2005 DODGE RAM 2500 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 2500 Year: 2005 Codes Chassis Code: DR (Third Generation) Vj Code: DR1 👋 Introduction Market Position Product Positioning: Essential diagnostic and repair resource for professionals and serious enthusiasts, mirroring dealership-level technical documentation. Competitive Analysis Differentiation: Provides the depth and detail typically reserved for factory-authorized service centers, far exceeding basic owner's manuals or aftermarket repair guides. Key Features Dealership Quality: Content equivalent to official Chrysler/Dodge factory service manuals. Comprehensive Coverage: Covers all major mechanical, electrical, and body systems for the specified model year and variants. Diagnostic Focus: Emphasis on diagnostic procedures and troubleshooting, empowering technicians to identify and resolve complex issues. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: PDF Page Count Estimated Page Count: 1500+ 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul procedures, component identification, torque specifications, timing procedures, lubrication system. Engine Performance: Fuel delivery, ignition system, emission controls, cooling system, engine diagnostics. Transmission Automatic: Overhaul, diagnostics, fluid specifications, torque converter, shift control, valve body. Transmission Manual: Overhaul, diagnostics, clutch system, driveline components. Brakes: Front and rear brake systems (disc and drum), ABS, parking brake, hydraulic components, bleeding procedures. Steering: Power steering system, steering gear, tie rods, linkages, steering column. Suspension: Front and rear suspension components (leaf springs, shocks, control arms), alignment specifications. Electrical System: Battery, charging system, starting system, lighting, accessories, body control module (BCM), fuse box diagrams. Electronics: ECU/PCM diagnostics, sensor identification and testing, powertrain control modules (PCM). Heating Ventilation Air Conditioning HVAC: Component testing, refrigerant handling, system diagnostics, blower motor, evaporator, condenser. Body And Frame: Body panel removal/installation, interior trim, door mechanisms, glass, chassis frame. Body Electrical: Power windows, door locks, mirrors, seats, alarm system, remote keyless entry. Procedures Included Scheduled Maintenance: Detailed maintenance schedules, fluid changes, filter replacements, inspections. Troubleshooting: Systematic diagnostic procedures, symptom-based troubleshooting guides, fault code interpretation. Component Replacement: Step-by-step instructions for replacing virtually all mechanical and electrical components. Engine Rebuild: Complete engine overhaul instructions, including disassembly, inspection, machining, and reassembly. Transmission Rebuild: Detailed rebuild procedures for both automatic and manual transmissions. Brake System Repair: Brake pad replacement, rotor service, caliper rebuilding, brake line replacement, ABS bleeding. Suspension Alignment: Front and rear wheel alignment procedures and specifications. Diagnostics: Extensive diagnostic flowcharts and procedures for all major systems. Technical Depth Depth Of Coverage: Comprehensive from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics and electrical troubleshooting. Target Audience: Professional Technicians, Dealership Service Departments, Advanced DIY Mechanics. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Fully searchable text for quick information retrieval. Printability: Printable pages for on-site reference. Resolution: High-resolution for clear diagrams and text. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Option 1: 8.3L V10 SOHC Triton (Viper-derived) Engine Option 1 Displacement: 8277 cc Engine Option 1 Horsepower: 500 hp @ 5600 rpm Engine Option 1 Torque: 525 lb-ft @ 4200 rpm Engine Option 2 Engine Option 2: 5.7L V8 OHV HEMI Engine Option 2 Displacement: 5654 cc Engine Option 2 Horsepower: 345 hp @ 5400 rpm Engine Option 2 Torque: 375 lb-ft @ 4000 rpm Engine Option 3 Engine Option 3: 5.9L L6 OHV Cummins Turbo Diesel Engine Option 3 Displacement: 5899 cc Engine Option 3 Horsepower: 325 hp @ 2800 rpm Engine Option 3 Torque: 610 lb-ft @ 1600 rpm Fuel System Fuel Delivery Gas: Multi-point Fuel Injection (MPI) for V10 and HEMI. Fuel Delivery Diesel: High-pressure Common Rail Fuel Injection (HPCR) for Cummins. 🔧 Transmission Standard Standard Transmission: 6-speed manual (NV5600 for V10 and Cummins, Getrag G360 for early models), 4-speed automatic (48RE for V10 and Cummins, 45RFE/545RFE for HEMI). Optional Optional Transmission: 5-speed automatic (545RFE) for HEMI. Features Transmission Fluid Gas Auto: ATF+4 (Chrysler Specification) Transmission Fluid Diesel Auto: ATF+4 (Chrysler Specification) Transmission Fluid Manual: Manual Transmission Fluid (e.g., Mopar GL-4 or equivalent, specific to transmission model) Transfer Case: 2-speed transfer case (New Process NP271D for manual, NP273D for manual with PTO, NV273 for automatic) with optional Power Take-Off (PTO) provision on some models. 📐 Dimensions Exterior Wheelbase Regular Cab: 134.5 inches (3416 mm) Wheelbase Crew Cab: 148.5 inches (3772 mm) Wheelbase Mega Cab: 160.5 inches (4077 mm) Overall Length Crew Cab: 236.4 inches (5990 mm) Weights Gvwr Gas: 8,800 lbs to 9,500 lbs (3992 kg to 4309 kg), depending on configuration. Gvwr Diesel: 9,200 lbs to 9,900 lbs (4173 kg to 4491 kg), depending on configuration. Curb Weight Gas: approx. 6,000-7,000 lbs (2722-3175 kg) Curb Weight Diesel: approx. 6,500-7,500 lbs (2948-3402 kg) Towing Capacity: Up to 12,750 lbs (5783 kg) for properly equipped models (e.g., 5.9L Cummins, 4.10 axle ratio, 3.73 axle ratio). Payload Capacity: Up to 4,000 lbs (1814 kg), depending on configuration. 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Good NHTSA...

