 Year: 2005 Chassis Code: DR/DH/DHC Codes Engine Code Primary: 360 (5.9L Magnum V8) Engine Code Optional 1: 5.7L HEMI V8 (1500/2500/3500) Engine Code Optional 2: 240 (4.7L Magnum V8) Engine Code Diesel: 505 (5.9L Cummins Turbo Diesel I6) 👋 Introduction Market Position Vehicle Segment: Heavy-duty pickup truck Target Audience: Work truck users, fleet owners, towing and hauling enthusiasts, off-road enthusiasts. Competitive Analysis Key Competitors: Ford F-250 Super Duty, Chevrolet Silverado 2500HD, GMC Sierra 2500HD. Key Features Vehicle Strengths: Legendary Cummins Turbo Diesel engine, robust chassis and suspension, strong towing and payload capacities, user-friendly interior, good value proposition in the heavy-duty segment. Manual Value Proposition: Empowers owners and technicians with the detailed information needed to perform accurate diagnostics and repairs, saving time and money, and ensuring the longevity of the vehicle. 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual / Repair Manual Language: English Format: PDF Page Count Estimated Page Count: Approximately 2000+ pages (typical for factory service manuals of this era) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel system (gasoline and diesel), exhaust system, intake manifold, turbocharger (diesel), intercooler (diesel), emission control systems. Engine Electrical: Ignition system, starting system, charging system, engine control module (ECM), sensors (crankshaft position, camshaft position, oxygen, mass air flow, manifold absolute pressure, coolant temperature, etc.), fuel injectors, glow plugs (diesel). Transmission Manual: Clutch system, manual transmission (NV3500, NV4500), transfer case (NV241DHD, NV271DHD), shift mechanisms, driveshafts, U-joints. Transmission Automatic: Automatic transmission (48RE, NV3500), torque converter, valve body, transmission control module (TCM), shift solenoids, transmission fluid cooling. Drivetrain: Front and rear axles, differentials, axle shafts, wheel bearings, locking hubs (if equipped), propeller shafts. Brakes: Front and rear brake systems (disc brakes), parking brake, hydraulic system, anti-lock braking system (ABS), brake fluid specifications, master cylinder, brake calipers, brake pads, rotors, brake lines. Suspension Steering: Front suspension (leaf springs, shocks, steering knuckles), rear suspension (leaf springs, shocks), steering system (power steering pump, steering gear, tie rods, steering linkage), wheel alignment specifications. Body Interior: Body panels, doors, hood, tailgate, bumpers, glass, mirrors, interior trim, seats, dashboard, HVAC system (heating, ventilation, air conditioning), cabin filters. Electrical Lighting: Lighting system (headlights, taillights, interior lights), wiring diagrams, fuses, relays, battery, starter, alternator, power windows, power locks, power seats, horn, wipers, washer system. Chassis Frame: Frame construction, welding procedures, rustproofing, chassis lubrication points. Procedures Included Maintenance: Oil change, filter replacement (oil, fuel, air), fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid, differential fluid), tire rotation and pressure, lubrication services, spark plug replacement, belt inspection and replacement. Diagnostics: Troubleshooting guides for common symptoms (no-start, rough idle, poor performance, brake issues, electrical faults), diagnostic trouble codes (DTCs) interpretation and clearing, use of diagnostic scan tools. Repair Rebuild: Engine overhaul, cylinder head gasket replacement, timing belt/chain replacement (if applicable), transmission removal and installation, brake system component replacement, suspension component replacement, steering system repair, electrical component repair and replacement, body panel repair and replacement. Installation Adjustment: Installation of accessories, adjustment of clutch, adjustment of parking brake, alignment procedures. Technical Depth Depth Level: Comprehensive - Covers everything from basic routine maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications. Schematics: Detailed electrical wiring diagrams for all vehicle systems. Torque Specs: Extensive torque specifications for all critical fasteners. Special Tools: Identification and usage of special tools required for specific procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable (if converted from original digital source or OCR'd) Print Quality Resolution: High-resolution images and diagrams suitable for printing. Binding Type Binding: Not Applicable (Digital PDF) Paper Type Paper: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Name: 5.9L Magnum V8 (360 cid) Displacement Liters: 5.9 Displacement Cid: 360 Configuration: V8 Horsepower Hp Est: 235 Torque Lb Ft Est: 330 Fuel System: Multi-point fuel injection (MPI) Block Material: Cast Iron Head Material: Aluminum Valve Train: Overhead Valve (OHV), 2 valves per cylinder Optional Engine 1 Engine Name: 5.7L HEMI V8 (345 cid) Displacement Liters: 5.7 Displacement Cid: 345 Configuration: V8 Horsepower Hp Est: 345 Torque Lb Ft Est: 375 Fuel System: Multi-point fuel injection (MPI) Valve Train: Overhead Valve (OHV), 2 valves per cylinder with HEMI heads Optional Engine 2 Engine Name: 4.7L Magnum V8 (240 cid) Displacement Liters: 4.7 Displacement Cid: 240 Configuration: V8 Horsepower Hp Est: 235 Torque Lb Ft Est: 300 Fuel System: Multi-point fuel injection (MPI) Valve Train: Overhead Valve (OHV), 2 valves per cylinder Diesel Engine Engine Name: 5.9L Cummins Turbo Diesel I6 Displacement Liters: 5.9 Configuration: Inline 6-cylinder Horsepower Hp Est: 305 Torque Lb Ft Est: 555 Fuel System: Direct injection, Bosch VP44 high-pressure injection pump Block Material: Cast Iron Head Material: Cast Iron Valve Train: Overhead Valve (OHV), 2...

