Dodge Ram 1500-2500-3500 Service Repair Manual 2003
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🏷️ Basic Information Identification Make: Dodge Model: Ram 1500, Ram 2500, Ram 3500 Year: 2003 Generation Generation Code: Third Generation (DR/DH/D2) Codes Chassis Codes: DR (1500 2WD), DH (1500 4WD), D2 (2500/3500) 👋 Introduction Market Position Vehicle Segment: Full-size pickup truck, catering to a wide range of consumer and commercial needs. Competitive Landscape 2003: Competed directly with Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra, and Nissan Titan. Key Features Of Vehicle Design Philosophy: Known for its bold styling, robust construction, and a strong emphasis on towing and hauling capabilities. Key Features Of Manual Value Proposition: Provides factory-level repair information in a digital format, offering cost savings over physical manuals or dealership services. Accessibility: Accessible on any PC-based Windows or Mac operating system, facilitating widespread use. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive workshop service and repair Secondary Coverage: Maintenance, diagnostics, troubleshooting, rebuilding, component replacement Page Count Estimated Page Count: Likely exceeds 2000 pages (typical for factory service manuals of this era and scope) Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: 3.7L Magnum V6, 4.7L Magnum V8, 5.7L HEMI V8, 5.9L Cummins Turbo Diesel I6 Transmission: 45RFE/545RFE (4-speed Automatic), NV3500 (5-speed Manual), NV4500 (5-speed Manual), G56 (6-speed Manual), NV5600 (6-speed Manual) Drivetrain: Front and Rear Axles, Transfer Case (NV241, NV243, NV271, NV273) Suspension: Front Independent Suspension (IFS), Rear Leaf Spring Suspension, Steering System, Wheel Alignment Brakes: Front Disc Brakes, Rear Disc Brakes (2500/3500), Rear Drum Brakes (some 1500), Anti-lock Braking System (ABS), Parking Brake Cooling System: Radiator, Fan Clutch, Water Pump, Thermostat, Hoses, Heater Core Fuel System: Fuel Tank, Fuel Pump, Fuel Filter, Fuel Injectors, Fuel Lines Exhaust System: Exhaust Manifold, Catalytic Converter, Muffler, Pipes Electrical System: Battery, Alternator, Starter, Ignition System, Lighting, Gauges, Fuses, Relays, Body Control Module (BCM) Heating And Air Conditioning: HVAC System Components, Refrigerant System, Blower Motor, Controls Emission Control Systems: Evaporative Emission Control (EVAP), Exhaust Gas Recirculation (EGR), Oxygen Sensors, Catalytic Converter Body: Body Panels, Doors, Hood, Tailgate, Bumpers, Interior Trim, Glass Wiring Diagrams: Complete schematics for all major electrical systems Procedures Included Maintenance: Oil Changes, Filter Replacements, Fluid Checks and Top-offs, Tire Rotation, Spark Plug Replacement Diagnostics: Troubleshooting charts, DTC (Diagnostic Trouble Code) interpretation, component testing procedures Repair: Engine overhaul, transmission rebuild, suspension component replacement, brake caliper replacement, electrical component repair Rebuilding: Detailed instructions for engine, transmission, and axle rebuilding Torque Specifications: Crucial torque values for engine, chassis, and drivetrain components Special Tools: Identification of specialized tools required for specific repair procedures Technical Depth Depth: Extensive, covering everything from basic fluid changes to complete engine and transmission overhauls. Includes factory-level diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text within the PDF, allowing for quick information retrieval. Print Quality Printability: High, allowing users to print specific sections or the entire manual. Binding Type Binding: Not applicable (Digital PDF format) Paper Type Paper Recommendation: Standard printer paper for printing. ⚙️ Engine Specifications Primary Engine Base Engine 1500: 3.7L Magnum V6 Optional Engine 1500: 4.7L Magnum V8 Performance Engine 1500: 5.7L HEMI V8 Diesel Engine 2500 3500: 5.9L Cummins Turbo Diesel I6 Performance Horsepower 3.7L V6: 215 hp @ 5200 rpm Torque 3.7L V6: 235 lb-ft @ 4000 rpm Horsepower 4.7L V8: 260 hp @ 4800 rpm Torque 4.7L V8: 330 lb-ft @ 3200 rpm Horsepower 5.7L Hemi V8: 345 hp @ 5000 rpm Torque 5.7L Hemi V8: 375 lb-ft @ 4000 rpm Horsepower 5.9L Cummins: 250 hp @ 2700 rpm (Standard output) Torque 5.9L Cummins: 460 lb-ft @ 1400 rpm (Standard output) Fuel System Injection Type Gasoline: Multi-port Fuel Injection (MPI) Injection Type Diesel: Inline Injection Pump (VE-style for earlier models, P7100 for later, this manual likely covers the P7100 or a transition model) Fuel Requirement Gasoline: 87 Octane Unleaded (recommended) Fuel Requirement Diesel: Diesel Fuel 🔧 Transmission Standard Standard Transmission 1500: 45RFE/545RFE (4-speed Automatic) Standard Transmission 2500 3500 Manual: NV3500 (5-speed Manual) Optional Optional Transmission 1500 Manual: NV3500 (5-speed Manual) Optional Transmission 2500 3500 Automatic: 48RE (4-speed Automatic - typically with Cummins) Optional Transmission 2500 3500 Manual: NV4500 (5-speed Manual), NV5600 (6-speed Manual - likely for higher torque applications), G56 (6-speed Manual - replacing NV5600) Features Overdrive Gears: Automatic transmissions typically feature overdrive for improved fuel economy. Manual transmissions offer various gear ratios suited for towing and highway cruising. Fluid Specifications Automatic Transmission Fluid Type: ATF+4 (Chrysler Material Standard MS-9602) Manual Transmission Fluid Type: API GL-4 or GL-5 gear oil (specific weight varies by transmission model, e.g., 75W-90) Transfer Case Fluid Type: ATF+4 (for NV243, NV271) or specific transfer case fluid (for NV241HD, NV273) 📐 Dimensions Exterior Body Styles: Regular Cab, Club Cab (Extended Cab), Mega Cab (4-door extended cab, introduced later in the generation) Bed Lengths: Short Bed (approx. 6.3 ft), Long Bed (approx....
