1999-2009 Dodge Ram 1500 / 2500 / 3500 Service & Repair Manual

GROUP TAB LOCATOR Introduction 0 Lubrication & Maintenance 2 Suspension 3 Differential & Driveline 5 Brakes 6 Clutch 7 Cooling 8A Audio 8B Chime/Buzzer 8E Electronic Control Modules 8F Engine Systems 8G Heated Systems 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8M Message Systems 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers/Washers 8W Wiring 9 Engine 11 Exhaust System 13 Frame & Bumpers 14 Fuel System 19 Steering 21 Transmission and Transfer Case 22 Tires/Wheels 23 Body 24 Heating & Air Conditioning 25 Emissions Control Service Manual Comment Forms (Rear of Manual)

INTRODUCTION TABLE OF CONTENTS page page VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION .......................... 1 VEHICLE IDENTIFICATION NUMBER DESCRIPTION .......................... 1 VEHICLE EMISSION CONTROL INFORMATION (VECI) DESCRIPTION .......................... 3 EQUIPMENT IDENTIFICATION PLATE DESCRIPTION .......................... 3 BODY CODE PLATE DESCRIPTION .......................... 4 INTERNATIONAL VEHICLE CONTROL & DISPLAY SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS ...5 FASTENER IDENTIFICATION DESCRIPTION .......................... 6 FASTENER USAGE DESCRIPTION .......................... 9 THREADED HOLE REPAIR DESCRIPTION .......................... 9 METRIC SYSTEM DESCRIPTION .......................... 9 TORQUE REFERENCES DESCRIPTION ......................... 11 VEHICLE SAFETY CERTIFICATION LABEL DESCRIPTION A vehicle safety certification label (Fig. 1) is attached to every Chrysler Corporation vehicle. The label certifies that the vehicle conforms to all appli- cable Federal Motor Vehicle Safety Standards. The label also lists: • Month and year of vehicle manufacture. • Gross Vehicle Weight Rating (GVWR). The gross front and rear axle weight ratings (GAWR’s) are based on a minimum rim size and maximum cold tire inflation pressure. • Vehicle Identification Number (VIN). • Type of vehicle. • Type of rear wheels. • Bar code. • Month, Day and Hour (MDH) of final assembly. • Paint and Trim codes. • Country of origin. The label is located on the driver-side door shut- face. VEHICLE IDENTIFICATION NUMBER DESCRIPTION VIN CODING/LOCATIONS The Vehicle Identification Number (VIN) plate is located on the lower windshield fence near the left A-pillar (Fig. 2). The VIN contains 17 characters that provide data concerning the vehicle. Refer to the VIN decoding chart to determine the identification of a vehicle. The Vehicle Identification Number is also imprinted on the: • Body Code Plate. • Equipment Identification Plate. • Vehicle Safety Certification Label. • Frame rail. Fig. 1 Vehicle Safety Certification Label BR/BE INTRODUCTION 1

To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden- tification Number. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta- tion. The formula to use the check digit is not released to the general public. POSITION INTERPRETATION CODE = DESCRIPTION 1 Country of Origin 3 = Mexico 2 Make B = Dodge 3 Vehicle Type 6 = Incomplete 7 = Truck 4 Gross Vehicle Weight Rating K = 8001-9000 M = 10,001-14,000 5 Vehicle Line C = Ram Cab Chassis/Ram Pick Up (4x2) F = Ram Cab Chassis/Ram Pick Up (4x4) 6 Series 2 = 2500 3 = 3500 7 Body Style 3 = Quad Cab 6 = Conventional Cab/Cab Chassis 8 Engine 6 = 5.9L 6 cyl. 24 Valve Diesel C = 5.9 6cyl. 24 Valve Turbo Diesel H/O W = 8.0L 10 cyl. MPI Z = 5.9L 8 cyl. MPI-LDC 5 = 5.9L 8cyl. MPI-HDC 9 Check Digit 0 through 9 or X 10 Model Year 2=2002 11 Plant Location M = Lago Alberto Assembly 12 thru 17 Vehicle Build Sequence Fig. 2 Vehicle 1 - INSTRUMENT PANEL 2 - VEHICLE IDENTIFICATION NUMBER PLATE VIN 2 INTRODUCTION BR/BE VEHICLE IDENTIFICATION NUMBER (Continued)

