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Dodge Ram 1500 2009-2012 Service & Repair Workshop Manual

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๐Ÿท๏ธ Basic Information Identification Make: Dodge Model: Ram 1500 Year: 2009-2012 Generation Generation Code: DS/DJ Codes Platform: Chrysler Y Platform ๐Ÿ‘‹ Introduction Market Position Market Segment: Full-size pickup truck segment, positioned as a capable and versatile workhorse. Competitive Analysis Key Competitors: Ford F-150, Chevrolet Silverado 1500, GMC Sierra 1500, Toyota Tundra. Key Features Vehicle Platform: Heavy-duty construction, robust suspension, powerful engine options, and towing/hauling capabilities were key selling points. Manual Value Proposition: Provides essential technical data, repair procedures, and diagnostic information for owners and mechanics to maintain and repair their Dodge Ram 1500, saving on labor costs and ensuring proper vehicle function. ๐Ÿ“‹ Manual Details Coverage Areas Coverage Summary: Complete factory service and repair workshop manual for Dodge Ram 1500 models from 2009 through 2012. Page Count Estimated Page Count: Varies by specific engine/drivetrain combination, but typically over 2000 pages for a comprehensive factory manual. Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download ๐Ÿ“– Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel delivery, ignition, exhaust, emissions, engine control systems (ECU/PCM). Transmission Systems: Automatic transmission (e.g., 545RFE, W5A580), manual transmission (e.g., NV3500, G56), transfer case, driveline, axle shafts. Brakes: Front and rear brake systems, ABS, traction control, stability control, parking brake. Steering Suspension: Power steering system, steering column, front and rear suspension components (shocks, springs, control arms), ball joints, tie rods. Electrical Systems: Battery, charging system, starting system, lighting, wiring diagrams, fuses, relays, body control modules (BCM). HVAC: Heating, ventilation, and air conditioning (HVAC) system components, refrigerant handling, climate control modules. Body Exterior: Body panels, doors, latches, hinges, glass, bumpers, exterior trim, power accessories (windows, mirrors, locks). Body Interior: Interior trim panels, seats, airbags, restraint systems, dashboard, instrument cluster, audio systems. Chassis Frame: Frame construction, collision repair information, chassis components. Diagnostics: Diagnostic trouble codes (DTCs), diagnostic procedures, scan tool usage, component testing. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacements, spark plug replacement. Repair Procedures: Engine overhauls, transmission rebuilds, brake caliper replacement, suspension component replacement, power steering pump replacement. Troubleshooting Guides: Systematic troubleshooting steps for common and uncommon drivability, electrical, and mechanical issues. Specifications Data: Torque specifications, clearances, fluid capacities, electrical resistance values, pressure tests. Wiring Diagrams: Comprehensive wiring schematics for all major electrical systems, color-coded for clarity. Special Tools: Identification and usage instructions for specialized tools required for specific repair procedures. Assembly Disassembly: Detailed step-by-step instructions for disassembling and reassembling major vehicle components. Technical Depth Depth Of Coverage: Comprehensive factory-level detail suitable for professional technicians and advanced DIY enthusiasts. Covers everything from routine maintenance to complete engine and transmission rebuilds. ๐Ÿ“Š Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, designed for clear viewing and printing of diagrams and text. Binding Type Binding Type: N/A (Digital Download - PDF) Paper Type Paper Type: N/A (Digital Download - PDF) Searchability Search Functionality: Searchable text within the PDF document for quick information retrieval. โš™๏ธ Engine Specifications Primary Engine Available Engines: 3.7L V6 (2009-2011), 4.7L V8, 5.7L HEMI V8. Performance 5.7L Hemi Horsepower: Approx. 