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DODGE RAM 1500 2500 3500 Workshop Repair Manual All 2003-2006 ModelS COVERED

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🏷️ Basic Information Identification Make: Dodge Model: Ram 1500, 2500, 3500 Model Years Covered: 2003, 2004, 2005, 2006 Codes Platform Code: DR/DH/D1 (Third Generation Ram) 👋 Introduction Market Position Segment: Heavy-Duty Pickup Truck Reputation: Renowned for towing, hauling capability, and robust construction Competitive Analysis Key Competitors: Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD Key Features Durability: Built for demanding work and off-road use Powertrain Options: Variety of powerful V8 gasoline and Cummins turbodiesel engines Towing Hauling: Segment-leading towing and payload capacities 📋 Manual Details Coverage Areas Primary Coverage: North America Secondary Coverage: Global variations may exist Page Count Estimated Page Count: 2000+ Manual Type Type: Workshop Service and Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine overhaul, fuel system, cooling, exhaust, lubrication, ignition, emissions control Transmission Drivetrain: Manual and automatic transmission overhaul, transfer case, axles, driveshafts, differentials, CV joints Chassis Suspension: Front and rear suspension, steering system, steering gear, power steering, chassis components Brakes: Hydraulic brake systems, ABS, parking brake, front and rear brake service and repair Electrical Electronics: Wiring diagrams, starter, alternator, battery, lighting, power windows, mirrors, instruments, body control modules, CAN bus architecture HVAC: Air conditioning system, heater, ventilation, climate control operation and repair Body Interior: Body panels, doors, glass, interior trim, seats, bumpers, exterior moldings, body repair procedures Procedures Included Maintenance: Scheduled maintenance, oil changes, fluid checks, filter replacements, lubrication, tire rotation Troubleshooting: Diagnostic procedures, symptom-based troubleshooting, fault code interpretation Repair Rebuild: Component removal and installation, detailed disassembly and reassembly instructions, critical torque specifications Diagnostics: OBD-II diagnostics, sensor testing, module programming concepts Technical Depth Depth: Comprehensive: from basic maintenance to complete engine and transmission rebuilds Detail Level: Detailed step-by-step instructions, exploded views, component identification Special Tools: Identifies required special tools and equipment for specific procedures 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Text-searchable (OCR layer likely present) Print Quality Printability: Printable pages for workshop use Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Option 1: 4.7L Magnum V8 (230-235 hp, 295-305 lb-ft torque) Engine Option 2: 5.7L HEMI V8 (345-345 hp, 375-390 lb-ft torque) Engine Option 3: 5.9L Cummins I6 Turbo Diesel (250-325 hp, 460-555 lb-ft torque) Engine Option 4 Engine Option 4: 8.3L V10 Viper (500 hp, 525 lb-ft torque - Ram SRT-10 variant) Performance Cylinder Configuration: V8, Inline-6, V10 Valve Train: Overhead Valve (OHV), Overhead Cam (OHC) for some Cummins variants Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI), Common Rail Direct Injection (CRDI) for Cummins Fuel Type: Unleaded Gasoline, Diesel Fuel 🔧 Transmission Standard Transmission Option 1: 4-Speed Automatic (42RE/44RE/45RFE/545RFE) Transmission Option 2: 6-Speed Manual (NV4500/G56 for Cummins) Optional Transmission Option 3: 5-Speed Automatic (545RFE, later 5-speed) Transmission Option 4: 6-Speed Manual (G56 for Cummins) Features Transfer Case: Command-Trac (2WD/4WD Part-Time), NV244 (Full-Time 4WD on select models) Gear Ratios: Refer to manual for specific transmission gear ratios Transmission Fluid: ATF+4 for automatic transmissions, gear oil for manual transmissions (specifics in manual) 📐 Dimensions Exterior Body Styles: Regular Cab, Club Cab (Extended Cab), Crew Cab Bed Lengths: 6.3 ft, 8.0 ft Wheelbase: Varies by cab and bed configuration (e.g., 134.5", 140.5", 160.5") Weights Curb Weight: Approx. 