Automatic transmissions typically feature overdrive for improved fuel economy. Manual transmissions offer various gear ratios suited for towing and highway cruising.
Fluid Specifications
Automatic Transmission Fluid Type:
ATF+4 (Chrysler Material Standard MS-9602)
Manual Transmission Fluid Type:
API GL-4 or GL-5 gear oil (specific weight varies by transmission model, e.g., 75W-90)
Transfer Case Fluid Type:
ATF+4 (for NV243, NV271) or specific transfer case fluid (for NV241HD, NV273)
📐 Dimensions
Exterior
Body Styles:
Regular Cab, Club Cab (Extended Cab), Mega Cab (4-door extended cab, introduced later in the generation)
Bed Lengths:
Short Bed (approx. 6.3 ft), Long Bed (approx. 8.0 ft)
Weights
Gvwr Range:
Varies significantly by model (1500, 2500, 3500) and configuration, typically from ~7000 lbs to over 12000 lbs.
Curb Weight Range:
Approximately 4800 lbs to over 7000 lbs depending on configuration.
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
Generally good for its class, but specific ratings can vary by year and configuration. Likely received 4 or 5 stars for frontal impact.
IIHS Crash Test Results:
Typically rated 'Good' or 'Acceptable' in frontal offset tests.
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Available on some models/trims
Passive Features
Airbags:
Driver and Passenger Front Airbags
Seatbelts:
Three-point seat belts with pretensioners
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo, CD player (single or in-dash changer), optional cassette player, optional Infinity audio system.
Driver Assistance
Cruise Control:
Standard on most trims
Tow Haul Mode:
Available on automatic transmissions for optimized towing performance
Connectivity
Power Outlets:
12V auxiliary power outlets
🔧 Maintenance
Service Intervals
Oil Change Interval Gasoline:
Typically 3,000-7,500 miles or 3-6 months, depending on driving conditions and oil type used (check manual for specifics).
Oil Change Interval Diesel:
Typically 7,500 miles or 6 months for Cummins, but check manual for specific recommendations.
Engine Coolant Flush:
Every 30,000-100,000 miles or 2-5 years, depending on coolant type and manufacturer recommendations.
Transmission Fluid Change:
Automatic: 30,000-60,000 miles. Manual: Check manual for recommendations, often longer intervals.
Fluid Specifications
Engine Oil Type Gasoline:
API SM or higher, viscosity 5W-30 (check manual for specific engine requirements).
Engine Oil Type Diesel:
API CJ-4 or equivalent, viscosity 15W-40 (check manual for specific Cummins requirements).
Coolant Type:
HOAT (Hybrid Organic Acid Technology) Orange or similar long-life coolant.
Known Issues
Common Wear Items:
Ball joints, tie rod ends, sway bar links, wheel bearings (especially on heavy-duty models), brake pads and rotors.
Engine Specific Concerns 4.7L V8:
Spark plug blowout in early models, potential head gasket issues if overheated.
Engine Specific Concerns 5.9L Cummins:
Lift pump failures, injector issues, potential for injector line vibration cracks. However, generally very robust.
Transmission Specific Concerns:
Overheating of automatic transmissions with heavy towing, wear on manual transmission synchros (especially reverse on NV4500/NV5600).
Suspension Concerns:
Front suspension wear due to vehicle weight and load capacity.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, with the Ram nameplate established in 1981.
Model Evolution
Third Generation Launch:
The third generation of the Ram pickup was launched for the 2002 model year, featuring a significantly redesigned exterior and interior, and introducing the HEMI engine option for 2003.
Key Updates For 2003:
Introduction of the legendary 5.7L HEMI V8 engine, and the availability of the Mega Cab body style in later years of the generation.
Production
Manufacturing Plant:
Primarily St. Louis (Missouri) Assembly Plant and Saltillo Truck Assembly Plant (Mexico).
🏆 Awards & Recognition
Recognitions
Truck Of The Year Awards General:
While specific awards for the 2003 model year might be sparse, the Ram platform generally received positive reviews for its capabilities and styling.
Engine Awards 5.7L Hemi:
The 5.7L HEMI V8 was widely praised for its power and sound, earning it a place on Ward's 10 Best Engines list in subsequent years.
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