390-395 hp @ 5600 rpm 5.7L Hemi Torque: Approx. 407-410 lb-ft @ 3950 rpm Fuel System Fuel Delivery: Multi-point fuel injection (MPI) or Sequential Fuel Injection (SFI). Fuel Type: Unleaded gasoline (87 octane recommended, higher for performance). Engine Codes 3.7L V6 Code: EWG 4.7L V8 Code: AKD 5.7L Hemi V8 Code: EZA ๐Ÿ”ง Transmission Standard Standard Transmission: 5-speed automatic (e.g., 545RFE) was common; manual transmissions were available on certain trims/engines (e.g., NV3500 for 3.7L V6). Optional Optional Transmission: 6-speed manual transmission (G56) was an option for HEMI engines and some V6 models. A 5-speed automatic (W5A580) was also available for certain powertrains. Features Transmission Features: Tow/Haul mode, electronic range selection, potential for manual shifting (AutoStick on some models). Fluid Specifications Automatic Transmission Fluid: Mopar ATF+4 (MS-9602) or equivalent. Manual Transmission Fluid: Refer to manual for specific GL-4 or GL-5 gear oil specifications (e.g., SAE 75W-90). ๐Ÿ“ Dimensions Exterior Wheelbase: Varies by cab and bed configuration (e.g., approx. 140.5 inches for Quad Cab 6.4 ft bed, 160.5 inches for Crew Cab 5.7 ft bed). Length: Varies by configuration (e.g., approx. 227.7 inches for Quad Cab 6.4 ft bed). Width: Approx. 79.1 inches (excluding mirrors). Height: Varies by configuration (e.g., approx. 74.6 inches for Quad Cab 4x2). Cargo Bed Lengths: Available in 5'7", 6'4", and 8' configurations. Weights Curb Weight: Varies significantly by configuration (e.g., approx. 4,700 lbs to over 5,500 lbs). Towing Capacity: Up to approx. 10,000 - 10,500 lbs depending on configuration (engine, drivetrain, axle ratio). ๐Ÿ›ก๏ธ Safety Features Ratings NHTSA Front Impact Driver: Good (for 2009 models) NHTSA Front Impact Passenger: Good (for 2009 models) IIHS Front Offset Crash Rating: Acceptable (for 2009 models) Active Features Active Safety Features: Anti-lock Braking System (ABS), Electronic Stability...
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Dodge Ram 1500 2009-2012 Service & Repair Workshop Manual
๐Ÿท๏ธ Basic Information
Identification
Make:
Dodge
Model:
Ram 1500
Year:
2009-2012
Generation
Generation Code:
DS/DJ
Codes
Platform:
Chrysler Y Platform
๐Ÿ‘‹ Introduction
Market Position
Market Segment:
Full-size pickup truck segment, positioned as a capable and versatile workhorse.
Competitive Analysis
Key Competitors:
Ford F-150, Chevrolet Silverado 1500, GMC Sierra 1500, Toyota Tundra.
Key Features
Vehicle Platform:
Heavy-duty construction, robust suspension, powerful engine options, and towing/hauling capabilities were key selling points.
Manual Value Proposition:
Provides essential technical data, repair procedures, and diagnostic information for owners and mechanics to maintain and repair their Dodge Ram 1500, saving on labor costs and ensuring proper vehicle function.
๐Ÿ“‹ Manual Details
Coverage Areas
Coverage Summary:
Complete factory service and repair workshop manual for Dodge Ram 1500 models from 2009 through 2012.
Page Count
Estimated Page Count:
Varies by specific engine/drivetrain combination, but typically over 2000 pages for a comprehensive factory manual.
Manual Type
Manual Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
๐Ÿ“– Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel delivery, ignition, exhaust, emissions, engine control systems (ECU/PCM).
Transmission Systems:
Automatic transmission (e.g., 545RFE, W5A580), manual transmission (e.g., NV3500, G56), transfer case, driveline, axle shafts.
Brakes:
Front and rear brake systems, ABS, traction control, stability control, parking brake.
Steering Suspension:
Power steering system, steering column, front and rear suspension components (shocks, springs, control arms), ball joints, tie rods.