5,000 - 7,500+ lbs depending on configuration Gross Vehicle Weight Rating Gvw R: Ranges from 6,300 lbs (1500) to 11,500 lbs (3500) Towing Capacity: Up to 10,500+ lbs (3500 Diesel DRW) Payload Capacity: Up to 5,000+ lbs (3500 Diesel DRW) 🛡️ Safety Features Ratings NHTSA Ratings: Varies by model year and specific test; generally competitive for its class Active Features ABS: Standard Anti-lock Braking System Traction Control: Available Traction Control System (TCS) Electronic Stability Control: Available Electronic Stability Program (ESP) Passive Features Airbags: Front airbags, optional side curtain airbags on later models Seatbelts: Three-point seat belts with pretensioners Structure: High-strength steel frame and reinforced cabin 💡 Technology Features Infotainment Infotainment System: Basic AM/FM radio, CD player, optional cassette player, available premium audio systems Navigation: Limited to aftermarket options or basic trip computers for most models Driver Assistance Cruise Control: Standard cruise control Parking Assist: Optional rear parking assist sensors on some models Connectivity Auxiliary Input: Optional auxiliary audio input jack Power Outlets: 12V power outlets 🔧 Maintenance Service Intervals Oil Change: Refer to manual; typically 3,000-7,500 miles depending on engine and oil type Transmission Fluid: Check manual; often recommended every 30,000-60,000 miles for severe use Coolant Flush: Refer to manual; generally 30,000-100,000 miles depending on coolant type Air Filter: Check manual; typically 15,000-30,000 miles or as needed based on driving conditions Fluid Specifications Engine Oil Gas: SAE 5W-30 (most gasoline engines), refer to manual for specific viscosities and API service classifications Engine Oil Diesel: CJ-4 or CK-4 rated Diesel engine oil, SAE 15W-40 or 5W-40 (refer to manual for exact specs)...
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DODGE RAM 1500 2500 3500 Workshop Repair Manual All 2003-2006 ModelS COVERED
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram 1500, 2500, 3500
Model Years Covered:
2003, 2004, 2005, 2006
Codes
Platform Code:
DR/DH/D1 (Third Generation Ram)
👋 Introduction
Market Position
Segment:
Heavy-Duty Pickup Truck
Reputation:
Renowned for towing, hauling capability, and robust construction
Competitive Analysis
Key Competitors:
Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD
Key Features
Durability:
Built for demanding work and off-road use
Powertrain Options:
Variety of powerful V8 gasoline and Cummins turbodiesel engines
Towing Hauling:
Segment-leading towing and payload capacities
📋 Manual Details
Coverage Areas
Primary Coverage:
North America
Secondary Coverage:
Global variations may exist
Page Count
Estimated Page Count:
2000+
Manual Type
Type:
Workshop Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine overhaul, fuel system, cooling, exhaust, lubrication, ignition, emissions control
Transmission Drivetrain:
Manual and automatic transmission overhaul, transfer case, axles, driveshafts, differentials, CV joints
Chassis Suspension:
Front and rear suspension, steering system, steering gear, power steering, chassis components
Brakes:
Hydraulic brake systems, ABS, parking brake, front and rear brake service and repair
Electrical Electronics:
Wiring diagrams, starter, alternator, battery, lighting, power windows, mirrors, instruments, body control modules, CAN bus architecture
HVAC:
Air conditioning system, heater, ventilation, climate control operation and repair
Body Interior:
Body panels, doors, glass, interior trim, seats, bumpers, exterior moldings, body repair procedures
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, fluid checks, filter replacements, lubrication, tire rotation
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting, fault code interpretation
Repair Rebuild:
Component removal and installation, detailed disassembly and reassembly instructions, critical torque specifications
Diagnostics:
OBD-II diagnostics, sensor testing, module programming concepts
Technical Depth
Depth:
Comprehensive: from basic maintenance to complete engine and transmission rebuilds
Detail Level:
Detailed step-by-step instructions, exploded views, component identification
Special Tools:
Identifies required special tools and equipment for specific procedures
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Text-searchable (OCR layer likely present)
Print Quality
Printability:
Printable pages for workshop use
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Option 1:
4.7L Magnum V8 (230-235 hp, 295-305 lb-ft torque)
Engine Option 2:
5.7L HEMI V8 (345-345 hp, 375-390 lb-ft torque)
Engine Option 3:
5.9L Cummins I6 Turbo Diesel (250-325 hp, 460-555 lb-ft torque)
