2005 Dodge Ram Pickup 2500 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Pickup 2500 Year: 2005 Body Style: Heavy Duty Pickup Truck Codes Chassis Code: DR 👋 Introduction Market Position Segment: Heavy-Duty Pickup Truck segment, designed for towing, hauling, and rugged work. Competitive Analysis Competitors: Ford Super Duty F-250/F-350, Chevrolet Silverado 2500HD, GMC Sierra 2500HD. Key Features Durability: Renowned for its robust construction and powerful engine options, particularly the Cummins diesel. Towing And Hauling: High towing and payload capacities suitable for commercial and recreational use. Off Road Capability: Offered in configurations like the Power Wagon with enhanced off-road features. 📋 Manual Details Coverage Areas Engine Options: All 2005 Ram 2500 gasoline and diesel engines Transmission Options: All 2005 Ram 2500 manual and automatic transmissions Drivetrain Options: 2WD and 4WD configurations Trim Levels: ST, SLT, Laramie, Power Wagon (where applicable) Page Count Estimated Pages: Over 2000 pages (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Service Repair Manual (WSRM) Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair procedures, component replacement for all engine variants (incl. 5.7L HEMI V8, 8.3L V10, 5.9L Cummins Turbo Diesel) Transmission: Service and repair for NV5600, G56 (manual), 48RE, 47RE (automatic) transmissions, including torque converters and clutch systems. Drivetrain: Front and rear axles, differentials, driveshafts, U-joints, transfer case (NV271, NV273, NP241DHD) Suspension: Front and rear suspension components, springs, shocks, steering linkage, power steering system. Brakes: Hydraulic system, ABS, front and rear brake systems, parking brake. Electrical: Wiring diagrams, lighting, charging system, starting system, ignition system, body control modules, power distribution. HVAC: Air conditioning, heating, ventilation system diagnostics and repair. Body: Body panels, doors, latches, windows, exterior trim, interior trim, seats. Chassis: Frame, exhaust system, fuel system, cooling system, chassis lubrication. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, lubrication. Diagnostics: Troubleshooting guides, symptom-to-cause diagnosis, OBD-II codes and interpretations. Repair: Step-by-step repair instructions for all major components and systems. Rebuilds: Complete engine and transmission rebuild procedures, including specifications. Component Replacement: Detailed instructions for replacing parts such as alternators, starters, water pumps, fuel injectors, etc. Alignment: Wheel alignment specifications and procedures. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to full drivetrain and electrical system overhauls. Suitable for professional technicians and advanced DIYers. 📊 Manual Specifications File Format Format: PDF Searchability: Fully searchable text Printability: Printable pages Resolution: High-resolution for clear diagrams and text Print Quality Quality: N/A (Digital Download) Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Gasoline V8: 5.7L (345 ci) HEMI Magnum V8 Gasoline V10: 8.3L (505 ci) Viper V10 Diesel: 5.9L (359 ci) Cummins ISB Turbo Diesel I6 Performance 5.7L Hemi Horsepower: 325 hp @ 4800 rpm 5.7L Hemi Torque: 375 lb-ft @ 4000 rpm 8.3L V10 Horsepower: 353 hp @ 4200 rpm 8.3L V10 Torque: 500 lb-ft @ 3200 rpm 5.9L Cummins Horsepower: 305 hp @ 2900 rpm (approx.) 5.9L Cummins Torque: 555 lb-ft @ 1400 rpm (approx.) Fuel System Gasoline Injection: Sequential Multi-Port Fuel Injection (MPI) Diesel Injection: High-pressure common rail (Cummins) Engine Management ECU: Engine Control Unit (ECU) with OBD-II diagnostics 🔧 Transmission Standard Manual: NV5600 6-speed manual (heavy duty) Optional Manual: G56 6-speed manual (later in production for some models) Automatic Automatic: 48RE 4-speed automatic (with electronic overdrive) Heavy Duty Automatic: 47RE 4-speed automatic (earlier or specific configurations) Features Tow Haul Mode: Available on automatic transmissions to optimize shift points for towing. Fluid Specifications Manual Fluid: Refer to manual for specific NV5600/G56 fluid type (e.g., Mopar Manual Transmission Lubricant or equivalent) Automatic Fluid: Chrysler ATF+4 (Mopar part #05013457AA or equivalent) 📐 Dimensions Exterior Wheelbase: Varies by cab and bed configuration (e.g., 134.0" for standard cab, 154.5" for quad cab) Bed Length: Varies (e.g., 6'4" or 8'0") Weights Curb Weight: Approx. 6,000 - 7,500 lbs (varies by configuration and engine) Gross Vehicle Weight Rating (Gvwr): 8800 - 9100 lbs (typical for 2500 series) Payload Capacity: Approx. 2,000 - 3,500 lbs (varies by configuration) Towing Capacity: Up to 13,000+ lbs (with appropriate equipment and configuration) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 4-star (typical for trucks of this era, highly configuration dependent) Active Features ABS: Anti-lock Braking System (ABS) standard on all wheels. Traction Control: Available Traction Control System (TCS) on certain configurations. Passive Features Airbags: Driver and passenger front airbags. Seatbelts: Three-point seatbelts with pretensioners. 💡 Technology Features Infotainment Audio System: Basic AM/FM/CD audio systems, optional Infinity premium audio, satellite radio readiness. Navigation: Not commonly available from factory for this model year; aftermarket solutions were popular. Driver Assistance Cruise Control: Standard cruise control. Connectivity Auxiliary Input: Limited connectivity; auxiliary audio input may be present on higher trims. 🔧 Maintenance Service Intervals Oil Change Gasoline: Every 3,000-7,500 miles or 6-12 months, depending on driving conditions and oil type. Consult manual...