VEHICLE EMISSION CONTROL INFORMATION (VECI) DESCRIPTION Vehicles equipped with 5.9L V-8 LDC-gas powered engines have a vehicle emission control information (VECI) label. The label combines both emission control information and vacuum hose routing. This label is located in the engine compartment in front of the radiator (Fig. 3). There are unique VECI labels for vehicles built for sale in the country of Canada and Heavy Duty Cycle (HDC) engines. Canadian labels are written in both the English and French languages. For all Canadian vehicles, the label is split into two different labels. The VECI labels are permanently attached and cannot be removed without defacing information and destroying label. The VECI label contains the following: • Engine family and displacement • Evaporative family • Emission control system schematic • Certification application • Engine timing specifications (if adjustable) • Idle speeds (if adjustable) • Spark plug and gap The 5.9L HDC-gas powered engine will have two labels. One of the labels is located in front of the radiator in the engine compartment (Fig. 3) and will contain vacuum hose routing only. The other is attached to the drivers side of the engine air cleaner housing (Fig. 3). The VECI label for the 5.9L HDC-gas powered engine will contain the following: • Engine family and displacement • Evaporative family • Certification application • Engine timing specifications (if adjustable) • Idle speeds (if adjustable) • Spark plug and gap The label for the 8.0L V-10 HDC-gas powered engine is also located in the engine compartment. It is attached to a riveted metal plate located to the right side of the generator (Fig. 4). EQUIPMENT IDENTIFICATION PLATE DESCRIPTION The Equipment Identification Plate (Fig. 5)is located at the left, front of the inner hood panel. The plate lists information concerning the vehicle as fol- lows: • The model. • The wheelbase. • The VIN (Vehicle Identification Number). • The T.O.N. (order number). • The optional and special equipment installed on the vehicle. Refer to the information listed on the plate when ordering replacement parts. Fig. 3 VECI Label Location 1 - VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL 2 - VECI LABEL (5.9L HDC FOR CANADA ONLY) 3 - VECI LABEL (5.9L HDC ONLY) (INCLUDES CANADA) Fig. 4 VECI Label Location—8.0L V-10 Engine 1 - VECI LABEL 2 - GENERATOR BR/BE INTRODUCTION 3

BODY CODE PLATE DESCRIPTION The Body Code Plate (Fig. 6) is located on the floor pan under the passenger seat or attached to the front face of the radiator closure panel. There are seven lines of information on the body code plate. Lines 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 4 in the center of the plate to line 1 at the bot- tom of the plate. The last code imprinted on a vehicle code plate will be followed by the imprinted word END. When two vehicle code plates are required, the last available spaces on the first plate will be imprinted with the letters CTD (for continued). When a second vehicle code plate is necessary, the first four spaces on each row will not be used because of the plate overlap. BODY CODE PLATE—LINE 4 DIGITS 1 THROUGH 12 Vehicle Order Number DIGITS 13, 14, AND 15 Transmission Codes • DGP = 4–speed Automatic (47RE) • DGT = 4–speed Automatic (46RE) • DGK = 4–speed Automatic (42RE) • DDP = 5–speed Manual (NVG-4500) • DDX = 5–speed Manual (NVG-4500 Heavy Duty) • DDC = 5–speed Manual (NVG-3500) • DEE = 6–speed Manual (NVG-5600) DIGITS 16, 17, AND 18 Car Line Shell • BR1 = 1500 4 X 2 • BE1 = 1500 4 X 2 • BR6 = 1500 4 X 4 • BE6 = 1500 4 X 4 • BR2 = 2500 4 X 2 • BE2 = 2500 4 X 2 • BR7 = 2500 4 X 4 • BE7 = 2500 4 X 4 • BR3 = 3500 4 X 2 • BE3 = 3500 4 X 2 • BR8 = 3500 4 X 4 • BE8 = 3500 4 X 4 DIGIT 19 Price Class • L = Ram Truck (All) DIGITS 20 AND 21 Body Type • 31 = Ram Truck Club Cab (138.7 in. Wheel Base) • 32 = Ram Truck Club Cab (154.7 in. Wheel Base) • 33 = Ram Truck Quad Cab (138.7 in. Wheel Base) • 34 = Ram Truck Quad Cab (154.7 in. Wheel Base) • 61 = Ram Truck (118.7 in. Wheel Base) • 62 = Ram Truck (134.7 in. Wheel Base) • 63 = Ram Truck Cab Chassis (138.7 in. Wheel Base) Fig. 5 Equipment Identification Plate Fig. 6 Body Code Plate 1 - PRIMARY PAINT 2 - SECONDARY PAINT 3 - TRANSMISSION CODE 4 - VEHICLE MODEL NUMBER 5 - ENGINE CODE 6 - INTERIOR TRIM CODE 7 - VEHICLE IDENTIFICATION NUMBER 8 - TAILGATE CODE 9 - CARGO BOX CODE 10 - TAILGATE TRIM CODE 11 - BODY-IN-WHITE SEQUENCE 12 - MARKET CODE 13 - SPECIES CODE 14 - PAINT PROCEDURE 15 - VEHICLE ORDER NUMBER 4 INTRODUCTION BR/BE EQUIPMENT IDENTIFICATION PLATE (Continued)

