2001-2008 Dodge Ram 1500, 2500, 3500 Troubleshooting, Diagnosis, Testing, Inspection, Cleaning, Removal & Installation Procedures Download.


TROUBLESHOOTING, DIAGNOSIS, TESTING & PART/PARTS REPAIR

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Before ever attempting to work on your Dodge Ram 1500, 2500 or 3500 truck always refer to the service repair manual as a reference guide as it is the same manual mechanics use to service and repair your 2001, 2002, 2003 2004 2005 2006 2007 2008 model year pick-up truck. Important information including specifications, diagrams, illustrations, pictures, procedures & part locations differ between each year & model.

Below are safe and secure pdf download links to the service manual for your convenience and can be download to your computer in just seconds. Plus, did I mention it contains diagrams, step-by-step procedures and picture illistrations to make the repair work a breeze?

Not sure what a Dodge Ram PDF service manual looks like, here is a sample (sample is restricted to one page only).

SERVICE MANUAL DOWNLOAD LINKS

Links contain the entire service manual and contains everthing you need to service your ride.

SERVICE MANUALS

2001 DODGE DOWNLOAD Ram 1500 2500 3500 Service Manual

2002 DODGE DOWNLOAD Ram 1500 2500 3500 Service Manual  

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Dodge Ram Truck Models & Years Covered in Each of the above Service Manuals:

2001 Dodge Ram 1500, 2500 & 3500 Service Manual for: 3.9 L 6 cyl. MPI Gasoline (5.9L),  5.2 L 8 cyl. MPI Gasoline (5.2L), 5.2 L 8 cyl. (CNG) (5.2L), 5.9 L 8 cyl. MPI Gasoline, 5.9 L 8 cyl. MPI Gasoline (Heavy Duty) (5.9L), 5.9 L 6 cyl. Turbo Diesel (5.9L), 8.0 L 10 cyl. MPI Gasoline (8.0L) Models.

2002 Dodge Ram 1500, 2500 & 3500 Service Manual for: 3.7L 6 cyl. MPI Gasoline  3.7 L, 4.7L 8 cyl. MPI Gasoline  4.7 L, 5.7L 8 cyl. SMPI Gasoline  5.7 L, 5.9L 6 cyl. Turbo Diesel 5.9 L 5.9L 6 cyl. Turbo Diesel High Output 5.9 L, 8.0L 10 cyl. MPI Gasoline 8.0 L, 5.9L 8 cyl. SMPI Gasoline Light Duty 5.9 L Models

2003 Dodge Ram 1500, 2500 & 3500 Service : 3.7L 6 cyl. MPI Gasoline, 4.7L 8 cyl. MPI Gasoline, 5.7L 8 cyl. SMPI Gasoline, 5.9L 6 cyl. Turbo Diesel, 5.9L 6 cyl. Turbo Diesel High Output, 8.0L 10 cyl. MPI Gasoline, 5.9L 8 cyl. SMPI Gasoline Light Duty Models.

2004 Dodge Ram 1500, 2500 & 3500 Service : 3.7L 6 cyl. MPI Gasoline, 4.7L 8 cyl. MPI Gasoline, 5.7L 8 cyl. SMPI Gasoline, 5.9L 6 cyl. Turbo Diesel, 5.9L 6 cyl. Turbo Diesel High Output, 8.0L 10 cyl. MPI Gasoline, 5.9L 8 cyl. SMPI Gasoline Light Duty Models.


AIRBAG CONTROL MODULE -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 8O-12

AIRBAG CONTROL MODULE -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8O-10