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Typ: Truck

Anbieter:

Art.-Nr: 511236

Sammlungen: ALL Dodge

Verfügbarkeit: Auf Lager

Stichworte: 2005 2500 RAM Cars Dodge Misc Truck

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram 2500

Year:

Chassis Code:

DR/DH/DHC

Codes

Engine Code Primary:

360 (5.9L Magnum V8)

Engine Code Optional 1:

5.7L HEMI V8 (1500/2500/3500)

Engine Code Optional 2:

240 (4.7L Magnum V8)

Engine Code Diesel:

505 (5.9L Cummins Turbo Diesel I6)

👋 Introduction

Market Position

Vehicle Segment:

Heavy-duty pickup truck

Target Audience:

Work truck users, fleet owners, towing and hauling enthusiasts, off-road enthusiasts.

Competitive Analysis

Key Competitors:

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

Key Features

Vehicle Strengths:

Legendary Cummins Turbo Diesel engine, robust chassis and suspension, strong towing and payload capacities, user-friendly interior, good value proposition in the heavy-duty segment.

Manual Value Proposition:

Empowers owners and technicians with the detailed information needed to perform accurate diagnostics and repairs, saving time and money, and ensuring the longevity of the vehicle.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Page Count

Estimated Page Count:

Approximately 2000+ pages (typical for factory service manuals of this era)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel system (gasoline and diesel), exhaust system, intake manifold, turbocharger (diesel), intercooler (diesel), emission control systems.

Engine Electrical:

Ignition system, starting system, charging system, engine control module (ECM), sensors (crankshaft position, camshaft position, oxygen, mass air flow, manifold absolute pressure, coolant temperature, etc.), fuel injectors, glow plugs (diesel).

Transmission Manual:

Clutch system, manual transmission (NV3500, NV4500), transfer case (NV241DHD, NV271DHD), shift mechanisms, driveshafts, U-joints.

Transmission Automatic:

Automatic transmission (48RE, NV3500), torque converter, valve body, transmission control module (TCM), shift solenoids, transmission fluid cooling.

Drivetrain:

Front and rear axles, differentials, axle shafts, wheel bearings, locking hubs (if equipped), propeller shafts.

Brakes:

Front and rear brake systems (disc brakes), parking brake, hydraulic system, anti-lock braking system (ABS), brake fluid specifications, master cylinder, brake calipers, brake pads, rotors, brake lines.

Suspension Steering:

Front suspension (leaf springs, shocks, steering knuckles), rear suspension (leaf springs, shocks), steering system (power steering pump, steering gear, tie rods, steering linkage), wheel alignment specifications.

Body Interior:

Body panels, doors, hood, tailgate, bumpers, glass, mirrors, interior trim, seats, dashboard, HVAC system (heating, ventilation, air conditioning), cabin filters.

Electrical Lighting:

Lighting system (headlights, taillights, interior lights), wiring diagrams, fuses, relays, battery, starter, alternator, power windows, power locks, power seats, horn, wipers, washer system.

Chassis Frame:

Frame construction, welding procedures, rustproofing, chassis lubrication points.

Procedures Included

Maintenance:

Oil change, filter replacement (oil, fuel, air), fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid, differential fluid), tire rotation and pressure, lubrication services, spark plug replacement, belt inspection and replacement.

Diagnostics:

Troubleshooting guides for common symptoms (no-start, rough idle, poor performance, brake issues, electrical faults), diagnostic trouble codes (DTCs) interpretation and clearing, use of diagnostic scan tools.