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Typ: Truck

Anbieter:

Art.-Nr: 395395

Sammlungen: ALL Dodge

Verfügbarkeit: Auf Lager

Stichworte: 2005 Cars Dodge Misc RAM 2500 Truck

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram 2500

Year:

Codes

Chassis Code:

DR (Third Generation)

Vj Code:

👋 Introduction

Market Position

Product Positioning:

Essential diagnostic and repair resource for professionals and serious enthusiasts, mirroring dealership-level technical documentation.

Competitive Analysis

Differentiation:

Provides the depth and detail typically reserved for factory-authorized service centers, far exceeding basic owner's manuals or aftermarket repair guides.

Key Features

Dealership Quality:

Content equivalent to official Chrysler/Dodge factory service manuals.

Comprehensive Coverage:

Covers all major mechanical, electrical, and body systems for the specified model year and variants.

Diagnostic Focus:

Emphasis on diagnostic procedures and troubleshooting, empowering technicians to identify and resolve complex issues.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Page Count

Estimated Page Count:

1500+

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul procedures, component identification, torque specifications, timing procedures, lubrication system.

Engine Performance:

Fuel delivery, ignition system, emission controls, cooling system, engine diagnostics.

Transmission Automatic:

Overhaul, diagnostics, fluid specifications, torque converter, shift control, valve body.

Transmission Manual:

Overhaul, diagnostics, clutch system, driveline components.

Brakes:

Front and rear brake systems (disc and drum), ABS, parking brake, hydraulic components, bleeding procedures.

Steering:

Power steering system, steering gear, tie rods, linkages, steering column.

Suspension:

Front and rear suspension components (leaf springs, shocks, control arms), alignment specifications.

Electrical System:

Battery, charging system, starting system, lighting, accessories, body control module (BCM), fuse box diagrams.

Electronics:

ECU/PCM diagnostics, sensor identification and testing, powertrain control modules (PCM).

Heating Ventilation Air Conditioning HVAC:

Component testing, refrigerant handling, system diagnostics, blower motor, evaporator, condenser.

Body And Frame:

Body panel removal/installation, interior trim, door mechanisms, glass, chassis frame.

