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DODGE MAGNUM SRT-8 2004-2008 Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Magnum SRT-8 Model Years: 2004, 2005, 2006, 2007, 2008 Codes Engine Codes Covered: 3.0L TD (Common Rail Diesel), 2.7L EER V6 (MPI), 3.5L EGG V6 (MPI High Output), 6.1L ESF V8 (Hemi), 5.7L EZB V8 (Hemi Multi-Displacement) Transmission Codes Covered: 42RLE (4-Speed Automatic), W5A580/NAG1 (5-Speed Automatic) 👋 Introduction Market Position Market Position: The Dodge Magnum SRT-8 occupied a niche as a high-performance, American-made five-door muscle car or 'shooting brake' variant of the LX platform, directly competing with other performance sedans and wagons. Competitive Analysis Competitive Analysis: Competed against performance versions of European wagons (e.g., Audi RS6 Avant, Mercedes-Benz E-Class AMG Wagon) and American performance sedans. Its distinctive styling and V8 power offered a unique proposition. Key Features Key Features: Powerful Hemi V8 engine options, rear-wheel drive bias, distinctive long-roof wagon body style, SRT performance enhancements, robust chassis shared with Chrysler 300 and Dodge Charger. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive repair and service for Dodge Magnum SRT-8 (2004-2008), with similarities noted for Dodge Charger LX and Chrysler 300 SRT-8. Page Count Page Count: >9500 pages Manual Type Manual Type: Factory Repair Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine Systems (including 3.0L TD, 2.7L V6, 3.5L V6, 5.7L Hemi, 6.1L Hemi), Cooling, Lubrication, Fuel System, Exhaust System, Ignition Control, Brakes, Suspension, Differential & Driveline, Steering, Automatic Transmissions (42RLE, W5A580/NAG1), Electrical Systems, Electronic Control Modules, HVAC, Restraints, Lighting, Wipers/Washers, Audio/Video, Navigation/Telecommunication, Vehicle Theft Security, Speed Control, Emissions Control, Body, Frame & Bumpers, Tires/Wheels, Instrumentation, Chime/Buzzer, Clock, Heated Systems, Horn, Message Systems, Power Systems. Procedures Included Procedures Included: Step-by-step repair instructions, maintenance procedures, diagnostics, troubleshooting, component replacement, fluid specifications, torque specifications, wiring diagrams, system overviews, overhaul procedures, component testing, and adjustments. Technical Depth Technical Depth: Highly detailed, covering everything from basic maintenance and fluid changes to complete engine and transmission overhauls, advanced diagnostics, and electrical system troubleshooting. Suitable for both DIY enthusiasts and professional mechanics. Engine Overhaul Engine Overhaul Detail: Detailed procedures for complete engine disassembly, inspection, repair, and reassembly for all covered engine variants, including torque specifications, bearing clearances, and ring gap measurements. Transmission Rebuild Transmission Rebuild Detail: Comprehensive instructions for the W5A580/NAG1 and 42RLE automatic transmissions, covering valve body repairs, clutch pack replacement, seal and gasket renewal, and hydraulic system testing. Electrical Diagnostics Electrical Diagnostics Detail: Extensive wiring diagrams, component location charts, diagnostic trouble code (DTC) explanations, and step-by-step troubleshooting guides for all major electrical systems. Body And Frame Body And Frame Detail: Information on body panel removal and installation, frame straightening, bumper repairs, glass replacement, and interior trim component servicing. Hvac System HVAC System Detail: Service and repair procedures for the heating, ventilation, and air conditioning (HVAC) system, including refrigerant handling, compressor service, blower motor replacement, and climate control module diagnostics. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) File Compression: ZIP Archive Print Quality Print Quality: Printable pages for individual tasks. High-resolution illustrations and diagrams. Binding Type Binding Type: N/A (Electronic Format) Paper Type Paper Type: N/A (Electronic Format) Software Requirements Software Requirements: Adobe Acrobat Reader (free download from Adobe website), File extraction utility (e.g., WinZip or WinRAR). Operating Systems Operating Systems: Compatible with all Windows and Mac operating systems. ⚙️ Engine Specifications Primary Engine Primary Engine: 6.1L ESF Hemi V8 (SRT-8 specific) Performance 6.1L Hemi Srt8 Horsepower: 425 hp @ 6000 rpm 6.1L Hemi Srt8 Torque: 420 lb-ft @ 4800 rpm Fuel System 6.1L Hemi Srt8 Fuel System: Sequential Multi-Port Fuel Injection (SMPI) Other Engines Covered Other Engines Covered: 5.7L EZB V8 Hemi (Multi-Displacement System), 3.5L EGG V6 (High Output), 2.7L EER V6, 3.0L TD (Common Rail Diesel). Engine Construction Engine Construction: Cast Iron Block (Diesel), Aluminum Block (V6 and Hemi V8s). Valvetrain Valvetrain: Overhead Valve (OHV) with semi-hemispherical combustion chambers (Hemi), Dual Overhead Camshafts (DOHC) for V6 engines. 🔧 Transmission Standard Standard Transmission: 5-Speed W5A580/NAG1 Automatic (SRT-8 specific) Optional Optional Transmission: 4-Speed 42RLE Automatic (standard on non-SRT-8 models) Features Transmission Features: Manual shift modes (AutoStick), electronic control with adaptive shift logic. Fluid Type W5A580 Fluid Type: Pentosin ATF1 or equivalent (refer to manual for specific part numbers and DEXRON compatibility). 42Rle Fluid Type: Chrysler ATF+4 (or equivalent Mopar specification). 📐 Dimensions Exterior Wheelbase: Approximately 120 inches (3048 mm) Length: Approximately 199.0 inches (5055 mm) Width: Approximately 74.1 inches (1882 mm) Height: Approximately 58.4 inches (1483 mm) Weights Curb Weight Srt8: Approximately 4,100 - 4,200 lbs (1860 - 1905 kg) Gross Vehicle Weight Rating: Refer to specific vehicle VIN plate; typically around 5,300 lbs (2400 kg). Towing Capacity: Not specified for SRT-8 models; typically around 1000 lbs for non-SRT models if equipped with towing package. Cargo Cargo Volume: Approximately 21.2 cubic feet (rear seats up) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5-star (for Dodge Magnum,...
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DODGE MAGNUM SRT-8 2004-2008 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Magnum SRT-8
Model Years:
2004, 2005, 2006, 2007, 2008
Codes
Engine Codes Covered:
3.0L TD (Common Rail Diesel), 2.7L EER V6 (MPI), 3.5L EGG V6 (MPI High Output), 6.1L ESF V8 (Hemi), 5.7L EZB V8 (Hemi Multi-Displacement)
Transmission Codes Covered:
42RLE (4-Speed Automatic), W5A580/NAG1 (5-Speed Automatic)
👋 Introduction
Market Position
Market Position:
The Dodge Magnum SRT-8 occupied a niche as a high-performance, American-made five-door muscle car or 'shooting brake' variant of the LX platform, directly competing with other performance sedans and wagons.
Competitive Analysis
Competitive Analysis:
Competed against performance versions of European wagons (e.g., Audi RS6 Avant, Mercedes-Benz E-Class AMG Wagon) and American performance sedans. Its distinctive styling and V8 power offered a unique proposition.
Key Features
Key Features:
Powerful Hemi V8 engine options, rear-wheel drive bias, distinctive long-roof wagon body style, SRT performance enhancements, robust chassis shared with Chrysler 300 and Dodge Charger.
📋 Manual Details
Coverage Areas
Coverage Areas:
Comprehensive repair and service for Dodge Magnum SRT-8 (2004-2008), with similarities noted for Dodge Charger LX and Chrysler 300 SRT-8.
Page Count
Page Count:
>9500 pages
Manual Type
Manual Type:
Factory Repair Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine Systems (including 3.0L TD, 2.7L V6, 3.5L V6, 5.7L Hemi, 6.1L Hemi), Cooling, Lubrication, Fuel System, Exhaust System, Ignition Control, Brakes, Suspension, Differential & Driveline, Steering, Automatic Transmissions (42RLE, W5A580/NAG1), Electrical Systems, Electronic Control Modules, HVAC, Restraints, Lighting, Wipers/Washers, Audio/Video, Navigation/Telecommunication, Vehicle Theft Security, Speed Control, Emissions Control, Body, Frame & Bumpers, Tires/Wheels, Instrumentation, Chime/Buzzer, Clock, Heated Systems, Horn, Message Systems, Power Systems.
