DODGE RAM Truck Petrol & Diesel Workshop Manual Repair All 2002-2008 ModelS COVERED
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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Generation: Third Generation (DR/DH/D1/HB) Codes Platform Codes: DR/DH/D1/HB 👋 Introduction Market Position Category: Heavy-Duty Pickup Truck Segment: Full-Size Pickup Competitive Analysis Key Competitors: Ford F-Series, Chevrolet Silverado, GMC Sierra, Toyota Tundra Key Features Distinctive Attributes: Robust construction, powerful engine options (including HEMI V8 and Cummins Diesel), versatile utility for work and personal use. Purpose Of Manual: To provide comprehensive guidance for maintenance, troubleshooting, and repair of all major systems. 📋 Manual Details Coverage Areas Years Covered: 2002-2008 Engine Variants Covered: Petrol (Gasoline) and Diesel Page Count Estimated Pages: 1000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Drivetrain, Fuel System, Exhaust System Chassis: Suspension (Front & Rear), Steering, Brakes (ABS/Non-ABS), Wheels & Tires Electrical: Body Electrical, Powertrain Control Module (PCM), Engine Control Unit (ECU), Lighting, Instruments, HVAC Controls, Power Accessories Body: Body Panels, Doors, Windows, Seats, Interior Trim, Exterior Trim, HVAC System, Cooling System, Air Conditioning HVAC: Air conditioning system, heater, blower motor, controls, refrigerant handling. Fuel System: Fuel tanks, fuel pumps, fuel injectors, fuel lines, fuel filters (including diesel particulate filter for later models/emissions standards). Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication Repair: Component Removal & Installation, System Diagnosis & Repair, Overhaul Procedures Diagnostics: Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Wiring Diagrams, Component Testing Electrical Diagnostics: Detailed wiring diagrams, component location charts, diagnostic procedures for all major electrical systems. Technical Depth Depth: Comprehensive: From basic fluid checks and routine maintenance to complex engine and transmission rebuilds, electrical system troubleshooting, and bodywork repairs. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text enabled Print Quality Printability: Printable pages for offline use Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Common Petrol Engine 1: 4.7L Magnum V8 (235 hp @ 4500 rpm, 295 lb-ft @ 3200 rpm) Common Petrol Engine 2: 5.7L HEMI V8 (345 hp @ 5000 rpm, 375 lb-ft @ 4000 rpm) - Introduced 2003 Common Diesel Engine: 5.9L Cummins I6 Turbo Diesel (250-345 hp, 450-610 lb-ft torque, depending on configuration) Performance Horsepower Range: 235 hp - 345 hp (petrol), 250 hp - 345 hp (diesel) Torque Range: 295 lb-ft - 375 lb-ft (petrol), 450 lb-ft - 610 lb-ft (diesel) Fuel System Petrol Injection: Sequential Electronic Fuel Injection (SEFI) Diesel Injection: High-pressure Common Rail Direct Injection (Cummins ISB) Engine Codes Engine Code Example 4.7L: EVC, EVG Engine Code Example 5.7L Hemi: EHD, EHE Engine Code Example 5.9L Cummins: Different specific codes based on HP/torque output and emission standards. 🔧 Transmission Standard Common Petrol Transmission 1: 4-speed automatic (45RFE/48RE) Common Diesel Transmission: 5-speed manual (NV5600), 4-speed automatic (47RE/48RE) Optional Manual Transmission: 6-speed manual (G56) for later models with 5.9L Cummins Features 4Wd System: Part-time 4WD with electronic transfer case shift or manual transfer case lever. Transmission Fluid Spec Auto: ATF+4 (Mopar Material Standard MS-9602) Transmission Fluid Spec Manual: GL-3 or GL-4 gear oil (specific viscosity dependent on model and temperature) 📐 Dimensions Exterior Wheelbase Options: 131.3 inches (standard cab), 140.5 inches (club cab/quad cab), 160.5 inches (mega cab) Overall Length Approx: 229.7 - 260.7 inches (depending on cab and bed configuration) Cargo Bed Length Options: 6.3 feet (short bed), 8.0 feet (long bed) Weights Curb Weight Range: Approx. 5,000 lbs to 7,000 lbs (depending on configuration and engine) Gross Vehicle Weight Rating Gvwr Range: 6,000 lbs to 13,000 lbs (depending on model designation - 1500, 2500, 3500) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4-star (for models tested) NHTSA Frontal Impact Passenger: 4-star (for models tested) Active Features ABS: Standard on most models, with variations between 1500 and heavier duty trucks. Traction Control: Optional on some models, more common on higher trims. Passive Features Airbags: Driver and passenger front airbags. Side curtain airbags became available on later models and higher trims. Seatbelts: Three-point seatbelts with pretensioners. 💡 Technology Features Infotainment Available Features: CD player, AM/FM radio, optional cassette player, Sirius Satellite Radio, optional Infinity sound system. Navigation: Factory navigation systems were an option on higher trim levels. Driver Assistance Cruise Control: Standard on most models. Parking Sensors: Optional rear parking assist system available on some trims. Connectivity Auxiliary Input: Not commonly available; later models may have offered basic auxiliary audio inputs. Trailer Brake Controller: Optional integrated trailer brake controller on certain configurations. 🔧 Maintenance Service Intervals Oil Change Interval Petrol: Every 3,000-7,500 miles or 6 months, depending on driving conditions and oil type used (refer to manual for specifics). Oil Change Interval Diesel: Every 7,500-15,000 miles or 6-12 months, depending on oil quality and driving conditions (refer to manual for specifics). Tire Rotation: Every 5,000-7,500 miles Air Filter Replacement: Every 15,000-30,000 miles or as needed based on inspection. Fluid Specifications...
