Dodge Ram 1999-2006 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Generation: Third Generation (DR/DH/D2) Codes Chassis Codes: DR, DH, D2 Model Years: 1999-2006 👋 Introduction Market Position Segment: Full-size pickup truck Target Audience: DIY mechanics, independent repair shops, fleet maintenance personnel, serious enthusiasts. Competitive Analysis Key Competitors: Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra. Key Features Vehicle Strengths: Robust chassis, strong towing and hauling capabilities, wide range of engine options, comfortable ride for a pickup. Manual Value Proposition: Provides essential, factory-level information to accurately diagnose, maintain, and repair the vehicle, saving significant costs compared to dealership service. 📋 Manual Details Coverage Areas Primary Coverage: North America Region Specific Variants: Covers models sold in the US, Canada, and Mexico, potentially including minor regional differences. Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures, component testing, diagnostic charts for all engines. Engine Performance: Fuel injection system, ignition system, emissions control systems, turbocharger (if applicable). Transmission Manual: Repair, overhaul, and troubleshooting of manual transmissions (NV3500, NV4500). Transmission Automatic: Repair, overhaul, and troubleshooting of automatic transmissions (42RE, 44RE, 45RFE, 48RE). Drivetrain: Transfer case (NV241HD, NV271D, NV273D), front and rear axles, drive shafts, differentials. Suspension: Front and rear suspension systems, steering system, wheel alignment specifications. Brakes: Front and rear brake systems (disc/drum, disc/disc), ABS, hydraulic system, parking brake. Electrical System: Complete wiring diagrams, component testing, diagnostic procedures for all electrical circuits. Body And Frame: Body panel repair, interior trim removal, chassis structural information, door and window mechanisms. HVAC: Heating, ventilation, and air conditioning system diagnosis and repair. Safety Systems: Airbag system diagnosis and repair, seat belt mechanisms. Procedures Included Preventive Maintenance: Detailed service intervals for oil changes, filter replacements, fluid checks, and component inspections. Diagnostic Troubleshooting: Flowcharts, symptom-based troubleshooting guides, and specific diagnostic procedures for common and complex issues. Repair And Rebuild: Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation. Technical Specifications Data: Torque specifications, clearances, fluid capacities, electrical resistance values, and other critical data. Wiring Diagrams: Comprehensive and detailed wiring schematics for all vehicle systems. Special Tools: Identification and usage instructions for specialized tools required for specific repairs. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds and complex electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text within the PDF for quick access to information. Print Quality Quality: High-resolution digital reproduction, ensuring clarity of text and illustrations. Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine 1 Type: 3.7L Magnum V6 Engine 1 Displacement: 3701 cc (225 cu in) Engine 1 Bore X Stroke: 3.91 x 3.12 in (99.3 x 79.4 mm) Engine 1 Compression Ratio: 9.1:1 Engine 1 Power Hp: 215 hp @ 5200 rpm (approx.) Engine 1 Torque Lb-Ft: 245 lb-ft @ 3200 rpm (approx.) Secondary Engine Engine 2 Type: 4.7L Magnum V8 (2V and 4V variants) Engine 2 Displacement: 4701 cc (287 cu in) Engine 2 Bore X Stroke: 3.88 x 3.13 in (98.5 x 79.5 mm) Engine 2 Compression Ratio: 8.9:1 (2V), 9.0:1 (4V) Engine 2 Power Hp: 235-245 hp @ 4800-5200 rpm (approx.) Engine 2 Torque Lb-Ft: 295-325 lb-ft @ 3200-3600 rpm (approx.) Tertiary Engine Engine 3 Type: 5.9L Magnum V8 (Cummins Turbo Diesel - '2500' and '3500' models) Engine 3 Displacement: 5899 cc (359 cu in) Engine 3 Bore X Stroke: 4.02 x 4.72 in (102 x 120 mm) Engine 3 Compression Ratio: 21.2:1 Engine 3 Power Hp: 235-250 hp @ 2500-2800 rpm (approx., depending on year/tuning) Engine 3 Torque Lb-Ft: 460-525 lb-ft @ 1400-1600 rpm (approx., depending on year/tuning) Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) for Magnum gasoline engines. Bosch VP44 Injection Pump for Cummins Diesel. Fuel Type: Unleaded Gasoline (87 octane recommended for V6/V8), Diesel Fuel (ULSD for Cummins). Ignition System: Distributorless Ignition System (DIS) with coil-on-plug or coil-near-plug technology for gasoline engines. Electronic control unit (ECU) manages ignition timing. 🔧 Transmission Standard Standard Transmission Light Duty: 5-speed manual (NV3500) Standard Transmission Heavy Duty: 5-speed manual (NV4500) on some 2500/3500 models Optional Optional Transmission Light Duty: 4-speed automatic (42RE, 44RE) Optional Transmission Heavy Duty: 4-speed automatic (45RFE, 48RE) on some V8 and diesel models Features Overdrive Gears: All automatic transmissions feature overdrive (4th gear). Transfer Case Options: Part-time 2-speed transfer cases (NV241HD, NV271D, NV273D) with manual or electronic shifting options. Fluid Specifications Automatic Transmission Fluid: ATF+4 (Mopar Spec. MS-9602) or equivalent for 45RFE/48RE. ATF+3 (Mopar Spec. MS-9224) for 42RE/44RE. Manual Transmission Fluid: API GL-3 or GL-4 Gear Oil, SAE 75W-90 or 75W-140 depending on application. Transfer Case Fluid: NV241HD: ATF+3. NV271D/273D: ATF+4 or appropriate Mopar spec. 📐 Dimensions Exterior Wheelbase Regular Cab: 134.9 inches (3426 mm) Wheelbase Quad Cab:...