• 64 = Ram Truck Cab Chassis (162.7 in. Wheel Base) BODY CODE PLATE—LINE 3 DIGITS 1,2, AND 3 Paint Procedure • APA = Monotone • AP9 = Special • APB = Two-tone (Waterfall) • APC = Two-tone (Centerband) • APD = Two-tone (Lower break) DIGIT 4 Open Space DIGITS 5 THROUGH 8 Primary Paint Refer to Group 23, Body for color codes. DIGIT 9 Open Space DIGITS 10 THROUGH 13 Secondary Paint DIGIT 14 Open Space DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20, 21, AND 22 Engine Code • EML = 5.9 L 8 cyl. MPI Gasoline • EMM = 5.9 L 8 cyl. MPI Gasoline (Heavy Duty) • ETC = 5.9 L 6 cyl. Turbo Diesel • EWA = 8.0 L 10 cyl. MPI Gasoline BODY CODE PLATE—LINE 2 DIGIT 1 Open Space DIGITS 2 AND 3 Species Code. (Used for Manufacturing) DIGIT 4 Open Space DIGIT 5 Market Code • B = International • C = Canada • M = Mexico • U = United States DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number (VIN) Refer to Vehicle Identification Number (VIN) para- graph for proper breakdown of VIN code. BODY CODE PLATE—LINE 1 DIGITS 1 THROUGH 6 Body-in-white assembly sequence. DIGIT 7 Open Space DIGIT 8 Tailgate trim code. DIGIT 9 Open Space DIGITS 10 THROUGH 12 Cargo box code • XBS = Sweptline DIGIT 13 Open Space DIGITS 14 THROUGH 16 Tailgate code • MWD = Plain Tailgate • MPB = Tailgate Applique (Black) INTERNATIONAL VEHICLE CONTROL & DISPLAY SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel. BR/BE INTRODUCTION 5 BODY CODE PLATE (Continued)

FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 7) and (Fig. 8). INTERNATIONAL SYMBOLS 1 High Beam 13 Rear Window Washer 2 Fog Lamps 14 Fuel 3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature 4 Turn Warning 16 Battery Charging Condition 5 Hazard Warning 17 Engine Oil 6 Windshield Washer 18 Seat Belt 7 Windshield Wiper 19 Brake Failure 8 Windshield Wiper and Washer 20 Parking Brake 9 Windscreen Demisting and Defrosting 21 Front Hood 10 Ventilating Fan 22 Rear hood (Decklid) 11 Rear Window Defogger 23 Horn 12 Rear Window Wiper 24 Lighter 6 INTRODUCTION BR/BE INTERNATIONAL VEHICLE CONTROL & DISPLAY SYMBOLS (Continued)

Fig. 7 FASTENER IDENTIFICATION BR/BE INTRODUCTION 7 FASTENER IDENTIFICATION (Continued)

Fig. 8 FASTENER STRENGTH 8 INTRODUCTION BR/BE FASTENER IDENTIFICATION (Continued)

FASTENER USAGE DESCRIPTION WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY. Figure art, specifications and torque references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used. THREADED HOLE REPAIR DESCRIPTION Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommen- dations for application and repair procedures. METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million. The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa. CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY BY TO GET MULTIPLY BY TO GET in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches Feet x 0.3048 = Meters (M) M x 3.281 = Feet Yards x 0.9144 = Meters M x 1.0936 = Yards mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph Kilometers/Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h) COMMON METRIC EQUIVALENTS 1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters 1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter 1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter 1 Mile = 1.6 Kilometers Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.) BR/BE INTRODUCTION 9

1999-2009 Dodge Ram 1500 / 2500 / 3500 Service & Repair Manual

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