2006-2008 Dodge Ram 3500 Diesel Service & Repair Manual

GROUP TAB LOCATOR Introduction 0 Lubrication & Maintenance 2 Suspension 3 Differential & Driveline 4 Vehicle Quick Reference 5 Brakes 6 Clutch 7 Cooling 8A Audio/Video 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 8T Navigation/Telecommunication 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 Component and System Index DTC Index Service Manual Comment Forms (Rear of Manual)

INTRODUCTION TABLE OF CONTENTS page page VEHICLE IDENTIFICATION NUMBER DESCRIPTION – VIN CODING/LOCATIONS ...... 2 VEHICLE EMISSION CONTROL INFORMATION (VECI) DESCRIPTION ................................. 4 BODY CODE PLATE DESCRIPTION ................................. 5 INTERNATIONAL VEHICLE CONTROL & DISPLAY SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS ..... 9 FASTENER IDENTIFICATION DESCRIPTION ................................ 10 FASTENER USAGE DESCRIPTION FASTENER USAGE ......................... 12 THREADED HOLE REPAIR DESCRIPTION THREADED HOLE REPAIR .................. 13 METRIC SYSTEM DESCRIPTION ................................ 14 TORQUE REFERENCES DESCRIPTION ................................ 16 VEHICLE CERTIFICATION LABEL DESCRIPTION ................................ 17 DR INTRODUCTION 1

VEHICLE IDENTIFICATION NUMBER DESCRIPTION – VIN CODING/LOCATIONS The Vehicle Identification Number (VIN) plate (2) is located on the lower windshield fence near the left a-pillar. The VIN contains 17 characters that provide data concerning the vehicle. Refer to the VIN decod- ing chart to determine the identification of a vehicle. The VIN is also imprinted on the: • Body Code Plate. • Equipment Identification Plate. • Vehicle Safety Certification Label. • Frame rail. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the VIN. The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official doc- umentation. The formula to use the check digit is not released to the general public. POSITION INTERPRETATION CODE = DESCRIPTION 1 Country of Origin 1 = Manufactured By DaimlerChrysler Corporation 3 = Manufactured By DaimlerChrysler De Mexico 2 Make D = Dodge 3 Vehicle Type 2 = Incomplete with Side Airbag 5 = Truck with Side Airbag 6 = Incomplete Less Side Airbag 7 = Truck Less Side Airbag 4 Gross Vehicle Weight Rating G = 5,001-6000 lbs. H = 6,001-7,000 lbs. J = 7,001-8,000 lbs. K = 8,001-9,000 lbs. L = 9,001-10,000 lbs. M = 10,001-14,000 lbs. W = Buses/Incomplete Vehicles with Hydraulic Brakes 5 Vehicle Line A = Ram Pickup 1500 4X2 U = Ram Pickup 1500 4X4 R = Ram Pickup 2500 4X2 S = Ram Pickup 2500 4X4 N = Ram Cab Chassis 4X2 DX Family L = Ram Pickup 3500 4X2 X = Ram Pickup 3500 4X4 6 Series 1 = 1500 2 = 2500 3 = 3500 Less Dual Rear Wheels 4 = 3500 With Dual Rear Wheels 5 = 4000 DX Family 2 INTRODUCTION DR

POSITION INTERPRETATION CODE = DESCRIPTION 7 Body Style 6 = Conventional Cab/Cab Chassis 8 = Quad Cab Full Rear Doors 9 = Mega Cab Ram Pickup 8 Engine K = 3.7L 6 cyl. MPI Gasoline N = 4.7L 8 cyl. MPI Gasoline P = 4.7L 8 cyl. Flex Fuel D = 5.7L 8 cyl. SMPI Gasoline C = 5.9L 6 cyl. Turbo Diesel High Output H = 8.3L 10 cyl. SFI Gasoline 9 Check Digit 0 through 9 or X 10 Model Year 6 = 2006 11 Plant Location S = Dodge City G = Saltillo J = St. Louis (North) 12 – 17 Vehicle Build Sequence DR INTRODUCTION 3