AIRBAG CONTROL MODULE -

OPERATION, SIDE IMPACT . . . . . . . . . . . . . 8O-54

AIRBAG CONTROL MODULE - REMOVAL . . 8O-11

AIRBAG INDICATOR - DESCRIPTION . . . . . . 8J-18

AIRBAG INDICATOR - OPERATION . . . . . . . 8J-18

AIRBAG ON/OFF SWITCH -

DESCRIPTION, PASSENGER . . . . . . . . . . . . 8O-38

AIRBAG ON/OFF SWITCH -

INSTALLATION, PASSENGER . . . . . . . . . . . 8O-39

AIRBAG ON/OFF SWITCH - OPERATION,

PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8O-38

AIRBAG ON/OFF SWITCH - REMOVAL,

PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . 8O-39

AJAR INDICATOR - DESCRIPTION, DOOR . . 8J-23

AJAR INDICATOR - OPERATION, DOOR . . . 8J-23

AJAR SWITCH - DESCRIPTION, DOOR . . . . 8L-25

AJAR SWITCH - OPERATION, DOOR . . . . . . 8L-25

ALIGNMENT - DESCRIPTION, WHEEL . . . . . . . 2-1

ALIGNMENT - OPERATION, WHEEL . . . . . . . . 2-2

ALIGNMENT - SPECIAL TOOLS,

HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-7

ALIGNMENT LINK/COIL SUSPENSION -

STANDARD PROCEDURE . . . . . . . . . . . . . . . . . 2-5

ALIGNMENT, SPECIAL TOOLS - WHEEL . . . . . 2-7

ALIGNMENT, SPECIFICATIONS . . . . . . . . . . . . 2-6

ALUMINUM THREAD REPAIR -

STANDARD PROCEDURE . . 21-156,21-337,21-495

AMBIENT TEMP SENSOR - DESCRIPTION . 8M-10

AMBIENT TEMP SENSOR - OPERATION . . 8M-10

AMBIENT TEMPERATURE SENSOR -

DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8M-11

AMBIENT TEMPERATURE SENSOR

CIRCUIT - DIAGNOSIS AND TESTING . . . . 8M-11

AMPLIFIER - DESCRIPTION . . . . . . . . . . . . . 8A-3

AMPLIFIER - INSTALLATION . . . . . . . . . . . . . 8A-4

AMPLIFIER - OPERATION . . . . . . . . . . . . . . . 8A-3

AMPLIFIER - REMOVAL . . . . . . . . . . . . . . . . 8A-3

ANCHOR - DESCRIPTION, CHILD

RESTRAINT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-14

ANCHOR - INSTALLATION, CHILD

RESTRAINT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-17

ANCHOR - OPERATION, CHILD

RESTRAINT . . . . . . . . . . . . . . . . . . . . . . . . . 8O-16

ANCHOR - REMOVAL, CHILD RESTRAINT . 8O-16

ANCHOR & RIGHT OUTBOARD -

INSTALLATION, CENTER . . . . . . . . . . . . . . . 8O-45

ANCHOR & RIGHT OUTBOARD -

REMOVAL, CENTER . . . . . . . . . . . . . . . . . . . 8O-43

ANTENNA BODY & CABLE -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 8A-4

ANTENNA BODY & CABLE -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 8A-6

ANTENNA BODY & CABLE - OPERATION . . . 8A-4

ANTENNA BODY & CABLE - REMOVAL . . . . . 8A-6

ANTENNA BODY AND CABLE -

DIAGNOSIS AND TESTING . . . . . . . . . . . . . . 8A-4

ANTENNA CABLE - INSTALLATION,

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8A-7

ANTENNA CABLE - REMOVAL,

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8A-6

ANTILOCK - DIAGNOSIS AND TESTING,

REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . 5-42

ANTILOCK BRAKE - DESCRIPTION,

CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . 8E-3

ANTILOCK BRAKE - INSTALLATION,

CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . 8E-3

ANTILOCK BRAKE - OPERATION,

CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . 8E-3

ANTILOCK BRAKE - REMOVAL,

CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . 8E-3

A-PILLAR TRIM/GRAB HANDLE -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 23-64

A-PILLAR TRIM/GRAB HANDLE -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 23-64

A-PILLAR WEATHERSTRIP RETAINER -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 23-91

A-PILLAR WEATHERSTRIP RETAINER -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 23-91

