Dodge Ram 3500 Complete Workshop Service Repair Manual 2006 2007
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🏷️ Basic Information Identification Make: Dodge Model: Ram 3500 Year: 2006-2007 👋 Introduction Market Position Vehicle Segment: Heavy-duty pickup truck, designed for towing, hauling, and commercial applications. Competitive Analysis Key Competitors: Ford F-Series Super Duty (F-250/F-350), Chevrolet Silverado HD (2500HD/3500HD), GMC Sierra HD (2500HD/3500HD). Key Features Robust Chassis: Built on a ladder frame chassis designed for durability and heavy loads. Powerful Engines: Availability of potent gasoline and diesel engines to handle demanding tasks. Towing Capacity: Segment-leading towing and payload capabilities. 📋 Manual Details Coverage Areas Manual Type: Complete Workshop Service Repair Manual Language: English Format: Downloadable Digital File (Likely PDF) Page Count Estimated Pages: Over 2000 pages (typical for comprehensive workshop manuals of this era). 📖 Manual Coverage Systems Covered Engine Mechanical: All engine types, components, internal and external, disassembly, assembly, specifications. Engine Performance: Fuel system, ignition system, emissions control systems, cooling system, lubrication system. Transmission Manual: Manual transmission systems, including clutch, gearbox, driveline components, disassembly, repair, specifications. Transmission Automatic: Automatic transmission systems, including torque converter, valve body, internal components, repair, fluid specifications, diagnostic procedures. Drivetrain: Front and rear axles, differentials, transfer case (if applicable), driveshafts, U-joints, wheel bearings. Suspension System: Front and rear suspension components, springs, shock absorbers/struts, control arms, steering knuckles, alignment procedures. Steering System: Power steering pump, steering gear/rack, tie rods, steering column, alignment specifications. Brake System: Front and rear brakes (disc/drum), ABS system, hydraulic lines, master cylinder, calipers/wheel cylinders, rotor/drum specifications, bleeding procedures. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting, fuses, relays, wiring diagrams. Electronics Control: ECU/PCM (Engine Control Unit/Powertrain Control Module) diagnostics, sensors, actuators, related control modules. Climate Control: HVAC system (heating, ventilation, air conditioning), compressor, condenser, evaporator, refrigerant, blower motor, controls. Body Interior: Interior trim, seats, dashboard, door panels, headliner, carpet, insulation. Body Exterior: Body panels, doors, hoods, tailgates, bumpers, glass, mirrors, seals, trim, body repair procedures. Chassis Frame: Frame construction, crossmembers, mounting points, corrosion protection. Procedures Included Preventative Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotations, inspections. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, identification of common problems. Component Repair: Detailed step-by-step instructions for the repair or replacement of virtually all vehicle components. Diagnostics: On-Board Diagnostics (OBD-II) system information, diagnostic trouble codes (DTCs), procedures for reading and clearing codes. Disassembly Assembly: Complete procedures for removing and reinstalling major and minor components, often with torque specifications. Wiring Diagrams: Detailed electrical schematics for all vehicle systems, including power distribution, component locations, and circuit tracing. Engine Rebuild: Detailed instructions for complete engine disassembly, inspection, repair, and reassembly, including piston ring gaps, bearing clearances, valve timing, etc. Torque Specifications: Crucial torque values for all fasteners to ensure proper assembly and prevent component failure. Diagnostic Trouble Codes: Exhaustive list of OBD-II DTCs with descriptions and diagnostic pathways. Body Repair Procedures: Guidelines for minor dent repair, panel replacement, and structural component repair. Technical Depth Level Of Detail: Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls. Target Audience: Professional automotive technicians and experienced DIY mechanics. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format), allowing for searchability and easy navigation. Print Quality Digital Quality: High-resolution scans ensuring clarity of text, diagrams, and illustrations. Binding Type Digital Access: Downloadable file accessible on computers, tablets, and smartphones. Paper Type Print Recommendation: Printable on standard paper, recommended to print relevant sections for workshop use. Manual Completeness Coverage Scope: Extremely comprehensive, covering all aspects of vehicle repair and maintenance. ⚙️ Engine Specifications Primary Engine Gasoline Options: 5.7L HEMI V8 (345 cu in), 8.3L V10 Magnum (505 cu in - Viper-derived). Diesel Options: 5.9L Cummins Turbo Diesel I6 (359 cu in). Performance 5.7L Hemi V8: Approx. 345-355 hp, 375-395 lb-ft torque. 8.3L V10 Magnum: Approx. 500 hp, 525 lb-ft torque. 5.9L Cummins Turbo Diesel: Approx. 305-325 hp, 555-610 lb-ft torque (depending on configuration). Fuel System Gasoline Injection: Sequential Multi-Port Fuel Injection (MPI). Diesel Injection: High-pressure common rail (HPCR) fuel injection system (for Cummins). 🔧 Transmission Standard Transmission Options: 6-speed manual (NV5600 for diesel, G56 for late 2005/2006 diesel) or 4-speed automatic (48RE for diesel, 4-speed automatic for gasoline). Optional Automatic Transmission: 48RE automatic (heavy-duty, electronically controlled) for Cummins Diesel models, 4-speed automatic for gasoline models. Features Transfer Case: Part-time, electronic shift-on-the-fly 4WD system (BorgWarner 4447 or similar) on most models. 📐 Dimensions Exterior Wheelbase: Varies by cab configuration and bed length (e.g., 140.5" single rear wheel, 160.5" dual rear wheel standard cab). Bed Lengths: 6'4" (short bed), 8'0" (long bed). Weights Curb Weight: Varies significantly by configuration, typically starting around 6,000-7,000 lbs and upwards. Gross Vehicle Weight Rating Gvw: Exceeds 10,000 lbs, up to 11,500 lbs or more depending on configuration. 🛡️ Safety Features Ratings NHTSA Ratings: Information varies by year and specific test; generally designed for robust occupants protection given its class. Active Features ABS: Standard Anti-lock Braking System (ABS) on...
Diagnostic flowcharts, symptom-based troubleshooting guides, identification of common problems.
Component Repair:
Detailed step-by-step instructions for the repair or replacement of virtually all vehicle components.
Diagnostics:
On-Board Diagnostics (OBD-II) system information, diagnostic trouble codes (DTCs), procedures for reading and clearing codes.
Disassembly Assembly:
Complete procedures for removing and reinstalling major and minor components, often with torque specifications.
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems, including power distribution, component locations, and circuit tracing.
Engine Rebuild:
Detailed instructions for complete engine disassembly, inspection, repair, and reassembly, including piston ring gaps, bearing clearances, valve timing, etc.
Torque Specifications:
Crucial torque values for all fasteners to ensure proper assembly and prevent component failure.
Diagnostic Trouble Codes:
Exhaustive list of OBD-II DTCs with descriptions and diagnostic pathways.
Body Repair Procedures:
Guidelines for minor dent repair, panel replacement, and structural component repair.
Technical Depth
Level Of Detail:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls.
Target Audience:
Professional automotive technicians and experienced DIY mechanics.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format), allowing for searchability and easy navigation.
Print Quality
Digital Quality:
High-resolution scans ensuring clarity of text, diagrams, and illustrations.
Binding Type
Digital Access:
Downloadable file accessible on computers, tablets, and smartphones.
Paper Type
Print Recommendation:
Printable on standard paper, recommended to print relevant sections for workshop use.
Manual Completeness
Coverage Scope:
Extremely comprehensive, covering all aspects of vehicle repair and maintenance.
⚙️ Engine Specifications
Primary Engine
Gasoline Options:
5.7L HEMI V8 (345 cu in), 8.3L V10 Magnum (505 cu in - Viper-derived).
Diesel Options:
5.9L Cummins Turbo Diesel I6 (359 cu in).
Performance
5.7L Hemi V8:
Approx. 345-355 hp, 375-395 lb-ft torque.
8.3L V10 Magnum:
Approx. 500 hp, 525 lb-ft torque.
5.9L Cummins Turbo Diesel:
Approx. 305-325 hp, 555-610 lb-ft torque (depending on configuration).
Fuel System
Gasoline Injection:
Sequential Multi-Port Fuel Injection (MPI).
Diesel Injection:
High-pressure common rail (HPCR) fuel injection system (for Cummins).