Procedures Included
Procedures Included:
Step-by-step repair instructions, maintenance procedures, diagnostics, troubleshooting, component replacement, fluid specifications, torque specifications, wiring diagrams, system overviews, overhaul procedures, component testing, and adjustments.
Technical Depth
Technical Depth:
Highly detailed, covering everything from basic maintenance and fluid changes to complete engine and transmission overhauls, advanced diagnostics, and electrical system troubleshooting. Suitable for both DIY enthusiasts and professional mechanics.
Engine Overhaul
Engine Overhaul Detail:
Detailed procedures for complete engine disassembly, inspection, repair, and reassembly for all covered engine variants, including torque specifications, bearing clearances, and ring gap measurements.
Transmission Rebuild
Transmission Rebuild Detail:
Comprehensive instructions for the W5A580/NAG1 and 42RLE automatic transmissions, covering valve body repairs, clutch pack replacement, seal and gasket renewal, and hydraulic system testing.
Electrical Diagnostics
Electrical Diagnostics Detail:
Extensive wiring diagrams, component location charts, diagnostic trouble code (DTC) explanations, and step-by-step troubleshooting guides for all major electrical systems.
Body And Frame
Body And Frame Detail:
Information on body panel removal and installation, frame straightening, bumper repairs, glass replacement, and interior trim component servicing.
Hvac System
HVAC System Detail:
Service and repair procedures for the heating, ventilation, and air conditioning (HVAC) system, including refrigerant handling, compressor service, blower motor replacement, and climate control module diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
File Compression:
ZIP Archive
Print Quality
Print Quality:
Printable pages for individual tasks. High-resolution illustrations and diagrams.
Binding Type
Binding Type:
N/A (Electronic Format)
Paper Type
Paper Type:
N/A (Electronic Format)
Software Requirements
Software Requirements:
Adobe Acrobat Reader (free download from Adobe website), File extraction utility (e.g., WinZip or WinRAR).
Operating Systems
Operating Systems:
Compatible with all Windows and Mac operating systems.
⚙️ Engine Specifications
Primary Engine
Primary Engine:
6.1L ESF Hemi V8 (SRT-8 specific)
Performance
6.1L Hemi Srt8 Horsepower:
425 hp @ 6000 rpm
6.1L Hemi Srt8 Torque:
420 lb-ft @ 4800 rpm
Fuel System
6.1L Hemi Srt8 Fuel System:
Sequential Multi-Port Fuel Injection (SMPI)
Other Engines Covered
Other Engines Covered:
5.7L EZB V8 Hemi (Multi-Displacement System), 3.5L EGG V6 (High Output), 2.7L EER V6, 3.0L TD (Common Rail Diesel).
Engine Construction
Engine Construction:
Cast Iron Block (Diesel), Aluminum Block (V6 and Hemi V8s).
Valvetrain
Valvetrain:
Overhead Valve (OHV) with semi-hemispherical combustion chambers (Hemi), Dual Overhead Camshafts (DOHC) for V6 engines.
🔧 Transmission
Standard
Standard Transmission:
5-Speed W5A580/NAG1 Automatic (SRT-8 specific)
Optional
Optional Transmission:
4-Speed 42RLE Automatic (standard on non-SRT-8 models)
Features
Transmission Features:
Manual shift modes (AutoStick), electronic control with adaptive shift logic.
Fluid Type
W5A580 Fluid Type:
Pentosin ATF1 or equivalent (refer to manual for specific part numbers and DEXRON compatibility).
42Rle Fluid Type:
Chrysler ATF+4 (or equivalent Mopar specification).
📐 Dimensions
Exterior
Wheelbase:
Approximately 120 inches (3048 mm)
Length:
Approximately 199.0 inches (5055 mm)
Width:
Approximately 74.1 inches (1882 mm)
Height:
Approximately 58.4 inches (1483 mm)
Weights
Curb Weight Srt8:
Approximately 4,100 - 4,200 lbs (1860 - 1905 kg)
Gross Vehicle Weight Rating:
Refer to specific vehicle VIN plate; typically around 5,300 lbs (2400 kg).