Electrical Systems:
Battery, charging system, starting system, lighting, wiring diagrams, fuses, relays, body control modules (BCM).
HVAC:
Heating, ventilation, and air conditioning (HVAC) system components, refrigerant handling, climate control modules.
Body Exterior:
Body panels, doors, latches, hinges, glass, bumpers, exterior trim, power accessories (windows, mirrors, locks).
Body Interior:
Interior trim panels, seats, airbags, restraint systems, dashboard, instrument cluster, audio systems.
Chassis Frame:
Frame construction, collision repair information, chassis components.
Diagnostics:
Diagnostic trouble codes (DTCs), diagnostic procedures, scan tool usage, component testing.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacements, spark plug replacement.
Repair Procedures:
Engine overhauls, transmission rebuilds, brake caliper replacement, suspension component replacement, power steering pump replacement.
Troubleshooting Guides:
Systematic troubleshooting steps for common and uncommon drivability, electrical, and mechanical issues.
Specifications Data:
Torque specifications, clearances, fluid capacities, electrical resistance values, pressure tests.
Wiring Diagrams:
Comprehensive wiring schematics for all major electrical systems, color-coded for clarity.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures.
Assembly Disassembly:
Detailed step-by-step instructions for disassembling and reassembling major vehicle components.
Technical Depth
Depth Of Coverage:
Comprehensive factory-level detail suitable for professional technicians and advanced DIY enthusiasts. Covers everything from routine maintenance to complete engine and transmission rebuilds.
๐Ÿ“Š Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, designed for clear viewing and printing of diagrams and text.
Binding Type
Binding Type:
N/A (Digital Download - PDF)
Paper Type
Paper Type:
N/A (Digital Download - PDF)
Searchability
Search Functionality:
Searchable text within the PDF document for quick information retrieval.
โš™๏ธ Engine Specifications
Primary Engine
Available Engines:
3.7L V6 (2009-2011), 4.7L V8, 5.7L HEMI V8.
Performance
5.7L Hemi Horsepower:
Approx. 390-395 hp @ 5600 rpm
5.7L Hemi Torque:
Approx. 407-410 lb-ft @ 3950 rpm
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) or Sequential Fuel Injection (SFI).
Fuel Type:
Unleaded gasoline (87 octane recommended, higher for performance).
Engine Codes
3.7L V6 Code:
EWG
4.7L V8 Code:
AKD
5.7L Hemi V8 Code:
EZA
๐Ÿ”ง Transmission
Standard
Standard Transmission:
5-speed automatic (e.g., 545RFE) was common; manual transmissions were available on certain trims/engines (e.g., NV3500 for 3.7L V6).
Optional
Optional Transmission:
6-speed manual transmission (G56) was an option for HEMI engines and some V6 models. A 5-speed automatic (W5A580) was also available for certain powertrains.
Features
Transmission Features:
Tow/Haul mode, electronic range selection, potential for manual shifting (AutoStick on some models).
Fluid Specifications
Automatic Transmission Fluid:
Mopar ATF+4 (MS-9602) or equivalent.
Manual Transmission Fluid:
Refer to manual for specific GL-4 or GL-5 gear oil specifications (e.g., SAE 75W-90).
๐Ÿ“ Dimensions
Exterior
Wheelbase:
Varies by cab and bed configuration (e.g., approx. 140.5 inches for Quad Cab 6.4 ft bed, 160.5 inches for Crew Cab 5.7 ft bed).
Length:
Varies by configuration (e.g., approx. 227.7 inches for Quad Cab 6.4 ft bed).
Width:
Approx. 79.1 inches (excluding mirrors).
Height:
Varies by configuration (e.g., approx. 74.6 inches for Quad Cab 4x2).
Cargo
Bed Lengths:
Available in 5'7", 6'4", and 8' configurations.
