2001-2006 Dodge Ram Pickup Truck 1500/2500/3500 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Pickup 1500/2500/3500 Model Years Covered: 2001, 2002, 2003, 2004, 2005, 2006 Codes Chassis Code: DR/DH/DHK (Third Generation Ram) Platform: Chrysler VB Platform 👋 Introduction Market Position Market Position: Heavy-duty pickup truck designed for towing, hauling, and demanding work applications. Competed directly with Ford Super Duty and Chevrolet Silverado HD. Competitive Analysis Key Competitors: Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD Key Features Design Philosophy: Robust construction, powerful engine options (especially the Cummins diesel), impressive towing and payload capacities, commanding road presence. Distinguishing Features: Iconic crosshair grille, large interior dimensions, widely available and highly regarded Cummins Turbo Diesel engine. 📋 Manual Details Coverage Areas Engine Coverage: 5.9L Magnum V8 (2001-2003), 5.7L HEMI V8 (2003-2006), 5.9L Cummins Turbo Diesel I6 (2003-2006), 8.0L Magnum V10 (2001-2003) Transmission Coverage: 4-Speed Automatic (42RE, 48RE), 5-Speed Manual (NV4500, G56) Drivetrain Coverage: 2WD, 4WD, Various Transfer Cases (NV243, NV244, NV271D, NV273D) Model Variant Coverage: 1500, 2500, 3500 (including Cab & Chassis variants) Body Style Coverage: Regular Cab, Extended Cab (Club Cab), Crew Cab Page Count Estimated Page Count: Approx. 2000+ pages (combined across multiple years) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: Digital Download (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, valve train, timing components, cooling system, lubrication system Fuel System: Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, fuel lines, evaporative emission control (EVAP) Exhaust System: Exhaust manifolds, catalytic converter, mufflers, pipes, emissions control components Transmission And Drivetrain: Automatic transmission (disassembly, assembly, torque converter), Manual transmission (disassembly, assembly), Transfer case (2WD/4WD operation, servicing), Drive shafts, U-joints, Differentials (front and rear), Axles Brakes: Hydraulic system, master cylinder, brake booster, front disc brakes (calipers, rotors, pads), rear drum/disc brakes (depending on model), parking brake, ABS (Anti-lock Braking System), brake fluid specifications Suspension: Front suspension (independent), rear suspension (solid axle, leaf springs), shock absorbers, struts, ball joints, tie rod ends, control arms, sway bars Steering: Power steering system, steering gear, steering column, intermediate shaft, tie rods Electrical System: Battery, charging system (alternator), starting system (starter motor), ignition system, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module (BCM), engine control module (ECM) HVAC: Air conditioning system, heater core, blower motor, climate controls, refrigerant, service procedures Body And Chassis: Frame, body panels, doors, hood, tailgate, bumpers, interior trim, glass, mirrors Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad/shoe replacement, tire rotation Diagnostic Procedures: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) and their meanings, component testing procedures Repair Procedures: Engine overhaul, transmission repair/rebuild, brake system bleeding, suspension component replacement, steering system repair, electrical component diagnosis and replacement Installation Procedures: Component installation, accessory installation where applicable Torque Specifications: Essential torque values for critical fasteners (cylinder heads, main bearings, wheel nuts, etc.) Technical Depth Technical Depth: Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic strategies and repair sequences. Includes factory-level technical data. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Likely searchable text, allowing for quick information retrieval Print Quality Print Quality: High resolution, suitable for printing individual pages or sections Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine 5.7L Hemi V8: {'displacement': '5.7 Liters (345 cu in)', 'configuration': 'V8', 'fuel_type': 'Gasoline', 'horsepower': '345-353 hp @ 5200-5400 rpm (model year dependent)', 'torque': '375-395 lb-ft @ 3200-4000 rpm (model year dependent)', 'valvetrain': 'Overhead Valve (OHV), 2 valves per cylinder, Pushrod Actuated'} 5.9L Cummins Turbo Diesel I6: {'displacement': '5.9 Liters (359 cu in)', 'configuration': 'Inline 6-Cylinder', 'fuel_type': 'Diesel', 'horsepower': '250-325 hp @ 2800-3000 rpm (model year and application dependent)', 'torque': '475-610 lb-ft @ 1600-1800 rpm (model year and application dependent)', 'valvetrain': 'Overhead Valve (OHV), 4 valves per cylinder, Pushrod Actuated', 'fuel_system': 'Common Rail Fuel Injection (starting 2003 model year)'} Optional Engine Gas 8.0L Magnum V10: {'displacement': '8.0 Liters (488 cu in)', 'configuration': 'V10', 'fuel_type': 'Gasoline', 'horsepower': '305-310 hp @ 4200-4800 rpm', 'torque': '450-470 lb-ft @ 2400-3200 rpm', 'valvetrain': 'Overhead Valve (OHV), 2 valves per cylinder, Pushrod Actuated'} 5.9L Magnum V8: {'displacement': '5.9 Liters (360 cu in)', 'configuration': 'V8', 'fuel_type': 'Gasoline', 'horsepower': '245-250 hp @ 4400-4600 rpm', 'torque': '345-350 lb-ft @ 3200-3600 rpm', 'valvetrain': 'Overhead Valve (OHV), 2 valves per cylinder, Pushrod Actuated'} Fuel System Fuel Delivery Gasoline: Multi-point fuel injection (MPI) Fuel Delivery Diesel: High-pressure common rail (HPCR) for 2003+ models, Bosch VP44 rotary injection pump for 2001-2002 models. 🔧 Transmission Standard Transmission Type: 4-Speed Automatic (48RE Heavy Duty) Optional Transmission Type: 5-Speed Manual (NV4500/G56 for Diesel/V10 models) Features Automatic Transmission Features: Electronically controlled, overdrive, torque converter lock-up Manual Transmission Features: Heavy-duty construction, dual-mass flywheel (NV4500) Fluid Specifications...