VEHICLE EMISSION CONTROL INFORMATION (VECI) DESCRIPTION All models have a Vehicle Emission Control Informa- tion (VECI) Label (1). DaimlerChrysler permanently attaches the label in the engine compartment. The label cannot be removed without defacing label infor- mation and destroying label. The label contains the vehicle’s emission specifica- tions and vacuum hose routings. All hoses must be connected and routed according to the label. The label also contains an engine vacuum schematic. There are unique labels for vehicles built for sale in the state of California and the country of Canada. Canadian labels are written in both the English and French languages. 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 4 INTRODUCTION DR

BODY CODE PLATE DESCRIPTION The Body Code Plate is located on the right front hydroform fender rail just behind the headlight assem- bly. 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 bottom of the plate. The last code imprinted on a vehicle code plate will be followed by the imprinted word END. When two vehi- cle 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 (15) DIGITS 13, 14, AND 15 Transmission Codes (3) • DDP = 5–speed Manual (NV4500) • DEC = 6–speed Manual (NV5600) • DEE = 6–speed Manual Tremec (T-56) • DEG = 6–speed Manual (G56) • DEJ = 6–speed Manual (GETRAG 238) • DG4 = 4–speed Automatic (45RFE) • DG8 = 4–speed Automatic (48RE) • DGQ = 4–speed Automatic (5-45RFE) DIGITS 16 and 17 Family (4) • DR = 1500 • DH = 2500 • D1 = 3500 • DC = 3500 (Cab Chassis) • DX = Mexico Work Truck DIGIT 18 Vehicle Line (4) DR INTRODUCTION 5

2 - Wheel Drive • 1 = 1500 • 2 = 2500 • 3 = 3500 4 - Wheel Drive • 6 = 1500 • 7 = 2500 • 8 = 3500 DIGIT 19 Price Class (4) • L = Low • H = Highline • P = Premium • S = SRT-10 DIGITS 20 AND 21 Body Type (4) • 41 = Ram Truck Quad Cab, 6.5’ Box • 42 = Ram Truck Quad Cab, 8.0’ Box • 61 = Ram Truck Standard Cab, 6.5’ Box • 62 = Ram Truck Standard Cab, 8.0’ Box • 81 = Ram Truck Mega Cab, 6.5’ Box BODY CODE PLATE – LINE 3 DIGITS 1,2, AND 3 Paint Procedure (14) • APA = Monotone • AP9 = Special • APD = Two-tone (Lower break) DIGIT 4 Open Space DIGITS 5 THROUGH 8 Primary Paint (1) (Refer to 23 - BODY/PAINT - SPECIFICATIONS) for color codes. DIGIT 9 Open Space DIGITS 10 THROUGH 13 Secondary Paint (2) DIGIT 14 Open Space 6 INTRODUCTION DR

DIGITS 15 THROUGH 18 Interior Trim Code (6) DIGIT 19 Open Space DIGITS 20, 21, AND 22 Engine Code (5) • EKG = 3.7L 6 cyl. MPI Gasoline • EVA = 4.7L 8 cyl. MPI Gasoline • EVD = 4.7L 8 cyl. Flex Fuel • EZA = 5.7L 8 cyl. SMPI Gasoline • ETH = 5.9L 6 cyl. Cummins Turbo Diesel High Output • EWC = 8.3L 19 cyl. SFI Gasoline BODY CODE PLATE – LINE 2 DIGIT 1 Open Space DIGITS 2 AND 3 Species Code. (Used for Manufacturing) (13) DIGIT 4 Open Space DIGIT 5 Market Code (12) • B = International • C = Canada • M = Mexico • U = United States DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number (VIN) (7) (Refer to VEHICLE DATA/VEHICLE INFORMATION/VEHICLE IDENTIFICATION NUMBER - DESCRIPTION) for proper breakdown of VIN code. DR INTRODUCTION 7

BODY CODE PLATE – LINE 1 DIGITS 1 THROUGH 6 Body-in-white assembly sequence (11) DIGIT 7 Open Space DIGIT 8 Tailgate trim code (10) DIGIT 9 Open Space DIGITS 10 THROUGH 12 Cargo box code (9) DIGIT 13 Open Space DIGITS 14 THROUGH 16 Tailgate code (8) 8 INTRODUCTION DR

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. DR INTRODUCTION 9