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DODGE 2500 RAM Truck 2006 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 2500 Year: 2006 Codes Platform: Ram Heavy Duty (DR/DH/D2 platform) 👋 Introduction Market Position Segment: Full-size heavy-duty pickup truck. Target Audience: Commercial users, fleet operators, towing enthusiasts, and DIY mechanics. Competitive Analysis Key Competitors: Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD. Key Features Durability: Renowned for its robust construction and heavy-duty capabilities. Towing Capacity: Industry-leading towing and hauling capabilities. Engine Options: Powerful V8 gasoline and inline-6 diesel engine choices. 📋 Manual Details Coverage Areas Vehicle Coverage: All Dodge Ram 2500 models for the 2006 model year. Page Count Page Count: Approximately 1500-2000 pages (estimated for a comprehensive service manual). Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, tuning, component replacement for all available engines. Transmission: Manual and automatic transmission repair, diagnostics, fluid services, torque converter information. Drivetrain: Four-wheel drive (4WD) system, transfer case, differentials, axles, driveshafts, U-joints. Brakes: Front and rear brake systems (disc and drum), ABS, parking brake, hydraulic systems. Suspension: Front and rear suspension components, steering system, alignment specifications, shocks, springs, bushings. Electrical System: Wiring diagrams, charging system, starting system, lighting, accessories, fuses, relays, sensors. Body And Frame: Body panel removal and installation, interior trim, glass, doors, tailgate, chassis and frame inspection. Heating Ventilation And Air Conditioning: HVAC system diagnosis and repair, refrigerant handling, climate control components. Fuel System: Fuel tank, fuel pump, fuel injectors, fuel lines, evaporative emissions control (EVAP). Exhaust System: Exhaust manifolds, catalytic converter, mufflers, pipes, emissions controls. Cooling System: Radiator, water pump, thermostat, hoses, fan, coolant specifications. Diagnostics: Diagnostic trouble codes (DTCs), on-board diagnostics (OBD-II), troubleshooting flowcharts. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, fluid checks, belt replacements. Repair: Detailed step-by-step repair procedures for all major components and systems. Troubleshooting: Symptom-based troubleshooting guides and diagnostic procedures. Torque Specifications: All critical fastener torque specifications for various components. Special Tools: Identification and usage of specialized tools required for specific repairs. Technical Depth Depth: Comprehensive coverage from basic maintenance to complete engine and transmission rebuilds. Diagnostic Level: Advanced diagnostic procedures using scan tools and electrical troubleshooting techniques. 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable text content for quick information retrieval. Printability: Printable pages for in-shop use. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code Gas: 5.7L V8 Magnum (HEMI is optional or not standard on all trims). Engine Description Gas: 345 cubic inch OHV V8. Engine Power Gas: Approx. 325-345 hp (varies by specific application within the year). Engine Torque Gas: Approx. 370-390 lb-ft. Optional Engine Diesel Engine Code Diesel: 5.9L Cummins Turbo Diesel (ISB) Engine Description Diesel: 359 cubic inch inline-6, overhead camshaft, direct injection, turbocharger. Engine Power Diesel: Approx. 305-325 hp. Engine Torque Diesel: Approx. 555-610 lb-ft. Fuel System Fuel Type Gas: Unleaded gasoline. Fuel Type Diesel: Diesel fuel. Injection Type Gas: Multi-point fuel injection (MPI). Injection Type Diesel: Common rail direct injection. 🔧 Transmission Standard Transmission Type: 6-speed manual transmission (NV5600 for some diesel applications). Optional Transmission Type: 4-speed automatic transmission (48RE for diesel, 45RFE/545RFE for gasoline). Features Overdrive: Both transmissions typically feature overdrive gears. Transfer Case: Part-time 4WD with electronic shift-on-the-fly or manual transfer case options. 📐 Dimensions Exterior Wheelbase Std: Approx. 135.2 inches (standard cab, short bed). Wheelbase Long: Approx. 140.5 inches (crew cab, standard bed) and 160.5 inches (crew cab, long bed). Bed Length: Available in 6.3 ft (short bed) and 8 ft (long bed). Weights Curb Weight: Varies significantly by configuration, generally starting around 6,000 lbs. Gross Vehicle Weight Rating Gvwr: Typically rated between 8,800 lbs and 10,500 lbs. Payload Capacity: Substantial payload capacity, often exceeding 3,000 lbs depending on configuration. Towing Capacity: Can exceed 12,000 lbs with proper configuration (fifth-wheel/gooseneck and trailer brake controller). 🛡️ Safety Features Ratings NHTSA Front Impact: Generally good ratings for its class in frontal impacts. NHTSA Side Impact: Good ratings for its class in side impacts. Active Features ABS: Standard Anti-lock Braking System (ABS). Traction Control: Available Traction Control (often linked with ABS). Passive Features Airbags: Front airbags for driver and passenger. Seatbelts: Three-point seat belts with pretensioners. 💡 Technology Features Infotainment Radio: AM/FM stereo with CD player, cassette player (early models), or optional satellite radio. Display: Basic digital display for radio and vehicle information. Driver Assistance Cruise Control: Standard cruise control. Trailer Brake Controller: Optional integrated trailer brake controller. Connectivity Phone Integration: No integrated smartphone connectivity like Bluetooth or USB ports; typically aftermarket solutions. 🔧 Maintenance Service Intervals Oil Change Gas: Every 3,000-5,000 miles or 3-6 months, depending on usage and oil type. Oil Change Diesel: Every 7,500-10,000 miles or 6-12 months for Cummins diesel,...