Repair Rebuild:

Engine overhaul, cylinder head gasket replacement, timing belt/chain replacement (if applicable), transmission removal and installation, brake system component replacement, suspension component replacement, steering system repair, electrical component repair and replacement, body panel repair and replacement.

Installation Adjustment:

Installation of accessories, adjustment of clutch, adjustment of parking brake, alignment procedures.

Technical Depth

Depth Level:

Comprehensive - Covers everything from basic routine maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications.

Schematics:

Detailed electrical wiring diagrams for all vehicle systems.

Torque Specs:

Extensive torque specifications for all critical fasteners.

Special Tools:

Identification and usage of special tools required for specific procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable (if converted from original digital source or OCR'd)

Print Quality

Resolution:

High-resolution images and diagrams suitable for printing.

Binding Type

Binding:

Not Applicable (Digital PDF)

Paper Type

Paper:

Not Applicable (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Name:

5.9L Magnum V8 (360 cid)

Displacement Liters:

Displacement Cid:

Configuration:

Horsepower Hp Est:

Torque Lb Ft Est:

Fuel System:

Multi-point fuel injection (MPI)

Block Material:

Cast Iron

Head Material:

Aluminum

Valve Train:

Overhead Valve (OHV), 2 valves per cylinder

Optional Engine 1

Engine Name:

5.7L HEMI V8 (345 cid)

Displacement Liters:

Displacement Cid:

Configuration:

Horsepower Hp Est:

Torque Lb Ft Est:

Fuel System:

Multi-point fuel injection (MPI)

Valve Train:

Overhead Valve (OHV), 2 valves per cylinder with HEMI heads

Optional Engine 2

Engine Name:

4.7L Magnum V8 (240 cid)

Displacement Liters:

Displacement Cid:

Configuration:

Horsepower Hp Est:

Torque Lb Ft Est:

Fuel System:

Multi-point fuel injection (MPI)

Valve Train:

Overhead Valve (OHV), 2 valves per cylinder

Diesel Engine

Engine Name:

5.9L Cummins Turbo Diesel I6

Displacement Liters:

Configuration:

Inline 6-cylinder

Horsepower Hp Est:

Torque Lb Ft Est:

Fuel System:

Direct injection, Bosch VP44 high-pressure injection pump

Block Material:

Cast Iron

Head Material:

Cast Iron

Valve Train:

Overhead Valve (OHV), 2 valves per cylinder

Turbocharger:

Holset HY35W or similar

Intercooler:

Standard

🔧 Transmission

Standard Gas

Type:

5-speed Manual (NV3500)

Gear Ratios Manual:

Refer to manual for specific ratios (varies by application)

Optional Gas 1

Type:

4-speed Automatic (48RE)

Gear Ratios Automatic:

Refer to manual for specific ratios (e.g., 2.45, 1.45, 1.00, 0.69)

Optional Gas 2

Type:

5-speed Manual (NV4500 - Heavy Duty)

Gear Ratios Heavy Duty Manual:

Refer to manual for specific ratios (e.g., 5.61, 3.04, 1.67, 1.00, 0.73)

Optional Diesel

Type:

5-speed Manual (NV4500 - Heavy Duty)

Type Auto:

4-speed Automatic (48RE - often coupled with Cummins)

Features

Transfer Case Options:

NV241DHD (2WD/4WD Part-Time), NV271DHD (2WD/4WD Part-Time, Heavy Duty)

Fluid Specifications

Automatic Transmission Fluid:

ATF+4 (Mopar Material Standard MS-9602)

Manual Transmission Fluid:

Refer to manual (typically SAE 75W-90 GL-5 for NV4500, NV3500 may vary)

Transfer Case Fluid:

Refer to manual (typically ATF+4 or similar for NV241DHD, NV271DHD)

📐 Dimensions

Exterior Cab Styles

Cab Types:

Regular Cab, Quad Cab (Club Cab)

Exterior Bed Styles

Bed Lengths:

6.3 ft (short bed), 8.0 ft (long bed)

Exterior Dimensions

Wheelbase Regular Cab 8Ft:

Approximately 140.5 inches

Wheelbase Quad Cab 6.3Ft:

Approximately 140.5 inches

Wheelbase Regular Cab 6.3Ft:

Approximately 133.2 inches

Overall Length Est:

230-250 inches (varies by cab and bed)

Weights

Curb Weight Est:

5,800 - 7,500 lbs (varies significantly by configuration and engine)

Gross Vehicle Weight Rating Gvwr Est:

8,800 - 9,900 lbs

Max Towing Capacity Est:

Up to 12,500 lbs (with proper configuration and equipment)

Max Payload Capacity Est:

Up to 4,000 lbs (varies by configuration)

🛡️ Safety Features

Ratings

NHTSA Front Impact Est:

Good (varies by specific test results, generally strong for trucks of this era)

NHTSA Side Impact Est:

Good (varies by specific test results)

IIHS Front Offset Est:

Acceptable or Good (varies by specific test results)

Active Features

Standard (Anti-lock Braking System)

Traction Control:

Optional (Electronic Traction Control)

Brake Assist:

Not commonly advertised for this model year, but basic hydraulic assist is standard.