Detailed wiring diagrams, component location charts, diagnostic procedures for all major electrical systems.
Technical Depth
Depth:
Comprehensive: From basic fluid checks and routine maintenance to complex engine and transmission rebuilds, electrical system troubleshooting, and bodywork repairs.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text enabled
Print Quality
Printability:
Printable pages for offline use
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Common Petrol Engine 1:
4.7L Magnum V8 (235 hp @ 4500 rpm, 295 lb-ft @ 3200 rpm)
Factory navigation systems were an option on higher trim levels.
Driver Assistance
Cruise Control:
Standard on most models.
Parking Sensors:
Optional rear parking assist system available on some trims.
Connectivity
Auxiliary Input:
Not commonly available; later models may have offered basic auxiliary audio inputs.
Trailer Brake Controller:
Optional integrated trailer brake controller on certain configurations.
🔧 Maintenance
Service Intervals
Oil Change Interval Petrol:
Every 3,000-7,500 miles or 6 months, depending on driving conditions and oil type used (refer to manual for specifics).
Oil Change Interval Diesel:
Every 7,500-15,000 miles or 6-12 months, depending on oil quality and driving conditions (refer to manual for specifics).
Tire Rotation:
Every 5,000-7,500 miles
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on inspection.
Fluid Specifications
Engine Oil Petrol 5.7L Hemi:
SAE 5W-20, API SN/SN PLUS, ILSAC GF-5 (check manual for exact spec, some early models used 10W-30)
Engine Oil Diesel 5.9L Cummins:
API CJ-4 or CI-4 PLUS (e.g., Shell Rotella T Triple Protection 15W-40 recommended)
Coolant:
Chrysler/Mopar OAT (Organic Additive Technology) or HOAT (Hybrid OAT) coolant, typically pink or orange (e.g., Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula)
Brake Fluid:
DOT 3
Known Issues
Common Complaint 1:
Age-related wear on suspension components (ball joints, tie rods, control arm bushings)
Common Complaint 2:
Heater core leaks (particularly on the 5.7L HEMI engine)
Common Complaint 3:
Power steering pump whine or leaks
Common Complaint 4:
Fuel pump failures, particularly in warmer climates.
Common Complaint 5:
5.9L Cummins: Injector issues, grid heater failures, and occasional turbocharger problems (though generally very reliable).
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, with the Ram nameplate originating in 1981.
Model Evolution
Generation Transition:
The 2002-2008 models represent the third generation of the Ram pickup, introduced with a significant redesign featuring a more aggressive and distinctive 'crosshair' grille and updated chassis.
Production
Manufacturing Locations:
Primary assembly plants in Warren, Michigan, and Saltillo, Mexico.
Sales Performance:
Consistently one of the best-selling full-size pickup trucks in North America during its production run.
🏆 Awards & Recognition
Recognitions
Major Truck Awards:
While specific awards vary annually, the Dodge Ram consistently received positive reviews for its styling, powertrain options (especially the HEMI and Cummins), and towing/hauling capabilities within its segment.
Ratings
Consumer Reports Reliability:
Reliability ratings varied by model year and specific powertrain, generally considered average to slightly below average for the brand during these years, with the Cummins diesel typically rated higher.
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