Oil changes, filter replacements, fluid checks and top-offs, lubrication.
Diagnostics:
Troubleshooting guides, symptom-to-cause diagnosis, OBD-II codes and interpretations.
Repair:
Step-by-step repair instructions for all major components and systems.
Rebuilds:
Complete engine and transmission rebuild procedures, including specifications.
Component Replacement:
Detailed instructions for replacing parts such as alternators, starters, water pumps, fuel injectors, etc.
Alignment:
Wheel alignment specifications and procedures.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to full drivetrain and electrical system overhauls. Suitable for professional technicians and advanced DIYers.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Fully searchable text
Printability:
Printable pages
Resolution:
High-resolution for clear diagrams and text
Print Quality
Quality:
N/A (Digital Download)
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Gasoline V8:
5.7L (345 ci) HEMI Magnum V8
Gasoline V10:
8.3L (505 ci) Viper V10
Diesel:
5.9L (359 ci) Cummins ISB Turbo Diesel I6
Performance
5.7L Hemi Horsepower:
325 hp @ 4800 rpm
5.7L Hemi Torque:
375 lb-ft @ 4000 rpm
8.3L V10 Horsepower:
353 hp @ 4200 rpm
8.3L V10 Torque:
500 lb-ft @ 3200 rpm
5.9L Cummins Horsepower:
305 hp @ 2900 rpm (approx.)
5.9L Cummins Torque:
555 lb-ft @ 1400 rpm (approx.)
Fuel System
Gasoline Injection:
Sequential Multi-Port Fuel Injection (MPI)
Diesel Injection:
High-pressure common rail (Cummins)
Engine Management
ECU:
Engine Control Unit (ECU) with OBD-II diagnostics
🔧 Transmission
Standard
Manual:
NV5600 6-speed manual (heavy duty)
Optional
Manual:
G56 6-speed manual (later in production for some models)
Not commonly available from factory for this model year; aftermarket solutions were popular.
Driver Assistance
Cruise Control:
Standard cruise control.
Connectivity
Auxiliary Input:
Limited connectivity; auxiliary audio input may be present on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Gasoline:
Every 3,000-7,500 miles or 6-12 months, depending on driving conditions and oil type. Consult manual for specific recommendation based on oil viscosity.
Oil Change Diesel:
Every 7,500-15,000 miles or 6-12 months (severe duty may require more frequent changes). Refer to Cummins recommendations.
Engine Air Filter:
Inspect every 15,000 miles, replace as needed. Severe conditions may require more frequent replacement.
Fuel Filter Diesel:
Replace every 15,000 miles (critical for Cummins reliability).
Transmission Fluid Automatic:
Change fluid and filter every 30,000-60,000 miles, depending on towing and load usage.
Fluid Specifications
Engine Oil Gasoline:
API SN or SP certified, SAE 5W-20 or 5W-30 recommended (check specific engine, e.g., 5.7L HEMI often uses 5W-20).
Engine Oil Diesel:
API CI-4/CJ-4 or newer, SAE 15W-40 heavy-duty diesel engine oil (e.g., Rotella T4/T5).
Coolant:
Mopar OAT (Orange) Antifreeze/Coolant, 5/150,000 Mile Formula (MS-9800) or equivalent.
Known Issues
Cummin Injector Hosing:
Early 5.9L Cummins (pre-2007.5) can be prone to injector line leaks due to heat and pressure cycling, requiring periodic inspection and potential replacement.
48Re Overheating:
Automatic transmission (48RE) can be susceptible to overheating under heavy load without proper cooling upgrades.
Radiator Sway Bar Links:
Radiator may develop leaks, and sway bar end links can wear prematurely due to the truck's weight and usage.
📚 Vehicle History
Brand Heritage
Dodge Trucks:
Dodge has a long history of producing robust and capable trucks, dating back to the 1930s.
Model Evolution
Third Generation Ram:
The 2002-2008 Ram generation (often referred to as the 'Third Gen' or 'DR' platform) introduced a significantly redesigned exterior and interior, focusing on improved aerodynamics, comfort, and functionality. It was the first generation to offer the HEMI V8 and the robust Cummins turbo diesel as options.
The 5.9L Cummins turbo diesel engine is widely praised for its durability, longevity, and performance, often considered one of the best diesel engines ever put in a pickup truck.
Ratings
Truck Of The Year:
While specific awards for the 2005 model vary, the Ram line generally received positive reviews for its design and capability during this generation.