Passive Features

Airbags:

Driver and passenger front airbags.

Seatbelts:

Three-point front seat belts, rear seat belts (in Quad Cab).

Structure:

High-strength steel frame and body structure.

💡 Technology Features

Infotainment

Audio System:

Base AM/FM stereo with CD player. Optional premium Infinity audio system available. SiriusXM satellite radio not typically factory installed but can be added.

Navigation:

No factory navigation system offered for this model year. Aftermarket units are common.

Driver Assistance

Parking Assist:

Rear parking assist sensors were an optional feature on some trims.

Cruise Control:

Standard

Trailer Brake Controller:

Optional integrated trailer brake controller available.

Connectivity

Bluetooth:

Not typically factory-equipped. Aftermarket Bluetooth integration is common.

Usb Ports:

Not factory-equipped.

🔧 Maintenance

Service Intervals

Oil Change Gas:

Every 3,000-5,000 miles or 3-6 months (depending on driving conditions and oil type)

Oil Change Diesel:

Every 7,500-10,000 miles or 6-12 months (depending on driving conditions and oil type - refer to manual)

Engine Air Filter:

Inspect every 6,000-7,500 miles, replace as needed or every 15,000-30,000 miles.

Fuel Filter Gas:

Replace every 30,000-50,000 miles.

Fuel Filter Diesel:

Replace every 15,000-30,000 miles (critical for diesel longevity).

Coolant Flush:

Every 30,000-50,000 miles or 2-3 years.

Transmission Fluid Change Auto:

Every 30,000-50,000 miles (severe service recommendations are more frequent).

Transmission Fluid Change Manual:

Every 50,000-100,000 miles (refer to manual).

Fluid Specifications

Engine Oil Gas 5.9L:

API SN or higher, SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on temperature)

Engine Oil Gas 5.7L Hemi:

API SN or higher, SAE 5W-20 (refer to manual for specific viscosity)

Engine Oil Diesel 5.9L Cummins:

API CI-4 or CH-4, SAE 15W-40 (synthetic recommended for severe service)

Coolant:

Mopar Antifreeze/Coolant (MS-9769) - 50/50 mix with distilled water

Brake Fluid:

DOT 3

Power Steering Fluid:

ATF+4 or Chrysler Power Steering Fluid (MS-5931)

Known Issues

Diesel Vp44 Pump:

The Bosch VP44 injection pump is a known weak point on the 5.9L Cummins, prone to failure if fuel pressure drops. Upgraded lift pumps are recommended.

Automatic Transmission 48Re:

Can benefit from upgraded internal components and improved cooling for heavy towing. Torque converter lock-up can be hesitant.

Suspension Wear:

Leaf springs can sag over time, especially under heavy loads. Ball joints and tie rod ends are common wear items.

Brake Wear:

Front brake pads and rotors can wear relatively quickly due to the vehicle's weight and towing use.

Evap Emissions System:

On gasoline models, the evaporative emissions system (EVAP) can sometimes develop leaks, leading to check engine lights.

📚 Vehicle History

Brand Heritage

Dodge Trucks:

Dodge has a long history of producing robust and capable trucks, with the Ram nameplate becoming synonymous with heavy-duty performance and durability.

Model Evolution

Third Generation Ram:

The 2005 Ram 2500 belongs to the third generation of the Ram trucks (2002-2008), which marked a significant redesign with a bolder, more aggressive styling and improved chassis.

Engine Introductions:

The 5.7L HEMI engine was introduced in 2003, offering a significant power upgrade over previous V8s. The renowned 5.9L Cummins Turbo Diesel continued to be a benchmark in the segment.

Production

Manufacturing Location:

Saltillo, Mexico; Warren, Michigan, USA

🏆 Awards & Recognition

Recognitions

Cummin Diesel Reputation:

The 5.9L Cummins Turbo Diesel engine consistently received accolades for its reliability, durability, and power, making it a highly sought-after powertrain in the heavy-duty truck market.

Truck Of The Year:

While specific awards for the 2005 model year can vary, the Ram line generally performed well in truck comparison tests and often earned praise for its capability.