Weights
Curb Weight:
Varies significantly by configuration (e.g., approx. 4,700 lbs to over 5,500 lbs).
Towing Capacity:
Up to approx. 10,000 - 10,500 lbs depending on configuration (engine, drivetrain, axle ratio).
๐Ÿ›ก๏ธ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (for 2009 models)
NHTSA Front Impact Passenger:
Good (for 2009 models)
IIHS Front Offset Crash Rating:
Acceptable (for 2009 models)
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Electronic Stability Control (ESC), Traction Control.
Passive Features
Passive Safety Features:
Front airbags, available side curtain airbags, available front seat-mounted side airbags, front seat belt pretensioners.
๐Ÿ’ก Technology Features
Infotainment
Infotainment Options:
Uconnect multimedia system with touchscreen, navigation (optional), satellite radio, CD/DVD player, auxiliary input, USB ports.
Driver Assistance
Driver Assistance Features:
ParkSense parking assist (rear, optional), rearview camera (optional).
Connectivity
Connectivity Options:
Bluetooth hands-free calling and audio streaming, voice command functionality.
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 miles or 6 months, depending on driving conditions and oil type (refer to manual for specific recommendations).
Engine Air Filter Replacement:
Inspect every 15,000 miles, replace as needed (usually around 30,000 miles or sooner in dusty conditions).
Cabin Air Filter Replacement:
Inspect every 15,000 miles, replace as needed (typically annually or every 15,000-30,000 miles).
Transmission Fluid Service:
Refer to manual; typically around 50,000 - 100,000 miles for fluid and filter change, depending on usage (e.g., towing).
Fluid Specifications
Engine Oil Type:
SAE 5W-20 or 5W-30, meeting Chrysler MS-6395 specification (e.g., Pennzoil, Mobil 1).
Engine Oil Capacity:
3.7L V6: approx. 5 quarts; 4.7L V8: approx. 6 quarts; 5.7L HEMI: approx. 7 quarts (with filter).
Coolant Type:
Mopar OAT (Organic Additive Technology) 5-Year Coolant / Antifreeze (HOAT or OAT types can be mixed with caution, but best to use specified type).
Known Issues
Common Issues 37L V6:
Oil filter housing leaks, intake manifold gasket leaks, occasional spark plug ejection (on older versions).
Common Issues 47L V8:
Valve cover gasket leaks, intake manifold gasket leaks, oil filter adapter leaks, cylinder head issues (less common than older versions).
Common Issues 57L Hemi:
Actuator housing leaks (for MDS system), oil filter adapter leaks, occasional piston slap (early models), exhaust manifold leaks.
Transmission Common Issues:
Erratic shifting, torque converter shudder, delayed engagement (especially on 545RFE).
Suspension Common Issues:
Worn ball joints, tie rod ends, and control arm bushings, leading to steering looseness and uneven tire wear.
Electrical Common Issues:
Faulty TIPM (Totally Integrated Power Module) causing various electrical gremlins, HVAC blower motor issues.
๐Ÿ“š Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, with the Ram nameplate establishing itself as a strong contender in the pickup market.
Model Evolution
Fourth Generation Launch:
The 2009 model year marked the introduction of the fourth-generation Ram 1500, featuring a significant redesign with improved aerodynamics, updated interior, and new powertrain options.
Production
Manufacturing Locations:
Primarily Warren Truck Assembly Plant in Warren, Michigan, and St. Louis Assembly in Fenton, Missouri (until closure).
Model Year Range Coverage:
Covers the initial years of the fourth-generation (DS/DJ) platform, a period of significant updates and refinements.
๐Ÿ† Awards & Recognition
Recognitions
Motortrend Truck Of The Year:
While the specific generation might not have won Truck of the Year for its debut year, Dodge/Ram trucks have historically received numerous accolades.
Ratings
Consumer Reports Reliability:
Reliability ratings varied by year and specific powertrain; typically rated average to below average in some categories during this period according to Consumer Reports.
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