Gen 3 Year By Year Changes

Gen 3 Year-By-Year Changes

NOTICE: This page is still under construction. Page Completion: 70%

During its lifespan from 2003 to 2006, the Gen 3 would undergo a number of alterations and changes between the years.

2003:

Mechanical Changes:

– No “changes” so to speak, but things to note: ’03 and ’04 Gen 3s can suffer from main bearing failure in the engine’s bottom end. There are many contributing factors to the failure, and one of them is the angle of the main bearings. On 2003 and 2004 ZB Is, 120 degree main bearings were used. On later ’05 and ’06 models, 180 degree main bearings were used instead. This dropped the hot idle oil pressure from 40+ PSI on the ’03-’04 models to around 25 or 35 PSI on the ’05 and ’06 models. This change was made to help with rod oiling issues. [1]

• 10w30 Oil was used and recommended for this year of Gen 3. {1}

• 2003-2004 Vipers had forged rods. 2005-2006 Models changed to powered metal rods (these came from the HEMI). {1}

• It’s possible some later 2003s utilized a smaller, less secure crankshaft damper bolt that could become finger tight (see: not tight at all) and thus cause damage to the engine.

• Crank position trigger is on the flywheel (look on the bellhousing for the pickup). {1}

• (Generally) Larger crank damper bolt. {1} – {2}

• Less intuitive storage mode. {1}

• Initial gauge sweep layout. {1}

Visual Changes:

• No trunk carpet. {1} – {2}

• No convertible boot. {1} – {2}

• Black brake calipers. {1} – {2} – {3}
  • Apparently some (I’m assuming) very late ’03 production cars did come with red brake calipers. {1}

Issues for this year:

• Some valve grind on around 200 examples (said to have affected early-to-mid run cars. {1}

• Flickering headlights (fixable with a PCM reflash). {1}

• Slight bog between gear shifts (also corrected with a reflash). {1}

• Early ’03s are susceptible to rear diff carrier shaft failure. Simply replace the shaft to rectify the issue. {1}

2004:

– Carryovers from ’03: Location of crank position trigger, main harness wires, 10w30 factory oil {1} ,

Mechanical Changes:

• Smaller crank damper bolt. {1}

• Engine Harness C104 connector (might be the same as ’03?). {1}

• New gauge sweeps in the interior (this impacts how you read the mechanical state of the car, hence its inclusion here and not visual changes). Oil Pressure and Oil Temperature were the gauges that changed, all others stayed the same. 2003 is 0 to 80 PSI while 2004 onward is 0 to 100 PSI. {1} – {2} – {3}

• The seal for the airbox to the hood changed material. {1}

• Ribbed belt for the pulleys on the engine. {1}

• Carrier pin in the differential might’ve been strengthened slightly. {1}

Visual Changes:

• Introduction of red brake calipers instead of black. {1} – {2} – {3}

• Trunk carpet was added. {1} – {2}

• Convertible boot was added. {1} – {2}

Issues for this year:

A cam bolt recall. Possibly not affecting ’04s built after 1/31/04′. {1} – {2}

2005:

– Carryovers from ’04: Red brake calipers, updated storage mode, new gauge sweeps, trunk carpet and convertible boot, ribbed belt for engine pulleys, material for the airbox seal to the hood, and carrier pin in the differential. {1}

Mechanical Changes:

• Change to 0W-40 Mobil 1 engine oil. {1}

• Main Harness (in the engine) has 16 wires. {1}

• Different engine harness C104 connector. {1}

• Addition of knock sensors (2 of them, which necessitated a different PCM). {1} – {2}

• Reintroduction of larger crank damper bolt. {1}

• 180 Degree main bearings (a change made to improve oiling). This is why ’05-’06 Vipers have slightly lower oil pressure at idle. Neither the oil pump and relief or tolerances changed. {1} – {2}

• The breather system for the crank case was relocated to the front of the valve covers rather than the back. {1}
• Exhaust insulation was improved (potentially a mid-2004 change). {1}

• New crank shaft with grooves for the knock sensors. {1}

• Crank position trigger is now on the crankshaft (with the pickup being in the side of the block). {1} – {2} – {3}

• Marginally different valve covers (vent tubes are in the front rather than the rear on the prior two years). {1}

• Introduction of powdered metal rods versus the forged ones of prior years. Crank balance was also changed. {1}

• Timing cover was altered to include a wire holder for the cam sensor (prior covers used a bolt-on clip). {1}

Interior Changes:

• New radio head unit. {1} – {2}

Issues for this year:

A turned metal flange on the underside of the trunk, which could risk tearing the convertible boot. {1}

Rough running above 5,000 RPM (fixable with a PCM reflash, apparently didn’t affect later builds). {1}

2006:

Mechanical Changes:

• Same as ’05. {1}

Lineup Changes:

– Introduction of the Gen 3/ZB-platform SRT-10 Coupe

More information to come!