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Art.-Nr: 400001

Sammlungen: ALL Dodge

Verfügbarkeit: Auf Lager

Stichworte: 1999 2000 2001 2002 2003 2004 2005 2006 Cars Dodge Misc Ram Truck

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Generation:

Third Generation (DR/DH/D2)

Codes

Chassis Codes:

DR, DH, D2

Model Years:

1999-2006

👋 Introduction

Market Position

Segment:

Full-size pickup truck

Target Audience:

DIY mechanics, independent repair shops, fleet maintenance personnel, serious enthusiasts.

Competitive Analysis

Key Competitors:

Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra.

Key Features

Vehicle Strengths:

Robust chassis, strong towing and hauling capabilities, wide range of engine options, comfortable ride for a pickup.

Manual Value Proposition:

Provides essential, factory-level information to accurately diagnose, maintain, and repair the vehicle, saving significant costs compared to dealership service.

📋 Manual Details

Coverage Areas

Primary Coverage:

North America

Region Specific Variants:

Covers models sold in the US, Canada, and Mexico, potentially including minor regional differences.

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul procedures, component testing, diagnostic charts for all engines.

Engine Performance:

Fuel injection system, ignition system, emissions control systems, turbocharger (if applicable).

Transmission Manual:

Repair, overhaul, and troubleshooting of manual transmissions (NV3500, NV4500).

Transmission Automatic:

Repair, overhaul, and troubleshooting of automatic transmissions (42RE, 44RE, 45RFE, 48RE).

Drivetrain:

Transfer case (NV241HD, NV271D, NV273D), front and rear axles, drive shafts, differentials.

Suspension:

Front and rear suspension systems, steering system, wheel alignment specifications.

Brakes:

Front and rear brake systems (disc/drum, disc/disc), ABS, hydraulic system, parking brake.

Electrical System:

Complete wiring diagrams, component testing, diagnostic procedures for all electrical circuits.

Body And Frame:

Body panel repair, interior trim removal, chassis structural information, door and window mechanisms.

HVAC:

Heating, ventilation, and air conditioning system diagnosis and repair.

Safety Systems:

Airbag system diagnosis and repair, seat belt mechanisms.

Procedures Included

Preventive Maintenance:

Detailed service intervals for oil changes, filter replacements, fluid checks, and component inspections.

Diagnostic Troubleshooting:

Flowcharts, symptom-based troubleshooting guides, and specific diagnostic procedures for common and complex issues.

Repair And Rebuild:

Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation.

Technical Specifications Data:

Torque specifications, clearances, fluid capacities, electrical resistance values, and other critical data.

Wiring Diagrams:

Comprehensive and detailed wiring schematics for all vehicle systems.

Special Tools:

Identification and usage instructions for specialized tools required for specific repairs.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds and complex electrical diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text within the PDF for quick access to information.