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DODGE 2500 RAM Truck 2006 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram 2500
Year:
2006
Codes
Platform:
Ram Heavy Duty (DR/DH/D2 platform)
👋 Introduction
Market Position
Segment:
Full-size heavy-duty pickup truck.
Target Audience:
Commercial users, fleet operators, towing enthusiasts, and DIY mechanics.
Competitive Analysis
Key Competitors:
Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD.
Key Features
Durability:
Renowned for its robust construction and heavy-duty capabilities.
Towing Capacity:
Industry-leading towing and hauling capabilities.
Engine Options:
Powerful V8 gasoline and inline-6 diesel engine choices.
📋 Manual Details
Coverage Areas
Vehicle Coverage:
All Dodge Ram 2500 models for the 2006 model year.
Page Count
Page Count:
Approximately 1500-2000 pages (estimated for a comprehensive service manual).
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnostics, tuning, component replacement for all available engines.
Transmission:
Manual and automatic transmission repair, diagnostics, fluid services, torque converter information.
Drivetrain:
Four-wheel drive (4WD) system, transfer case, differentials, axles, driveshafts, U-joints.
Brakes:
Front and rear brake systems (disc and drum), ABS, parking brake, hydraulic systems.
Suspension:
Front and rear suspension components, steering system, alignment specifications, shocks, springs, bushings.
Electrical System:
Wiring diagrams, charging system, starting system, lighting, accessories, fuses, relays, sensors.
Body And Frame:
Body panel removal and installation, interior trim, glass, doors, tailgate, chassis and frame inspection.
Heating Ventilation And Air Conditioning:
HVAC system diagnosis and repair, refrigerant handling, climate control components.
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel lines, evaporative emissions control (EVAP).
Exhaust System:
Exhaust manifolds, catalytic converter, mufflers, pipes, emissions controls.
Cooling System:
Radiator, water pump, thermostat, hoses, fan, coolant specifications.
Diagnostics:
Diagnostic trouble codes (DTCs), on-board diagnostics (OBD-II), troubleshooting flowcharts.
Procedures Included
Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, fluid checks, belt replacements.
Repair:
Detailed step-by-step repair procedures for all major components and systems.
Troubleshooting:
Symptom-based troubleshooting guides and diagnostic procedures.
Torque Specifications:
All critical fastener torque specifications for various components.
Special Tools:
Identification and usage of specialized tools required for specific repairs.
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Level:
Advanced diagnostic procedures using scan tools and electrical troubleshooting techniques.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Searchable text content for quick information retrieval.
Printability:
Printable pages for in-shop use.
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code Gas:
5.7L V8 Magnum (HEMI is optional or not standard on all trims).
Engine Description Gas:
345 cubic inch OHV V8.
Engine Power Gas:
Approx. 325-345 hp (varies by specific application within the year).
Engine Torque Gas:
Approx. 370-390 lb-ft.
Optional Engine Diesel
Engine Code Diesel:
5.9L Cummins Turbo Diesel (ISB)
Engine Description Diesel:
359 cubic inch inline-6, overhead camshaft, direct injection, turbocharger.
Engine Power Diesel:
Approx. 305-325 hp.
Engine Torque Diesel:
Approx. 555-610 lb-ft.