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Anbieter:

Art.-Nr: 329817

Sammlungen: ALL Dodge

Verfügbarkeit: Auf Lager

Stichworte: 2001 2002 2003 2004 2005 2006 Cars Dodge Misc Ram Pickup Truck 1500 Ram Pickup Truck 2500 Ram Pickup Truck 3500 Truck

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram Pickup 1500/2500/3500

Model Years Covered:

2001, 2002, 2003, 2004, 2005, 2006

Codes

Chassis Code:

DR/DH/DHK (Third Generation Ram)

Platform:

Chrysler VB Platform

👋 Introduction

Market Position

Market Position:

Heavy-duty pickup truck designed for towing, hauling, and demanding work applications. Competed directly with Ford Super Duty and Chevrolet Silverado HD.

Competitive Analysis

Key Competitors:

Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD

Key Features

Design Philosophy:

Robust construction, powerful engine options (especially the Cummins diesel), impressive towing and payload capacities, commanding road presence.

Distinguishing Features:

Iconic crosshair grille, large interior dimensions, widely available and highly regarded Cummins Turbo Diesel engine.

📋 Manual Details

Coverage Areas

Engine Coverage:

5.9L Magnum V8 (2001-2003), 5.7L HEMI V8 (2003-2006), 5.9L Cummins Turbo Diesel I6 (2003-2006), 8.0L Magnum V10 (2001-2003)

Transmission Coverage:

4-Speed Automatic (42RE, 48RE), 5-Speed Manual (NV4500, G56)

Drivetrain Coverage:

2WD, 4WD, Various Transfer Cases (NV243, NV244, NV271D, NV273D)

Model Variant Coverage:

1500, 2500, 3500 (including Cab & Chassis variants)

Body Style Coverage:

Regular Cab, Extended Cab (Club Cab), Crew Cab

Page Count

Estimated Page Count:

Approx. 2000+ pages (combined across multiple years)

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

Digital Download (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, valve train, timing components, cooling system, lubrication system

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, fuel lines, evaporative emission control (EVAP)

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, emissions control components

Transmission And Drivetrain:

Automatic transmission (disassembly, assembly, torque converter), Manual transmission (disassembly, assembly), Transfer case (2WD/4WD operation, servicing), Drive shafts, U-joints, Differentials (front and rear), Axles

Brakes:

Hydraulic system, master cylinder, brake booster, front disc brakes (calipers, rotors, pads), rear drum/disc brakes (depending on model), parking brake, ABS (Anti-lock Braking System), brake fluid specifications

Suspension:

Front suspension (independent), rear suspension (solid axle, leaf springs), shock absorbers, struts, ball joints, tie rod ends, control arms, sway bars

Steering:

Power steering system, steering gear, steering column, intermediate shaft, tie rods

Electrical System:

Battery, charging system (alternator), starting system (starter motor), ignition system, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module (BCM), engine control module (ECM)

HVAC:

Air conditioning system, heater core, blower motor, climate controls, refrigerant, service procedures

Body And Chassis:

Frame, body panels, doors, hood, tailgate, bumpers, interior trim, glass, mirrors

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad/shoe replacement, tire rotation

Diagnostic Procedures:

Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) and their meanings, component testing procedures

Repair Procedures:

Engine overhaul, transmission repair/rebuild, brake system bleeding, suspension component replacement, steering system repair, electrical component diagnosis and replacement

Installation Procedures:

Component installation, accessory installation where applicable

Torque Specifications:

Essential torque values for critical fasteners (cylinder heads, main bearings, wheel nuts, etc.)

Technical Depth

Technical Depth:

Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic strategies and repair sequences. Includes factory-level technical data.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Searchability:

Likely searchable text, allowing for quick information retrieval

Print Quality

Print Quality:

High resolution, suitable for printing individual pages or sections

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

5.7L Hemi V8:

{'displacement': '5.7 Liters (345 cu in)', 'configuration': 'V8', 'fuel_type': 'Gasoline', 'horsepower': '345-353 hp @ 5200-5400 rpm (model year dependent)', 'torque': '375-395 lb-ft @ 3200-4000 rpm (model year dependent)', 'valvetrain': 'Overhead Valve (OHV), 2 valves per cylinder, Pushrod Actuated'}

5.9L Cummins Turbo Diesel I6:

{'displacement': '5.9 Liters (359 cu in)', 'configuration': 'Inline 6-Cylinder', 'fuel_type': 'Diesel', 'horsepower': '250-325 hp @ 2800-3000 rpm (model year and application dependent)', 'torque': '475-610 lb-ft @ 1600-1800 rpm (model year and application dependent)', 'valvetrain': 'Overhead Valve (OHV), 4 valves per cylinder, Pushrod Actuated', 'fuel_system': 'Common Rail Fuel Injection (starting 2003 model year)'}

Optional Engine Gas

8.0L Magnum V10:

{'displacement': '8.0 Liters (488 cu in)', 'configuration': 'V10', 'fuel_type': 'Gasoline', 'horsepower': '305-310 hp @ 4200-4800 rpm', 'torque': '450-470 lb-ft @ 2400-3200 rpm', 'valvetrain': 'Overhead Valve (OHV), 2 valves per cylinder, Pushrod Actuated'}

5.9L Magnum V8:

{'displacement': '5.9 Liters (360 cu in)', 'configuration': 'V8', 'fuel_type': 'Gasoline', 'horsepower': '245-250 hp @ 4400-4600 rpm', 'torque': '345-350 lb-ft @ 3200-3600 rpm', 'valvetrain': 'Overhead Valve (OHV), 2 valves per cylinder, Pushrod Actuated'}

Fuel System

Fuel Delivery Gasoline:

Multi-point fuel injection (MPI)

Fuel Delivery Diesel:

High-pressure common rail (HPCR) for 2003+ models, Bosch VP44 rotary injection pump for 2001-2002 models.

🔧 Transmission

Standard

Transmission Type:

4-Speed Automatic (48RE Heavy Duty)

Optional

Transmission Type:

5-Speed Manual (NV4500/G56 for Diesel/V10 models)

Features

Automatic Transmission Features:

Electronically controlled, overdrive, torque converter lock-up

Manual Transmission Features:

Heavy-duty construction, dual-mass flywheel (NV4500)

Fluid Specifications

Automatic Transmission Fluid:

ATF+4 (Chrysler Material Standard MS-9602)

Manual Transmission Fluid:

GL-3 or GL-4 gear oil (specific viscosity depends on application and temperature)

📐 Dimensions

Exterior

Wheelbase Options:

130.5" (Regular Cab), 140.5" (Quad/Crew Cab), 154.5" (Mega Cab), 134.0" (Long Bed Regular Cab), 157.0" (Long Bed Extended Cab), 171.0" (Long Bed Crew Cab)

