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Dodge Ram 2002 (1500) Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 1500 Year: 2002 Codes Chassis Code: DR Vin Designator: B 👋 Introduction Market Position Segment: Full-size Pickup Truck Target Market: Work, heavy-duty towing, family hauling, off-road enthusiasts Competitive Analysis Key Competitors: Ford F-150, Chevrolet Silverado 1500, GMC Sierra 1500, Toyota Tundra Key Features Vehicle Attributes: Robust construction, powerful engine options, strong towing capacity, versatile platform Manual Advantage: Authoritative, detailed, and comprehensive repair information direct from the manufacturer's perspective. 📋 Manual Details Coverage Areas Main Focus: Workshop Service and Repair Target Audience: Professional Technicians and Advanced DIYers Page Count Estimated Pages: 2000+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Downloadable Digital File (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Yes (3.7L Magnum V6, 4.7L Magnum V8, 5.9L Magnum V8) Engine Performance: Yes (Fuel injection, ignition, emission controls) Transmission Manual: Yes (NV3500 5-speed, NV4500 5-speed) Transmission Automatic: Yes (45RFE/545RFE 4-speed, 47RE 4-speed) Drivetrain: Yes (Front axle, rear axle, transfer case, driveshafts, differentials) Suspension: Yes (Front independent, rear solid axle, springs, shocks, bushings) Steering: Yes (Power steering system, steering column, steering gear) Brakes: Yes (Front disc, rear disc, ABS, parking brake) Electrical System: Yes (Battery, charging system, starting system, lighting) Body And Frame: Yes (Body panels, doors, interior trim, frame components) HVAC: Yes (Heating, Ventilation, Air Conditioning system) Restraint Systems: Yes (Airbags, seatbelts) Diagnostics: Yes (OBD-II codes, diagnostic procedures, troubleshooting charts) Procedures Included Routine Maintenance: Yes (Oil changes, filter replacements, fluid checks) Component Removal Installation: Yes (Engine, transmission, axles, suspension, brakes) Troubleshooting: Yes (Detailed diagnostic flowcharts and symptom analysis) Rebuilding Overhauling: Yes (Engine, transmission, differential rebuilds) Wiring Diagrams: Yes (Comprehensive electrical schematics for all systems) Specifications Torque Values: Yes (Critical torque specifications for all fasteners) Special Tools: Yes (Identification and use of specialized tools) Technical Depth Depth: Comprehensive (From basic maintenance to full engine/transmission rebuilds) Diagnostic Capability: Advanced (Includes diagnostic trouble codes and fault finding) Diagrams Illustrations: Extensive (Step-by-step diagrams and exploded views) 📊 Manual Specifications File Format Type: PDF (Portable Document Format) Searchability: Searchable text content Printable: Printable pages Quality: High-resolution scans, clear text and images Print Quality Digital Resolution: Clear and legible for all sections Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 3.7L (226 cu in) Engine 1 Configuration: Inline 6-Cylinder (I6) Engine 1 Power: Approx. 205 hp @ 4800 rpm Engine 1 Torque: Approx. 235 lb-ft @ 3200 rpm Engine 2 Displacement: 4.7L (287 cu in) Engine 2 Configuration: V8 Engine 2 Power: Approx. 235 hp @ 4800 rpm Engine 2 Torque: Approx. 295 lb-ft @ 3200 rpm Engine 3 Displacement: 5.9L (360 cu in) Engine 3 Configuration: V8 Engine 3 Power: Approx. 245 hp @ 4000 rpm Engine 3 Torque: Approx. 335 lb-ft @ 3200 rpm Fuel System Induction Type: Electronic Fuel Injection (MPI) Fuel Type: Unleaded Gasoline 🔧 Transmission Standard Transmission 1 Type: NV3500 5-Speed Manual Optional Transmission 2 Type: 45RFE/545RFE 4-Speed Automatic Transmission 3 Type: 47RE 4-Speed Automatic (Heavy Duty) Features Transmission Fluid Type Auto: ATF+4 (MS-9602) Transmission Fluid Type Manual: Manual Transmission Fluid (GL-4 or GL-5, specific weight depends on model) Transfer Case: Command-Trac NV241 (Manual 4WD), Select-Trac NV241 (Full-time 4WD on some models) 📐 Dimensions Exterior Wheelbase Std: 131.3 inches (3335 mm) Wheelbase Long: 154.7 inches (3930 mm) Weights Curb Weight Approx: 4,500 - 5,500 lbs (2041 - 2495 kg) Gross Vehicle Weight Rating Gvwr: 6,200 - 8,000+ lbs (2812 - 3629+ kg, depending on configuration) Cargo Bed Lengths: 6.3 ft (Short Bed), 8.0 ft (Long Bed) 🛡️ Safety Features Ratings NHTSA Frontal Impact: Good (Driver), Acceptable (Passenger) - Varies by specific test and configuration Active Features ABS: Standard on all models Passive Features Airbags: Standard front airbags Seatbelts: All seating positions equipped with 3-point seat belts 💡 Technology Features Infotainment Audio System: Standard AM/FM stereo with CD player; optional Infinity premium audio system Navigation: Not available from factory Driver Assistance Cruise Control: Standard on most trims Connectivity Trailer Tow Package: Available, including trailer wiring harness and hitch receiver 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specifics) Engine Coolant Flush: Every 60,000 miles or 5 years Transmission Fluid Change Auto: Every 30,000-100,000 miles, depending on usage (refer to manual) Fluid Specifications Engine Oil Capacity 3.7L: 5.0 quarts (4.7 liters) with filter Engine Oil Capacity 4.7L: 5.0 quarts (4.7 liters) with filter Engine Oil Capacity 5.9L: 6.0 quarts (5.7 liters) with filter Engine Oil Viscosity: 5W-30 or 10W-30 (depending on temperature, refer to manual) Coolant Type: Mopar Antifreeze/Coolant (HOAT) Known Issues Common Complaints: Ball joint wear, rear main seal leaks (especially on 5.9L), power steering pump issues, transmission solenoid issues (on some automatics), plenum gasket leaks (on 5.9L). Rust Prone...
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Dodge Ram 2002 (1500) Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram 1500
Year:
2002
Codes
Chassis Code:
DR
Vin Designator:
B
👋 Introduction
Market Position
Segment:
Full-size Pickup Truck
Target Market:
Work, heavy-duty towing, family hauling, off-road enthusiasts
Competitive Analysis
Key Competitors:
Ford F-150, Chevrolet Silverado 1500, GMC Sierra 1500, Toyota Tundra
Key Features
Vehicle Attributes:
Robust construction, powerful engine options, strong towing capacity, versatile platform
Manual Advantage:
Authoritative, detailed, and comprehensive repair information direct from the manufacturer's perspective.
📋 Manual Details
Coverage Areas
Main Focus:
Workshop Service and Repair
Target Audience:
Professional Technicians and Advanced DIYers
Page Count
Estimated Pages:
2000+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Yes (3.7L Magnum V6, 4.7L Magnum V8, 5.9L Magnum V8)
Engine Performance:
Yes (Fuel injection, ignition, emission controls)
Transmission Manual:
Yes (NV3500 5-speed, NV4500 5-speed)
Transmission Automatic:
Yes (45RFE/545RFE 4-speed, 47RE 4-speed)
Drivetrain:
Yes (Front axle, rear axle, transfer case, driveshafts, differentials)
Suspension:
Yes (Front independent, rear solid axle, springs, shocks, bushings)
Steering:
Yes (Power steering system, steering column, steering gear)
Brakes:
Yes (Front disc, rear disc, ABS, parking brake)
Electrical System:
Yes (Battery, charging system, starting system, lighting)
Body And Frame:
Yes (Body panels, doors, interior trim, frame components)
HVAC:
Yes (Heating, Ventilation, Air Conditioning system)
Restraint Systems:
Yes (Airbags, seatbelts)
Diagnostics:
Yes (OBD-II codes, diagnostic procedures, troubleshooting charts)
Procedures Included
Routine Maintenance:
Yes (Oil changes, filter replacements, fluid checks)
Component Removal Installation:
Yes (Engine, transmission, axles, suspension, brakes)
Troubleshooting:
Yes (Detailed diagnostic flowcharts and symptom analysis)
Rebuilding Overhauling:
Yes (Engine, transmission, differential rebuilds)
Wiring Diagrams:
Yes (Comprehensive electrical schematics for all systems)
Specifications Torque Values:
Yes (Critical torque specifications for all fasteners)
Special Tools:
Yes (Identification and use of specialized tools)
Technical Depth
Depth:
Comprehensive (From basic maintenance to full engine/transmission rebuilds)