APPLICATION TABLE, SPECIFICATIONS -

A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-7

AREA LEAKS - DIAGNOSIS AND

TESTING, REAR SEAL . . . . . . . . 9-135,9-204,9-64

ARM / ADJUSTER ASSEMBLY -

DESCRIPTION, ROCKER . . . . . . . . . . . . . . . 9-124

ARM / ADJUSTER ASSEMBLY -

INSTALLATION, ROCKER . . . . . . . . . . 9-124,9-249

ARM / ADJUSTER ASSEMBLY -

REMOVAL, ROCKER . . . . . . . . . . . . . 9-124,9-249

ARM / ADJUSTER ASSY - CLEANING,

ROCKER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-310

ARM / ADJUSTER ASSY - DESCRIPTION,

ROCKER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-310

ARM / ADJUSTER ASSY - INSPECTION,

ROCKER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-311

ARM / ADJUSTER ASSY -

INSTALLATION, ROCKER . . . . . 9-198,9-312,9-379

ARM / ADJUSTER ASSY - REMOVAL,

ROCKER . . . . . . . . . . . . . . . . . 9-198,9-310,9-379

ARM - DESCRIPTION, ROCKER . . . . . . 9-30,9-36

ARM - DESCRIPTION, WIPER . . . . . . . . . . . 8R-18

ARM - INSTALLATION, LOWER

SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

ARM - INSTALLATION, PITMAN . . . . . . . . . 19-36

ARM - INSTALLATION, ROCKER . . . . . . . . . . 9-30

ARM - INSTALLATION, UPPER CONTROL . . . 2-27

ARM - INSTALLATION, WIPER . . . . . . . . . . 8R-19

ARM - OPERATION, WIPER . . . . . . . . . . . . 8R-18

ARM - REMOVAL, LOWER SUSPENSION . . . 2-35

ARM - REMOVAL, PITMAN . . . . . . . . . . . . . 19-35

ARM - REMOVAL, ROCKER . . . . . . . . . . 9-30,9-36

ARM - REMOVAL, UPPER CONTROL . . . . . . 2-27

ARM - REMOVAL, WIPER . . . . . . . . . . . . . . 8R-18

ARM BUSHINGS - 2WD (LD) -

INSTALLATION, LOWER CONTROL. . . . . . . . . . 2-14

ARM BUSHINGS - 2WD (LD) -

REMOVAL, LOWER CONTROL . . . . . . . . . . . . 2-12

ARM BUSHINGS - 4WD (LD) -

INSTALLATION, LOWER CONTROL . . . . . . . . 2-13

ARM BUSHINGS - 4WD (LD) -

REMOVAL, LOWER CONTROL . . . . . . . . . . . . 2-12

ARMREST / SEAT BACK - INSTALLATION,

CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-78

ARMREST / SEAT BACK - REMOVAL,

CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-77

ASD AND FUEL PUMP RELAYS -

DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . 8I-7

ASD SENSE - PCM INPUT - OPERATION . . . . 8I-6

ASH RECEIVER - INSTALLATION . . . . . . . . . 23-52

ASH RECEIVER - REMOVAL . . . . . . . . . . . . 23-51

AUDIO - DESCRIPTION . . . . . . . . . . . . . . . . . 8A-1

AUDIO - DIAGNOSIS AND TESTING . . . . . . . 8A-2

AUDIO - OPERATION . . . . . . . . . . . . . . . . . . . 8A-1

AUTOMATIC DAY / NIGHT MIRROR -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8N-12

AUTOMATIC DAY / NIGHT MIRROR -

DIAGNOSIS AND TESTING . . . . . . . . . . . . . 8N-12

AUTOMATIC DAY / NIGHT MIRROR -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8N-12

AUTOMATIC DAY / NIGHT MIRROR -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 8N-13

AUTOMATIC LOCKING RETRACTOR -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 8O-13

AUTOMATIC LOCKING RETRACTOR -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 8O-14

AUTOMATIC TRANSMISSION -

45RFE/545RFE - DESCRIPTION . . . . . . . . . 21-489

AUTOMATIC TRANSMISSION -

45RFE/545RFE - OPERATION. . . . . . . . . . . 21-490

AUTOMATIC TRANSMISSION - 46RE -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-131

AUTOMATIC TRANSMISSION - 46RE -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 21-133

AUTOMATIC TRANSMISSION - 48RE -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . 21-312

AUTOMATIC TRANSMISSION - 48RE -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 21-314