Towing Capacity:
Not specified for SRT-8 models; typically around 1000 lbs for non-SRT models if equipped with towing package.
Cargo
Cargo Volume:
Approximately 21.2 cubic feet (rear seats up)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-star (for Dodge Magnum, platform basis)
NHTSA Front Impact Passenger:
5-star (for Dodge Magnum, platform basis)
IIHS Front Offset Crash Rating:
Good (for Dodge Magnum, platform basis)
Active Features
Active Features:
Anti-lock Braking System (ABS), Electronic Stability Control (ESC - often called ESP), Traction Control System (TCS), All-Speed Traction Control, Brake Assist.
Passive Features
Passive Features:
Front advanced multi-stage airbags, Front side curtain airbags, Front seat-mounted side airbags, Active head restraints.
Brakes
Front Brake Type:
Vented Discs (SRT-8 specific: Brembo 4-piston calipers)
Rear Brake Type:
Solid Discs (SRT-8 specific: Brembo 2-piston calipers)
Wheels Tires
Srt8 Wheel Size:
20-inch forged aluminum wheels
Srt8 Tire Size:
245/45R20 Front, 255/45R20 Rear (Pirelli P Zero Asimmetrico)
💡 Technology Features
Infotainment
Infotainment System:
Optional Boston Acoustics premium audio system, Uconnect hands-free communication system (later models), optional navigation system.
Driver Assistance
Driver Assistance Features:
ParkSense rear park assist (optional), Tire Pressure Monitoring System (TPMS).
Connectivity
Connectivity:
CD/MP3 player, optional Sirius Satellite Radio, auxiliary input jack for audio.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 to 10,000 miles (9,600 to 16,000 km) or 6-12 months, depending on driving conditions and oil type (refer to manual for specific recommendations).
Transmission Fluid Change Interval:
Every 30,000 to 60,000 miles (48,000 to 96,000 km), or as recommended by the manual, particularly for heavy-duty use.
Coolant Change Interval:
Every 30,000 to 100,000 miles (48,000 to 160,000 km) or 2-5 years, depending on coolant type (HOAT recommended).
Fluid Specifications
Engine Oil Specification:
SAE 0W-40 Synthetic (for 6.1L Hemi SRT-8); SAE 5W-20 or 5W-30 for other engines. Refer to manual for precise API service classification (e.g., API SN, ILSAC GF-5).
Coolant Specification:
Mopar OAT (Orange) or HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, 50/50 mix with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4 (refer to manual for specific type; high-performance applications may benefit from DOT 4).
Known Issues
Known Issues:
Potential for EGR valve issues, front suspension wear (ball joints, control arms), wheel bearing noise, and occasional electrical gremlins (e.g., TIPM module). Hemi engines can exhibit lifter tick if oil maintenance is neglected. Transmission cooler line leaks have been reported on some models.
Filters
Oil Filter Part Number Example:
Mopar MO-349 or equivalent (e.g., Wix 57899, K&N HP-3001).
Engine Air Filter Part Number Example:
Mopar 04677902AA or equivalent (e.g., Wix WA10202).
📚 Vehicle History
Brand Heritage
Brand Heritage:
Dodge has a long history of performance vehicles, including muscle cars and powerful sedans, establishing a reputation for aggressive styling and potent powertrains.
Model Evolution
Model Evolution:
The Dodge Magnum (LC platform) was reintroduced for 2005 based on the LX platform shared with the Chrysler 300 and Dodge Charger. The SRT-8 variant, introduced for 2006, represented the pinnacle of performance for the Magnum line, featuring the larger 6.1L Hemi engine and SRT-specific tuning.
Production
Production Years Magnum:
2005-2008
Manufacturing Location:
Brampton Assembly Plant, Ontario, Canada
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for the Magnum SRT-8 are limited, the LX platform and its variants (Charger, 300) received numerous accolades for design and performance upon their introduction. The 6.1L Hemi engine itself was highly regarded for its power output.
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