🔧 Transmission
Standard
Transmission Options:
6-speed manual (NV5600 for diesel, G56 for late 2005/2006 diesel) or 4-speed automatic (48RE for diesel, 4-speed automatic for gasoline).
Optional
Automatic Transmission:
48RE automatic (heavy-duty, electronically controlled) for Cummins Diesel models, 4-speed automatic for gasoline models.
Features
Transfer Case:
Part-time, electronic shift-on-the-fly 4WD system (BorgWarner 4447 or similar) on most models.
📐 Dimensions
Exterior
Wheelbase:
Varies by cab configuration and bed length (e.g., 140.5" single rear wheel, 160.5" dual rear wheel standard cab).
Bed Lengths:
6'4" (short bed), 8'0" (long bed).
Weights
Curb Weight:
Varies significantly by configuration, typically starting around 6,000-7,000 lbs and upwards.
Gross Vehicle Weight Rating Gvw:
Exceeds 10,000 lbs, up to 11,500 lbs or more depending on configuration.
🛡️ Safety Features
Ratings
NHTSA Ratings:
Information varies by year and specific test; generally designed for robust occupants protection given its class.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Trailer Brake Controller:
Integrated trailer brake controller (optional, highly recommended for towing).
Passive Features
Airbags:
Front airbags for driver and passenger.
Seatbelts:
Three-point seat belts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with CD player, optional Infinity sound system, SiriusXM Satellite Radio (late models).
Navigation:
Optional factory navigation system on higher trim levels.
Driver Assistance
Parking Sensors:
Optional rear parking assist sensors.
Cruise Control:
Standard cruise control.
Connectivity
Power Outlets:
12V auxiliary power outlets.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles or 6 months for gasoline engines, and 7,500-10,000 miles or 6 months for Cummins diesel engines, depending on usage and oil type.
Transmission Service:
Automatic transmission fluid and filter change every 30,000-60,000 miles, depending on towing usage. Manual transmission fluid checks and potential change at higher mileage.
Fluid Specifications
Engine Oil Gasoline:
SAE 5W-20 or 5W-30 API SN, CJ-4 (check owner's manual for exact specs based on engine and temperature).
Engine Oil Diesel:
SAE 15W-40, API CJ-4 (Cummins recommended) or similar heavy-duty diesel engine oil.
Coolant:
Chrysler/Dodge HOAT (Hybrid Organic Acid Technology) or OAT (Organic Acid Technology) coolant, typically Mopar OAT (orange).
Transmission Fluid Auto:
ATF+4 (Automatic Transmission Fluid type 9602) for automatic transmissions.
Transmission Fluid Manual:
API GL-3 or GL-4 gear oil (e.g., SAE 75W-90 or 80W-90) for manual transmissions (specific type depends on gearbox model).
Known Issues
Diesel Injector Problems:
Some 5.9L Cummins models can experience injector issues, particularly the 2003-2004 model years with specific injector types, though less common in these later years.
Automatic Transmission Overheating:
Heavy towing can lead to overheating of the 48RE transmission; an auxiliary transmission cooler is often recommended.
Rear Main Seal Leaks:
Can occur on both diesel and gasoline engines, especially at higher mileage.
Front Suspension Wear:
Ball joints, tie rod ends, and steering linkage components can experience wear due to the vehicle's weight and typical use.
Filter Part Numbers
Oil Filter Cummins:
Fleetguard LF16035 or equivalent (e.g., Mopar 05013361AA).
Oil Filter Hemi:
Mopar MO-899 or equivalent.
📚 Vehicle History
Brand Heritage
Dodge Trucks:
Dodge has a long history of producing rugged and capable trucks, with the Ram line becoming a distinct brand in 1993.
Model Evolution
Third Generation Ram:
These models (2002-2008) represent the third generation of the Dodge Ram pickup. Significant redesign from the previous generation, featuring a larger, more aggressive styling and improved chassis.
Consistently recognized for its towing and hauling capabilities within the heavy-duty truck segment.
Ratings
Consumer Reports:
Often received mixed to good ratings depending on specific configurations and powertrain choices, praised for capability but sometimes criticized for ride quality or fuel economy.