AUTOMATIC TRANSMISSION -

DIAGNOSIS AND TESTING . . . . . . 21-139,21-320,

21-491

AUTOMATIC TRANSMISSION FLUID -

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-4

AUTOMATIC TRANSMISSION FLUID -

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5

AUXILIARY SPRING BUMPERS (3500) -

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 2-40

AUXILIARY SPRING BUMPERS (3500) -

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

AXLE - 10 1/2 AA - ADJUSTMENTS,

REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104

AXLE - 10 1/2 AA - DESCRIPTION, REAR . . 3-100

AXLE - 10 1/2 AA - DIAGNOSIS AND

TESTING, REAR . . . . . . . . . . . . . . . . . . . . . . 3-100


AXLE - 10 1/2 AA - INSTALLATION,

REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103

AXLE - 10 1/2 AA - OPERATION, REAR . . . 3-100

AXLE - 10 1/2 AA - REMOVAL, REAR . . . . . 3-103

AXLE - 10 1/2 AA - SPECIAL TOOLS,

REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

AXLE - 10 1/2 AA - SPECIFICATIONS,

REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

AXLE - 11 1/2 AA - ADJUSTMENTS,

REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-131

AXLE - 11 1/2 AA - DESCRIPTION, REAR . . 3-127

AXLE - 11 1/2 AA - DIAGNOSIS AND

TESTING, REAR . . . . . . . . . . . . . . . . . . . . . . 3-127

AXLE - 11 1/2 AA - INSTALLATION,

REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130

AXLE - 11 1/2 AA - OPERATION, REAR . . . 3-127

AXLE - 11 1/2 AA - REMOVAL, REAR . . . . . 3-130

AXLE - 11 1/2 AA - SPECIAL TOOLS,

REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135

AXLE - 11 1/2 AA - SPECIFICATIONS,

REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135

AXLE - 9 1/4 - ADJUSTMENTS, REAR . . . . . 3-74

AXLE - 9 1/4 - DESCRIPTION, REAR . . . . . . 3-69

AXLE - 9 1/4 - DIAGNOSIS AND

TESTING, REAR . . . . . . . . . . . . . . . . . . . . . . . 3-69

AXLE - 9 1/4 - INSTALLATION, REAR . . . . . . 3-74

AXLE - 9 1/4 - OPERATION, REAR . . . . . . . . 3-69

AXLE - 9 1/4 - REMOVAL, REAR . . . . . . . . . . 3-74

AXLE - 9 1/4 - SPECIAL TOOLS, REAR . . . . . 3-80

AXLE - 9 1/4 - SPECIFICATIONS, REAR . . . . . . 3-79

AXLE - 9 1/4 AA - ADJUSTMENTS,

FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

AXLE - 9 1/4 AA - DESCRIPTION, FRONT . . . 3-45

AXLE - 9 1/4 AA - DIAGNOSIS AND

TESTING, FRONT . . . . . . . . . . . . . . . . . . . . . . 3-45

AXLE - 9 1/4 AA - INSTALLATION,

FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48

AXLE - 9 1/4 AA - OPERATION, FRONT . . . . 3-45

AXLE - 9 1/4 AA - REMOVAL, FRONT . . . . . . 3-48

AXLE - 9 1/4 AA - SPECIAL TOOLS,

FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

AXLE - 9 1/4 AA - SPECIFICATIONS,

FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53

AXLE - C205F - ADJUSTMENTS, FRONT . . . . 3-21

AXLE - C205F - DESCRIPTION, FRONT . . . . . 3-18

AXLE - C205F - DIAGNOSIS AND

TESTING, FRONT . . . . . . . . . . . . . . . . . . . . . . 3-18

AXLE - C205F - INSTALLATION, FRONT . . . . 3-21

AXLE - C205F - OPERATION, FRONT . . . . . . 3-18

AXLE - C205F - REMOVAL, FRONT . . . . . . . . 3-21

AXLE - C205F - SPECIAL TOOLS, FRONT . . . 3-30

AXLE - C205F - SPECIFICATIONS, FRONT . . . 3-29

AXLE - DESCRIPTION . . . . . . . . . . . . . . . . . . . 0-4

AXLE BEARINGS - INSTALLATION . . 3-112,3-139,

3-34,3-84

AXLE BEARINGS - REMOVAL . . 3-112,3-138,3-33,

3-84

AXLE SHAFT SEALS - INSTALLATION . 3-33,3-58,

3-84

AXLE SHAFT SEALS - REMOVAL . 3-33,3-58,3-84

AXLE SHAFTS - ASSEMBLY . . . . . . . . . . . . . 3-58

AXLE SHAFTS - DISASSEMBLY . . . . . . . . . . . 3-56

AXLE SHAFTS - INSTALLATION . . . . 3-111,3-138,

3-33,3-58,3-83

AXLE SHAFTS - REMOVAL . . . . 3-111,3-138,3-33,

3-56,3-83

BACK - INSTALLATION, CENTER