Body Electrical:

Power windows, door locks, mirrors, seats, alarm system, remote keyless entry.

Procedures Included

Scheduled Maintenance:

Detailed maintenance schedules, fluid changes, filter replacements, inspections.

Troubleshooting:

Systematic diagnostic procedures, symptom-based troubleshooting guides, fault code interpretation.

Component Replacement:

Step-by-step instructions for replacing virtually all mechanical and electrical components.

Engine Rebuild:

Complete engine overhaul instructions, including disassembly, inspection, machining, and reassembly.

Transmission Rebuild:

Detailed rebuild procedures for both automatic and manual transmissions.

Brake System Repair:

Brake pad replacement, rotor service, caliper rebuilding, brake line replacement, ABS bleeding.

Suspension Alignment:

Front and rear wheel alignment procedures and specifications.

Diagnostics:

Extensive diagnostic flowcharts and procedures for all major systems.

Technical Depth

Depth Of Coverage:

Comprehensive from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics and electrical troubleshooting.

Target Audience:

Professional Technicians, Dealership Service Departments, Advanced DIY Mechanics.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Fully searchable text for quick information retrieval.

Printability:

Printable pages for on-site reference.

Resolution:

High-resolution for clear diagrams and text.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Option 1:

8.3L V10 SOHC Triton (Viper-derived)

Engine Option 1 Displacement:

8277 cc

Engine Option 1 Horsepower:

500 hp @ 5600 rpm

Engine Option 1 Torque:

525 lb-ft @ 4200 rpm

Engine Option 2

Engine Option 2:

5.7L V8 OHV HEMI

Engine Option 2 Displacement:

5654 cc

Engine Option 2 Horsepower:

345 hp @ 5400 rpm

Engine Option 2 Torque:

375 lb-ft @ 4000 rpm

Engine Option 3

Engine Option 3:

5.9L L6 OHV Cummins Turbo Diesel

Engine Option 3 Displacement:

5899 cc

Engine Option 3 Horsepower:

325 hp @ 2800 rpm

Engine Option 3 Torque:

610 lb-ft @ 1600 rpm

Fuel System

Fuel Delivery Gas:

Multi-point Fuel Injection (MPI) for V10 and HEMI.

Fuel Delivery Diesel:

High-pressure Common Rail Fuel Injection (HPCR) for Cummins.

🔧 Transmission

Standard

Standard Transmission:

6-speed manual (NV5600 for V10 and Cummins, Getrag G360 for early models), 4-speed automatic (48RE for V10 and Cummins, 45RFE/545RFE for HEMI).

Optional

Optional Transmission:

5-speed automatic (545RFE) for HEMI.

Features

Transmission Fluid Gas Auto:

ATF+4 (Chrysler Specification)

Transmission Fluid Diesel Auto:

ATF+4 (Chrysler Specification)

Transmission Fluid Manual:

Manual Transmission Fluid (e.g., Mopar GL-4 or equivalent, specific to transmission model)

Transfer Case:

2-speed transfer case (New Process NP271D for manual, NP273D for manual with PTO, NV273 for automatic) with optional Power Take-Off (PTO) provision on some models.

📐 Dimensions

Exterior

Wheelbase Regular Cab:

134.5 inches (3416 mm)

Wheelbase Crew Cab:

148.5 inches (3772 mm)

Wheelbase Mega Cab:

160.5 inches (4077 mm)

Overall Length Crew Cab:

236.4 inches (5990 mm)

Weights

Gvwr Gas:

8,800 lbs to 9,500 lbs (3992 kg to 4309 kg), depending on configuration.

Gvwr Diesel:

9,200 lbs to 9,900 lbs (4173 kg to 4491 kg), depending on configuration.

Curb Weight Gas:

approx. 6,000-7,000 lbs (2722-3175 kg)

Curb Weight Diesel:

approx. 6,500-7,500 lbs (2948-3402 kg)

Towing Capacity:

Up to 12,750 lbs (5783 kg) for properly equipped models (e.g., 5.9L Cummins, 4.10 axle ratio, 3.73 axle ratio).