Fuel System
Fuel Type Gas:
Unleaded gasoline.
Fuel Type Diesel:
Diesel fuel.
Injection Type Gas:
Multi-point fuel injection (MPI).
Injection Type Diesel:
Common rail direct injection.
🔧 Transmission
Standard
Transmission Type:
6-speed manual transmission (NV5600 for some diesel applications).
Optional
Transmission Type:
4-speed automatic transmission (48RE for diesel, 45RFE/545RFE for gasoline).
Features
Overdrive:
Both transmissions typically feature overdrive gears.
Transfer Case:
Part-time 4WD with electronic shift-on-the-fly or manual transfer case options.
📐 Dimensions
Exterior
Wheelbase Std:
Approx. 135.2 inches (standard cab, short bed).
Wheelbase Long:
Approx. 140.5 inches (crew cab, standard bed) and 160.5 inches (crew cab, long bed).
Bed Length:
Available in 6.3 ft (short bed) and 8 ft (long bed).
Weights
Curb Weight:
Varies significantly by configuration, generally starting around 6,000 lbs.
Gross Vehicle Weight Rating Gvwr:
Typically rated between 8,800 lbs and 10,500 lbs.
Payload Capacity:
Substantial payload capacity, often exceeding 3,000 lbs depending on configuration.
Towing Capacity:
Can exceed 12,000 lbs with proper configuration (fifth-wheel/gooseneck and trailer brake controller).
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Generally good ratings for its class in frontal impacts.
NHTSA Side Impact:
Good ratings for its class in side impacts.
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Traction Control:
Available Traction Control (often linked with ABS).
Passive Features
Airbags:
Front airbags for driver and passenger.
Seatbelts:
Three-point seat belts with pretensioners.
💡 Technology Features
Infotainment
Radio:
AM/FM stereo with CD player, cassette player (early models), or optional satellite radio.
Display:
Basic digital display for radio and vehicle information.
Driver Assistance
Cruise Control:
Standard cruise control.
Trailer Brake Controller:
Optional integrated trailer brake controller.
Connectivity
Phone Integration:
No integrated smartphone connectivity like Bluetooth or USB ports; typically aftermarket solutions.
🔧 Maintenance
Service Intervals
Oil Change Gas:
Every 3,000-5,000 miles or 3-6 months, depending on usage and oil type.
Oil Change Diesel:
Every 7,500-10,000 miles or 6-12 months for Cummins diesel, following specific oil recommendations.
Fuel Filter Diesel:
Recommended replacement every 15,000-25,000 miles (crucial for common rail systems).
Transmission Fluid Auto:
Every 30,000-60,000 miles, depending on towing and driving conditions.
Transfer Case Fluid:
Every 30,000-60,000 miles.
Fluid Specifications
Engine Oil Gas:
API SN, SAE 5W-30 or 10W-30 (refer to owner's manual for exact specification).
Engine Oil Diesel:
API CI-4 or CJ-4, SAE 15W-40 (Cummins recommends specific brands/types).
Transmission Fluid Auto:
ATF+4 (Chrysler's proprietary fluid) for 45RFE/545RFE, ATF+3 or compatible for 48RE.
Transmission Fluid Manual:
Refer to specific manual transmission fluid specifications (e.g., NV5600 requires specific fluid).
Coolant:
HOAT (Hybrid Organic Acid Technology) coolant, typically orange or yellow.
Known Issues
Diesel Injectors:
Potential for injector issues on early common rail Cummins engines, though generally robust.
Automatic Transmission 48Re:
Can experience wear on clutch packs and torque converter, especially under heavy load.
Front Suspension:
Ball joint and tie rod wear is common due to the truck's weight and usage.
Electrical Connectors:
Corrosion or loose connections in various electrical connectors can cause intermittent issues.
📚 Vehicle History
Brand Heritage
Heritage:
Dodge has a long history of producing robust trucks and commercial vehicles.
Model Evolution
Fourth Generation:
The 2006 Ram 2500 is part of Dodge's fourth-generation Ram pickup truck lineup (introduced for 2002).
Design Updates 2006:
While not a full redesign, the 2006 model year often received minor updates and package refinements.
Production
Manufacturing Location:
Primarily assembled in the United States (e.g., Saltillo, Mexico; Warren, Michigan).
🏆 Awards & Recognition
Recognitions
Powertrain Recognition:
The 5.9L Cummins Turbo Diesel engine has consistently received high praise for its durability and performance.
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