ARMREST / SEAT . . . . . . . . . . . . . . . . . . . . 23-78

BACK - REAR - INSTALLATION, SEAT . . . . . 23-84

BACK - REAR - REMOVAL, SEAT . . . . . . . . 23-84

BACK - REMOVAL, CENTER ARMREST /

SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-77

BACK CUSHION / COVER - FRONT -

INSTALLATION, SEAT . . . . . . . . . . . . . . . . . 23-83

BACK CUSHION / COVER - FRONT -

REMOVAL, SEAT . . . . . . . . . . . . . . . . . . . . . 23-83

BACK CUSHION / COVER - REAR -

INSTALLATION, SEAT . . . . . . . . . . . . . . . . . 23-85

BACK CUSHION / COVER - REAR -

REMOVAL, SEAT . . . . . . . . . . . . . . . . . . . . . 23-85

BACK HINGE - INSTALLATION, CENTER

SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-80

BACK HINGE - REMOVAL, CENTER SEAT . . 23-79

BACK INERTIA HINGE COVER -

INSTALLATION, CENTER SEAT . . . . . . . . . . 23-78

BACK INERTIA HINGE COVER -

REMOVAL, CENTER SEAT . . . . . . . . . . . . . . 23-78


DIAGNOSIS AND TESTING

LOW LUBRICANT LEVEL

 

A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill or an incorrect lubricant level check. Leaks can occur at the mating surfaces of the gear case, adaptor or extension housing, or from the front/rear seals. A suspected leak could also be the result of an overfill condition. Leaks at the rear of the extension or adapter housing will be from the housing oil seals.

Leaks at component mating surfaces will probably be the result of inadequate sealer, gaps in the sealer, incorrect bolt tightening or use of a non-recommended sealer. A leak at the front of the transmission will be from either the front bearing retainer or retainer seal. Lubricant may be seen dripping from the clutch housing after extended operation. If the leak is severe, it may also contaminate the clutch disc causing the disc to slip, grab and or chatter.

A correct lubricant level check can only be made when the vehicle is level. Also allow the lubricant to settle for a minute or so before checking. These recommendations will ensure an accurate check and avoid an underfill or overfill condition. Always check the lubricant level after any addition of fluid to avoid an incorrect lubricant level condition.

HARD SHIFTING

Hard shifting is usually caused by a low lubricant level, improper or contaminated lubricants. The consequence of using non-recommended lubricants is noise, excessive wear, internal bind and hard shifting. Substantial lubricant leaks can result in gear, shift rail, synchro, and bearing damage. If a leak goes undetected for an extended period, the first indications of component damage are usually hard shifting and noise.

Shift component damage or damaged clutch pressure plate or disc are additional probable causes of increased shift effort. Worn/damaged pressure plate or disc can cause incorrect release. If clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchro rings can cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most cases this condition will decline as the rings wear-in.

TRANSMISSION NOISE

 

Most manual transmissions make some noise during normal operation. Rotating gears generate a mild whine that is audible, but generally only at extreme speeds.


DIAGNOSIS AND TESTING - PRE-ALIGNMENT

INSPECTION

Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System

Diagnosis Chart below for additional information.

(1) Inspect tires for size, air pressure and tread wear.

(2) Inspect front wheel bearings for wear.

(3) Inspect front wheels for excessive radial or lateral runout and balance.

(4) Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding.

(5) Inspect suspension components for wear and noise.

(6) On 4x4 vehicles check suspension height (LD only).

(7) Road test the vehicle.