Engine Option 4
Engine Option 4:
8.3L V10 Viper (500 hp, 525 lb-ft torque - Ram SRT-10 variant)
Performance
Cylinder Configuration:
V8, Inline-6, V10
Valve Train:
Overhead Valve (OHV), Overhead Cam (OHC) for some Cummins variants
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI), Common Rail Direct Injection (CRDI) for Cummins
Fuel Type:
Unleaded Gasoline, Diesel Fuel
🔧 Transmission
Standard
Transmission Option 1:
4-Speed Automatic (42RE/44RE/45RFE/545RFE)
Transmission Option 2:
6-Speed Manual (NV4500/G56 for Cummins)
Optional
Transmission Option 3:
5-Speed Automatic (545RFE, later 5-speed)
Transmission Option 4:
6-Speed Manual (G56 for Cummins)
Features
Transfer Case:
Command-Trac (2WD/4WD Part-Time), NV244 (Full-Time 4WD on select models)
Gear Ratios:
Refer to manual for specific transmission gear ratios
Transmission Fluid:
ATF+4 for automatic transmissions, gear oil for manual transmissions (specifics in manual)
📐 Dimensions
Exterior
Body Styles:
Regular Cab, Club Cab (Extended Cab), Crew Cab
Bed Lengths:
6.3 ft, 8.0 ft
Wheelbase:
Varies by cab and bed configuration (e.g., 134.5", 140.5", 160.5")
Weights
Curb Weight:
Approx. 5,000 - 7,500+ lbs depending on configuration
Gross Vehicle Weight Rating Gvw R:
Ranges from 6,300 lbs (1500) to 11,500 lbs (3500)
Towing Capacity:
Up to 10,500+ lbs (3500 Diesel DRW)
Payload Capacity:
Up to 5,000+ lbs (3500 Diesel DRW)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Varies by model year and specific test; generally competitive for its class
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Available Traction Control System (TCS)
Electronic Stability Control:
Available Electronic Stability Program (ESP)
Passive Features
Airbags:
Front airbags, optional side curtain airbags on later models
Seatbelts:
Three-point seat belts with pretensioners
Structure:
High-strength steel frame and reinforced cabin
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio, CD player, optional cassette player, available premium audio systems
Navigation:
Limited to aftermarket options or basic trip computers for most models
Driver Assistance
Cruise Control:
Standard cruise control
Parking Assist:
Optional rear parking assist sensors on some models
Connectivity
Auxiliary Input:
Optional auxiliary audio input jack
Power Outlets:
12V power outlets
🔧 Maintenance
Service Intervals
Oil Change:
Refer to manual; typically 3,000-7,500 miles depending on engine and oil type
Transmission Fluid:
Check manual; often recommended every 30,000-60,000 miles for severe use
Coolant Flush:
Refer to manual; generally 30,000-100,000 miles depending on coolant type
Air Filter:
Check manual; typically 15,000-30,000 miles or as needed based on driving conditions
Fluid Specifications
Engine Oil Gas:
SAE 5W-30 (most gasoline engines), refer to manual for specific viscosities and API service classifications
Engine Oil Diesel:
CJ-4 or CK-4 rated Diesel engine oil, SAE 15W-40 or 5W-40 (refer to manual for exact specs)
Coolant:
Mopar Antifreeze/Coolant (HOAT) or equivalent (refer to manual for color and type)
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Common Issue 1:
Liftgate/tailgate handle failure
Common Issue 2:
Cracked exhaust manifolds (especially on early 5.7L HEMI)
Common Issue 3:
Transmission issues (e.g., solenoid packs, torque converter lockup problems on 45RFE/545RFE)
Common Issue 4:
Fuel pump failures
Common Issue 5:
Front suspension wear (ball joints, tie rods) due to heavy duty nature
📚 Vehicle History
Brand Heritage
Brand:
Dodge, now Ram Trucks as a distinct brand under Stellantis
Model Evolution
Generation:
Third Generation Ram (DR/DH/D1), introduced for the 2002 model year, updated for 2006
Updates:
Facelifted for 2006 with updated grille, headlights, interior, and powertrain options (e.g., HEMI availability)
Production
Manufacturing Locations:
Various Chrysler/FCA assembly plants in North America
🏆 Awards & Recognition
Recognitions
Awards History:
The Ram pickup line has historically received numerous 'Truck of the Year' awards from various automotive publications and organizations, including MotorTrend.
Ratings
Diesel Engine:
The 5.9L Cummins turbodiesel engine was highly regarded for its durability and torque in its class.
Certifications
Certification:
N/A (Manual is a technical document, not a vehicle certification)
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