Diagnostic Capability:
Advanced (Includes diagnostic trouble codes and fault finding)
Diagrams Illustrations:
Extensive (Step-by-step diagrams and exploded views)
📊 Manual Specifications
File Format
Type:
PDF (Portable Document Format)
Searchability:
Searchable text content
Printable:
Printable pages
Quality:
High-resolution scans, clear text and images
Print Quality
Digital Resolution:
Clear and legible for all sections
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1 Displacement:
3.7L (226 cu in)
Engine 1 Configuration:
Inline 6-Cylinder (I6)
Engine 1 Power:
Approx. 205 hp @ 4800 rpm
Engine 1 Torque:
Approx. 235 lb-ft @ 3200 rpm
Engine 2 Displacement:
4.7L (287 cu in)
Engine 2 Configuration:
V8
Engine 2 Power:
Approx. 235 hp @ 4800 rpm
Engine 2 Torque:
Approx. 295 lb-ft @ 3200 rpm
Engine 3 Displacement:
5.9L (360 cu in)
Engine 3 Configuration:
V8
Engine 3 Power:
Approx. 245 hp @ 4000 rpm
Engine 3 Torque:
Approx. 335 lb-ft @ 3200 rpm
Fuel System
Induction Type:
Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Transmission 1 Type:
NV3500 5-Speed Manual
Optional
Transmission 2 Type:
45RFE/545RFE 4-Speed Automatic
Transmission 3 Type:
47RE 4-Speed Automatic (Heavy Duty)
Features
Transmission Fluid Type Auto:
ATF+4 (MS-9602)
Transmission Fluid Type Manual:
Manual Transmission Fluid (GL-4 or GL-5, specific weight depends on model)
Transfer Case:
Command-Trac NV241 (Manual 4WD), Select-Trac NV241 (Full-time 4WD on some models)
📐 Dimensions
Exterior
Wheelbase Std:
131.3 inches (3335 mm)
Wheelbase Long:
154.7 inches (3930 mm)
Weights
Curb Weight Approx:
4,500 - 5,500 lbs (2041 - 2495 kg)
Gross Vehicle Weight Rating Gvwr:
6,200 - 8,000+ lbs (2812 - 3629+ kg, depending on configuration)
Cargo
Bed Lengths:
6.3 ft (Short Bed), 8.0 ft (Long Bed)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact:
Good (Driver), Acceptable (Passenger) - Varies by specific test and configuration
Active Features
ABS:
Standard on all models
Passive Features
Airbags:
Standard front airbags
Seatbelts:
All seating positions equipped with 3-point seat belts
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM stereo with CD player; optional Infinity premium audio system
Navigation:
Not available from factory
Driver Assistance
Cruise Control:
Standard on most trims
Connectivity
Trailer Tow Package:
Available, including trailer wiring harness and hitch receiver
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specifics)
Engine Coolant Flush:
Every 60,000 miles or 5 years
Transmission Fluid Change Auto:
Every 30,000-100,000 miles, depending on usage (refer to manual)
Fluid Specifications
Engine Oil Capacity 3.7L:
5.0 quarts (4.7 liters) with filter
Engine Oil Capacity 4.7L:
5.0 quarts (4.7 liters) with filter
Engine Oil Capacity 5.9L:
6.0 quarts (5.7 liters) with filter
Engine Oil Viscosity:
5W-30 or 10W-30 (depending on temperature, refer to manual)
Coolant Type:
Mopar Antifreeze/Coolant (HOAT)
Known Issues
Common Complaints:
Ball joint wear, rear main seal leaks (especially on 5.9L), power steering pump issues, transmission solenoid issues (on some automatics), plenum gasket leaks (on 5.9L).
Rust Prone Areas:
Rear quarter panels, rocker panels, cab corners, frame rails (depending on climate and care).
📚 Vehicle History
Brand Heritage
Dodge Trucks:
Dodge has a long history of producing rugged and capable trucks, establishing a reputation for durability and power.
Model Evolution
Third Generation Ram:
The 2002 model is part of the third generation (2002-2008) of the Dodge Ram, which introduced significant styling and engineering updates, including a more robust frame and coil-spring rear suspension on some models.
Production
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan, USA
🏆 Awards & Recognition
Recognitions
Truck Of The Year Contenders:
The Dodge Ram lineup has historically been a strong contender in various 'Truck of the Year' awards from automotive publications.
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