Print Quality

Quality:

High-resolution digital reproduction, ensuring clarity of text and illustrations.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Type:

3.7L Magnum V6

Engine 1 Displacement:

3701 cc (225 cu in)

Engine 1 Bore X Stroke:

3.91 x 3.12 in (99.3 x 79.4 mm)

Engine 1 Compression Ratio:

9.1:1

Engine 1 Power Hp:

215 hp @ 5200 rpm (approx.)

Engine 1 Torque Lb-Ft:

245 lb-ft @ 3200 rpm (approx.)

Secondary Engine

Engine 2 Type:

4.7L Magnum V8 (2V and 4V variants)

Engine 2 Displacement:

4701 cc (287 cu in)

Engine 2 Bore X Stroke:

3.88 x 3.13 in (98.5 x 79.5 mm)

Engine 2 Compression Ratio:

8.9:1 (2V), 9.0:1 (4V)

Engine 2 Power Hp:

235-245 hp @ 4800-5200 rpm (approx.)

Engine 2 Torque Lb-Ft:

295-325 lb-ft @ 3200-3600 rpm (approx.)

Tertiary Engine

Engine 3 Type:

5.9L Magnum V8 (Cummins Turbo Diesel - '2500' and '3500' models)

Engine 3 Displacement:

5899 cc (359 cu in)

Engine 3 Bore X Stroke:

4.02 x 4.72 in (102 x 120 mm)

Engine 3 Compression Ratio:

21.2:1

Engine 3 Power Hp:

235-250 hp @ 2500-2800 rpm (approx., depending on year/tuning)

Engine 3 Torque Lb-Ft:

460-525 lb-ft @ 1400-1600 rpm (approx., depending on year/tuning)

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI) for Magnum gasoline engines. Bosch VP44 Injection Pump for Cummins Diesel.

Fuel Type:

Unleaded Gasoline (87 octane recommended for V6/V8), Diesel Fuel (ULSD for Cummins).

Ignition System:

Distributorless Ignition System (DIS) with coil-on-plug or coil-near-plug technology for gasoline engines. Electronic control unit (ECU) manages ignition timing.

🔧 Transmission

Standard

Standard Transmission Light Duty:

5-speed manual (NV3500)

Standard Transmission Heavy Duty:

5-speed manual (NV4500) on some 2500/3500 models

Optional

Optional Transmission Light Duty:

4-speed automatic (42RE, 44RE)

Optional Transmission Heavy Duty:

4-speed automatic (45RFE, 48RE) on some V8 and diesel models

Features

Overdrive Gears:

All automatic transmissions feature overdrive (4th gear).

Transfer Case Options:

Part-time 2-speed transfer cases (NV241HD, NV271D, NV273D) with manual or electronic shifting options.

Fluid Specifications

Automatic Transmission Fluid:

ATF+4 (Mopar Spec. MS-9602) or equivalent for 45RFE/48RE. ATF+3 (Mopar Spec. MS-9224) for 42RE/44RE.

Manual Transmission Fluid:

API GL-3 or GL-4 Gear Oil, SAE 75W-90 or 75W-140 depending on application.

Transfer Case Fluid:

NV241HD: ATF+3. NV271D/273D: ATF+4 or appropriate Mopar spec.

📐 Dimensions

Exterior

Wheelbase Regular Cab:

134.9 inches (3426 mm)

Wheelbase Quad Cab:

140.5 inches (3569 mm)

Wheelbase Long Bed:

134.9 inches (3426 mm) for standard box, 160.5 inches (4077 mm) for long box.

Bed Lengths:

6.3 ft (Standard Box), 8.0 ft (Long Box)

Weights

Curb Weight Range:

4,500 - 6,500 lbs (approx., depending on configuration)

Gvwr Range:

6,300 - 10,000 lbs (approx., depending on model 1500, 2500, 3500)

Towing Capacity Max:

Up to 10,000 lbs (approx., with proper configuration and trailer brake controller)

Payload Capacity Max:

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

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

3-star rating (model year dependent).

IIHS Front Impact Rating:

Good (for models with side airbags)

Active Features

Standard on most models, four-wheel disc brakes with ABS on 2500/3500, optional on 1500.

Traction Control:

Optional on some models.

Passive Features

Airbags:

Driver and passenger front airbags standard. Optional side curtain airbags on later models.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

Child Seat Anchors:

LATCH system not standard on this generation.