Payload Capacity:

Up to 4,000 lbs (1814 kg), depending on configuration.

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

NHTSA Front Impact Passenger:

NHTSA Side Impact Front Driver:

NHTSA Side Impact Front Passenger:

NHTSA Rollover Resistance:

3-star (approx. 20-25% chance of rollover)

Active Features

Standard Anti-lock Braking System (ABS) on all wheels.

Traction Control:

Optional Electronic Stability Control (ESC) and Traction Control on some models/trims.

Passive Features

Airbags Front:

Driver and passenger front airbags.

Seatbelts:

Three-point seatbelts with pretensioners.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional Infinity audio system, SiriusXM Satellite Radio (early versions may require activation).

Navigation:

Optional factory navigation system available on higher trim levels.

Driver Assistance

Cruise Control:

Standard cruise control.

Parking Assist:

Optional rear parking assist sensors on some models.

Connectivity

Power Outlets:

12V auxiliary power outlets.

🔧 Maintenance

Service Intervals

Oil Change Gas:

Every 3,000-5,000 miles (4,800-8,000 km) or 6 months (severe service may require more frequent changes).

Oil Change Diesel:

Every 7,500-10,000 miles (12,000-16,000 km) or 6-12 months (depending on usage and oil type).

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Fuel Filter Replacement Diesel:

Every 15,000-30,000 miles (24,000-48,000 km) depending on diesel quality and operating conditions.

Coolant Flush:

Every 30,000-50,000 miles (48,000-80,000 km) or 3-5 years.

Fluid Specifications

Engine Oil Spec Gas:

SAE 5W-20 or 5W-30 (depending on engine and ambient temperature) meeting API SP or ILSAC GF-6 standards.

Engine Oil Spec Diesel:

SAE 15W-40 Heavy Duty Diesel Engine Oil meeting API CK-4 or CJ-4 standards.

Coolant Type:

Mopar OAT (Organic Additive Technology) 5/150 Antifreeze/Coolant (or equivalent approved coolant, typically orange).

Known Issues

Cummins Injector Issues:

Potential for injector failures or injector line issues, especially at higher mileage or with poor fuel quality.

Hemi Oil Consumption:

Some 5.7L HEMI engines may exhibit oil consumption; piston ring design and PCV system are key areas for diagnosis.

V10 Lifter Noise:

Possible lifter noise or ticking due to oil pressure or lifter wear.

Transmission Hard Shifts:

Automatic transmissions (especially 48RE) may develop hard shifting or delayed engagement, often related to solenoid issues or fluid condition.

Rear Main Seal Leaks:

Common on higher mileage trucks, particularly diesels, with rear main seal leaks.

Brake Wear:

Front brake pads and rotors can wear relatively quickly due to the truck's weight and braking demands.

📚 Vehicle History

Brand Heritage

Dodge Truck Legacy:

Dodge has a long-standing reputation for building robust and capable trucks, with the Ram nameplate evolving into a distinct brand known for its heavy-duty capabilities.

Model Evolution

Third Generation Ram:

The 2005 Ram 2500 is part of the third generation (2002-2008), which introduced a completely redesigned exterior and interior, improved powertrains, and significant chassis enhancements.

Mega Cab Introduction:

The 2005 model year saw the introduction of the Mega Cab, offering extended rear-seat legroom and a larger cabin.

Engine Updates:

The 5.7L HEMI engine was introduced in 2003, and the 8.3L V10 arrived in 2004, while the 5.9L Cummins received a significant power upgrade for 2004.5 onwards.

Production

Manufacturing Plant:

Saltillo Truck Assembly Plant, Mexico; Warren Truck Assembly Plant, Michigan, USA.

🏆 Awards & Recognition

Recognitions

Motor Trend Truck Of The Year:

While the 2005 model year itself may not have a specific 'Truck of the Year' award for this exact configuration, the Ram platform consistently received accolades for its design and capability in preceding and subsequent years.

Cummins Engine Reputation:

The 5.9L Cummins Turbo Diesel engine has a legendary reputation for durability and performance in the heavy-duty truck segment.