Overall Length Range:

Approx. 230" to 265" (depending on configuration)

Overall Width:

Approx. 79.9" (excluding mirrors)

Overall Height:

Approx. 74.7" to 78.2" (depending on configuration and suspension)

Weights

Curb Weight Range:

Approx. 4,500 lbs to 6,500+ lbs (depending on configuration and powertrain)

Gvwr Range:

Approx. 6,000 lbs (1500) to 11,500 lbs (3500)

Max Towing Capacity:

Up to 13,000+ lbs (depending on configuration, engine, and axle ratio)

Max Payload Capacity:

Up to 5,000+ lbs (depending on configuration and model)

Cargo

Bed Length Options:

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

Cargo Volume Bed:

Approx. 50-60 cu ft (depending on bed length)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

Likely 3/5 Stars for 2WD and 4WD models (typical for tall trucks of this era)

Active Features

Standard Anti-lock Braking System

Traction Control:

Optional traction control system, particularly on higher trims and 4WD models

Passive Features

Airbags:

Driver and passenger front airbags

Seatbelts:

Three-point seatbelts with pretensioners

Child Seat Anchors:

LATCH system (Lower Anchors and Tethers for Children) available on certain models/trims

💡 Technology Features

Infotainment

Infotainment System:

Base AM/FM radio with CD player. Optional premium audio systems, satellite radio (SiriusXM), and navigation systems available on higher trims.

Driver Assistance

Driver Assistance Features:

Limited by modern standards. Primarily focused on basic safety features. Cruise control standard on most models.

Connectivity

Connectivity Options:

Auxiliary input jacks available on some later models. No USB or Bluetooth connectivity as standard.

🔧 Maintenance

Service Intervals

Oil Change Interval:

7,500 miles or 6 months (for gasoline engines), 15,000 miles or 12 months (for Cummins Diesel engines, with appropriate oil)

Air Filter Replacement:

Check every 15,000 miles, replace as needed or every 30,000 miles

Coolant Flush:

Every 60,000 miles or 5 years (for extended life coolant)

Transmission Fluid Change:

Every 60,000-100,000 miles (depending on usage and fluid type)

Fluid Specifications

Engine Oil Gasoline:

SAE 5W-30, API SN/SM/SL rated. Check manual for specific viscosity at temperature extremes. (e.g., 5.7L HEMI capacity ~7 quarts)

Engine Oil Diesel:

CJ-4 or CK-4 rated diesel engine oil, SAE 15W-40 or 5W-40 depending on climate. (e.g., 5.9L Cummins capacity ~11 quarts)

Coolant:

Chrysler HOAT (Hybrid Organic Additive Technology) antifreeze, 50/50 mix with distilled water. Mopar Part Number 05136031AA (or equivalent)

Brake Fluid:

DOT 3 or DOT 4 brake fluid

Known Issues

Common Issues Gasoline:

Lifter noise (HEMI), intake manifold gasket leaks, throttle body issues, cracked exhaust manifolds (especially on V10).

Common Issues Diesel:

VP44 injection pump failures (2001-2002 models due to insufficient fuel pressure), cracked cylinder heads (early models under heavy load), HVAC blower motor failures, transmission cooler issues.

Common Issues General:

Rust on body panels (especially rear wheel wells and cab corners), HVAC blend door failures, ball joint wear, U-joint wear.

📚 Vehicle History

Brand Heritage

Dodge Truck Heritage:

Dodge has a long history of producing robust and capable trucks, often positioned as workhorses.

Model Evolution

Third Generation Ram:

Launched in 1994, the third generation (DR/DH/DHK) brought a significantly redesigned exterior and interior, new powertrains (including the introduction of the HEMI and common-rail Cummins), and improved chassis for enhanced capability and comfort.

Production

Production Plant:

Warren Truck Assembly Plant, Warren, Michigan, U.S.A.

Sales Context:

This generation was a strong seller for Dodge, particularly popular for its Cummins diesel engine among commercial users and diesel enthusiasts.

🏆 Awards & Recognition

Recognitions

Awards:

The 5.9L Cummins Turbo Diesel engine consistently received accolades for its power, reliability, and durability, making the Ram 2500/3500 a popular choice for truck enthusiasts and commercial users. Frequently lauded as one of the best diesel engines of its era.