2005 DODGE RAM Pickup 3500 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Pickup 3500 Year: 2005 Generation Generation Name: Third Generation (DR/DH/D2) Generation Years: 2002-2009 Codes Chassis Codes: DR/DH/D2 👋 Introduction Market Position Vehicle Segment: Heavy-Duty Pickup Truck Target Audience: Commercial users, fleet operators, heavy towing/hauling enthusiasts, DIY mechanics Competitive Analysis Key Competitors: Ford F-250/F-350 Super Duty, Chevrolet Silverado 2500HD/3500HD, GMC Sierra 2500HD/3500HD Key Features Vehicle Strengths: Robust chassis, high towing and payload capacity, powerful engine options, proven durability Manual Value Proposition: Comprehensive diagnostic and repair information crucial for maintaining heavy-duty vehicles, saving on professional labor costs 📋 Manual Details Coverage Areas Manual Type: Full Service and Repair Manual Language: English Format: Digital (Likely PDF based on description, intended for digital delivery) Page Count Estimated Page Count: 3000+ 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel delivery, ignition, emissions control, exhaust, engine diagnostics, turbocharger (if applicable) Transmission Systems: Manual transmission, automatic transmission, transfer case, driveline, clutch, torque converter Chassis Systems: Suspension (front and rear), steering system, braking system (ABS, disc/drum), wheels and tires, frame and body mounting Electrical Systems: Battery, starting system, charging system, lighting, ignition, instrumentation, power distribution, body control modules, infotainment, comfort and convenience systems, wiring diagrams Body Systems: Body panels, doors, windows, interior trim, seats, HVAC system, safety restraints (airbags, seatbelts), glass, exterior trim, paint and body repair basics Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections, belt and hose replacement Repair Procedures: Component removal and installation, engine overhauls, transmission rebuilding, brake caliper replacement, suspension component replacement, electrical component diagnosis and repair Troubleshooting Procedures: Diagnostic charts, symptom-based troubleshooting, error code interpretation, electrical circuit tracing Technical Specifications: Torque specifications, clearances, tolerances, diagnostic parameters, alignment specifications Technical Depth Diagnostic Capabilities: In-depth diagnostic procedures, component testing, electrical schematic analysis, OBD-II code interpretation Rebuild Instructions: Detailed step-by-step instructions for engine, transmission, and differential rebuilds Special Tools: Identification and usage instructions for specialized tools required for specific repairs 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable text content for quick information retrieval Print Quality Image Resolution: High-resolution images and diagrams for clarity Binding Type Delivery Method: Digital Download Paper Type Durability: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code And Type: Cummins ISB 5.9L (24-valve) OHV Turbo-Diesel (RVM), V8 5.7L HEMI Magnum (EZB, EZH - Gasoline) Performance Diesel Horsepower: Approx. 305-325 hp @ 2900 rpm (depending on tune) Diesel Torque: Approx. 555-610 lb-ft @ 1600 rpm (depending on tune) Gasoline Horsepower: Approx. 345-360 hp @ 5600 rpm Gasoline Torque: Approx. 375-400 lb-ft @ 3600 rpm Fuel System Diesel Fuel System: High-pressure common rail (HPCR) direct injection, Bosch fuel system Gasoline Fuel System: Sequential Multi-Point Fuel Injection (MPI) Engine Oil Diesel Oil Type: API CJ-4 or CK-4, SAE 15W-40 (check manual for specific approvals) Gasoline Oil Type: API SN, SAE 5W-20 or 10W-30 (check manual for specific approvals) 🔧 Transmission Standard Transmission Type Diesel: NV5600 6-Speed Manual, G56 6-Speed Manual (later models) Transmission Type Gasoline: NV3500 5-Speed Manual (less common on 3500), 48RE 4-Speed Automatic Optional Transmission Type Diesel Auto: 48RE 4-Speed Automatic Transmission Type Gasoline Auto: 48RE 4-Speed Automatic (primary auto) Features Transfer Case: New Process NV271 (manual shift) or NV273 (electronic shift) Command-Trac 2-speed transfer case Fluid Specifications Auto Trans Fluid Type: Chrysler ATF+4 (MS-9602) Manual Trans Fluid Type: MS-9224 SAE 75W-90 Synthetic Gear Oil 📐 Dimensions Exterior Wheelbase Options: 140.5 inches (Regular Cab), 154.5 inches (Club Cab/Mega Cab), 168.5 inches (Long Bed) Bed Length Options: 6.3 feet (short bed), 8.0 feet (long bed) Weights Gvwr Range: 10,500 lbs - 11,500 lbs (depending on configuration) Curb Weight Range: Approx. 6,500 - 7,500 lbs Towing Max Towing Capacity: Up to 13,000+ lbs (with appropriate configuration and hitch) Cargo Payload Capacity: Up to 4,500+ lbs 🛡️ Safety Features Ratings NHTSA Front Impact Rating: Not rated or varies by year/configuration (heavy-duty trucks often have different testing protocols) IIHS Crashworthiness Rating: Generally good for its class, but detailed specific ratings for 2005 3500 may vary Active Features Braking System: Front disc, rear disc (or disc/drum depending on specific configuration), Anti-lock Braking System (ABS) Traction Control: Available (e.g., Electronic Stability Control on some later models, but less common on early 3rd gen HD) Passive Features Airbags: Front airbags, available side curtain airbags Seatbelts: Three-point seat belts with pretensioners 💡 Technology Features Infotainment Audio System: AM/FM stereo, CD player, available premium audio systems, available navigation (later models) Connectivity: Available satellite radio, available auxiliary input Driver Assistance Cruise Control: Standard Parking Assist: Available rear parking sensors 🔧 Maintenance Service Intervals Oil And Filter Diesel: Every 7,500 miles or 6 months (severe service may require more frequent changes) Oil And Filter Gasoline: Every 5,000 miles or 6 months Air Filter Replacement: Every 15,000-30,000 miles or as needed based on conditions Fuel Filter Replacement Diesel: Every 15,000 miles Transmission...
Manual transmission, automatic transmission, transfer case, driveline, clutch, torque converter
Chassis Systems:
Suspension (front and rear), steering system, braking system (ABS, disc/drum), wheels and tires, frame and body mounting
Electrical Systems:
Battery, starting system, charging system, lighting, ignition, instrumentation, power distribution, body control modules, infotainment, comfort and convenience systems, wiring diagrams
Body Systems:
Body panels, doors, windows, interior trim, seats, HVAC system, safety restraints (airbags, seatbelts), glass, exterior trim, paint and body repair basics
Procedures Included
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections, belt and hose replacement
Repair Procedures:
Component removal and installation, engine overhauls, transmission rebuilding, brake caliper replacement, suspension component replacement, electrical component diagnosis and repair
Automatic transmission solenoid issues (48RE), clutch wear (manual), transfer case actuator issues (electronic shift)
Suspension And Steering:
Ball joint wear, tie rod end wear, steering stabilizer issues, U-joint wear
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing durable and capable trucks, particularly for commercial and work applications.
Model Evolution
Third Gen Ram Introduction:
The third generation (2002-2009) introduced a significant redesign with a larger, more aggressive styling and improved chassis.
Heavy Duty Enhancements:
The 3500 model specifically received upgrades to the frame, suspension, and powertrains to handle increased towing and payload demands compared to the 1500/2500 series.
While specific awards for the 2005 3500 may not be widely publicized, the Cummins-powered Ram trucks consistently received praise for their towing capability and diesel powertrain.