💡 Technology Features

Infotainment

Audio Systems:

Factory AM/FM/CD players, optional Infinity premium audio systems available on higher trims.

Navigation:

Rarely offered, typically aftermarket installations.

Driver Assistance

Cruise Control:

Standard on most models.

Parking Assist:

Rear parking sensors became available on later models.

Connectivity

Power Outlets:

12V power outlets in the cabin.

Trailer Wiring:

Provision for trailer brake controller and trailer lighting harness standard on towing-equipped models.

🔧 Maintenance

Service Intervals

Oil Change Interval Gasoline:

Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first, under normal driving conditions. Consult manual for severe service intervals.

Oil Change Interval Diesel:

Every 7,500 miles (12,000 km) or 6 months for Cummins (may vary by specific model year and oil specification).

Transmission Fluid Change Automatic:

Inspect every 30,000 miles (48,000 km), replace fluid and filter at 60,000 - 100,000 miles (96,000 - 160,000 km) depending on usage and fluid condition.

Spark Plug Replacement Gasoline:

Varies by engine: 60,000 - 100,000 miles (96,000 - 160,000 km) for platinum/iridium plugs.

Fuel Filter Replacement Diesel:

Recommended every 15,000 - 30,000 miles (24,000 - 48,000 km) to prevent injector issues.

Fluid Specifications

Engine Oil Viscosity Gasoline:

5W-30 or 10W-30 (refer to manual for specific engine and temperature range).

Engine Oil Type Diesel:

CJ-4 or CK-4 rated diesel engine oil, viscosity typically 15W-40 or 5W-40 depending on ambient temperature.

Coolant:

Mopar HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4 brake fluid (check specific requirements).

Known Issues

Common Issues Gasoline Engines:

Cracked cylinder heads (4.7L V8), faulty crankshaft position sensors, oil leaks from valve covers and oil pans, intake manifold leaks.

Common Issues Diesel Engines:

VP44 injection pump failure (early models), injector issues, turbocharger problems, coolant leaks from the block, cracked exhaust manifolds.

Common Issues Transmissions:

Automatic transmission solenoid issues, torque converter problems, manual transmission clutch wear, transfer case actuator failures (electronic models).

Common Issues Suspension Steering:

Ball joint wear, tie rod end wear, steering gearbox issues, rear axle seal leaks.

Common Issues Electrical:

Faulty alternator, power window motor failures, HVAC blower motor resistors, instrument cluster failures.

Common Repairs

Brake Pad Rotor Replacement:

Routine replacement due to wear and tear, especially under heavy use.

Exhaust System Repair:

Rust and corrosion can lead to muffler and pipe replacement.

📚 Vehicle History

Brand Heritage

Dodge Truck Legacy:

Dodge has a long-standing history of producing durable and capable trucks, with the Ram nameplate evolving from earlier Dodge D-Series.

Model Evolution

Generation Introduction:

The third generation Dodge Ram (DR/DH/D2 platform) was introduced for the 1994 model year, marking a significant redesign with a bolder, more aggressive exterior styling and improved interior comfort. This manual covers the refreshed styling and updated powertrains introduced in 1999 and subsequent updates through 2006.

Key Updates 1999-2006:

1999: Major refresh with new front fascia, grille, headlights, and interior updates. New 4.7L Magnum V8 introduced. 2001: Introduction of the Quad Cab. 2002: Introduction of the 4.7L 4V engine. 2003: Cummins Turbo Diesel engine updated with higher horsepower and torque ratings. 2005: Minor styling updates, introduction of the Ram 1500 HEMI 5.7L V8 (not covered in this specific manual as it's for the 1999-2006 generation which primarily predates the widespread HEMI integration into the Ram 1500). 2006: Last model year for this generation before the introduction of the fourth generation Ram.

Production

Manufacturing Locations:

Primarily St. Louis, Missouri, and Saltillo, Mexico.

Production Years:

1994-2001 (DR platform), 2002-2006 (DH/D2 platform - refreshed redesign).

🏆 Awards & Recognition

Recognitions

Motor Trend Truck Of The Year:

Dodge Ram did not win MotorTrend Truck of the Year during this specific generation's primary introduction/refresh cycles, but its design and capabilities were highly regarded.

Competitor Awards:

This generation of Ram competed directly with vehicles that often received accolades, establishing Dodge's strong presence in the truck market.