2002 Dodge Ram Pickup 1500 Truck Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Pickup 1500 Year: 2002 Product Name: 2002 Dodge Ram Pickup 1500 Truck Service Repair Workshop Manual Codes Chassis Code: DR/DN Platform: Third Generation Dodge Ram 👋 Introduction Market Position Segment: Full-size pickup truck. Target Audience: Owners, DIY mechanics, professional repair shops. Competitive Analysis Key Competitors: Ford F-150, Chevrolet Silverado 1500, Toyota Tundra. Key Features Vehicle Strengths: Robust construction, powerful engine options, towing capacity, comfortable ride for its class. Manual Value Proposition Benefit To Owner: Enables owners to perform maintenance and repairs themselves, saving money and understanding their vehicle better. Benefit To Professional: Provides essential factory-level data for efficient and accurate repairs. 📋 Manual Details Coverage Areas Primary Coverage: Complete service and repair for 2002 Dodge Ram 1500. Secondary Coverage: Troubleshooting, diagnostics, maintenance, wiring diagrams, exploded views. Page Count Estimated Pages: 2000+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Drivetrain, Fuel System, Exhaust System. Chassis: Suspension, Steering, Brakes, Wheels, Tires. Body: Exterior Body Panels, Interior Trim, Doors, Windows, Seats, HVAC System. Electrical: Battery, Starting System, Charging System, Ignition System, Lighting, Instrumentation, Power Accessories, Chassis Electrical, Powertrain Control Modules, Body Control Modules, Diagnostic Connectors. HVAC: Air Conditioning, Heating, Ventilation. Safety Systems: Airbags, Seatbelts, ABS. Procedures Included Maintenance: Scheduled maintenance, fluid checks and changes, filter replacements, lubrication. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics. Repair: Step-by-step repair instructions for all major components and systems, including removal, installation, and adjustment. Overhaul: Detailed procedures for engine and transmission overhauls, including component specifications and tolerances. Electrical Troubleshooting: Wiring diagrams, connector pinouts, component testing procedures, troubleshooting flowcharts. Component Replacement: Instructions for replacing common wear items and components like spark plugs, brake pads, belts, hoses, and more. Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds. Detail Level: Factory-level detail with illustrations and diagrams. 📊 Manual Specifications File Format Digital Format: PDF Searchability: Searchable text for quick information retrieval. Print Quality Illustrations: High-quality, detailed illustrations and diagrams. Binding Type Physical Binding: N/A (Digital format) Paper Type Physical Paper: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine 1: 4.7L Magnum V8 (P) (VIN Z) Engine 2: 5.9L Magnum V8 (Q) (VIN 6) Engine 3: 5.7L HEMI V8 (D) (VIN T) - Introduced in 2003 model year, but some early production could be present. Performance 4.7L Horsepower 4.7L: 245 hp @ 4800 rpm Torque 4.7L: 300 lb-ft @ 3200 rpm Performance 5.9L Horsepower 5.9L: 245 hp @ 4000 rpm Torque 5.9L: 335 lb-ft @ 3200 rpm Fuel System Fuel Delivery: Sequential Multiport Fuel Injection (MPI) Fuel Type: Unleaded gasoline Technical Specs Bore Stroke 4.7L: 3.70 in x 3.38 in Bore Stroke 5.9L: 3.90 in x 3.91 in Engine Management ECM: NGC (Next Generation Controller) or similar. 🔧 Transmission Standard Transmission Automatic Std 1500: 48RE 4-Speed Automatic (for 5.9L) Optional Transmission Automatic Opt 1500: 45RFE 4-Speed Automatic (for 4.7L) Manual Transmission: NV3500 5-Speed Manual (Less Common on 1500 models, more frequent on 2500) Features Overdrive: All automatics feature overdrive. Fluid Specs Auto Fluid 45Rfe: ATF+4 (Mopar P/N 05013457AA or equivalent) Auto Fluid 48Re: ATF+4 (Mopar P/N 05013457AA or equivalent) Manual Fluid: MS-9224 spec manual transmission fluid 📐 Dimensions Exterior 1500 Wheelbase: 134.0 inches (Standard Bed) Wheelbase Long: 134.0 inches (2002 - Crew Cab introduced with 134.0" wb, Regular/Quad Cab w/ standard box) Bed Length Options: 6.3 ft (standard), 8.0 ft (long bed) Weights 1500 Gvwr Start: Approx. 6,350 lbs (varies by configuration) Curb Weight Start: Approx. 4,700 lbs (varies by configuration) Towing Capacity Max Towing 1500: Up to 8,750 lbs (depending on engine, axle ratio, and configuration) 🛡️ Safety Features Ratings NHTSA Frontal Driver 2002: Five-star NHTSA Frontal Passenger 2002: Five-star IIHS Frontal Offset: Good Active Features ABS: Standard on all models. Traction Control: Optional on some models. Passive Features Airbags: Driver and passenger front airbags. Seatbelts: Three-point seat belts in all seating positions. 💡 Technology Features Infotainment Audio Options: Base AM/FM, AM/FM/CD, AM/FM/Cassette/CD, optional Infinity premium sound system. Navigation: Rare factory navigation system available on higher trims. Driver Assistance Cruise Control: Standard on most models. Connectivity Onboard Diagnostics: OBD-II compliant for emissions and diagnostic scanning. 🔧 Maintenance Service Intervals Oil Oil Change Interval: Every 3,000 miles or 3 months (severe service) or 6,000 miles/6 months (normal service), refer to manual for specific recommendation based on oil type. Oil Filter Part Number: Mopar: MO-090 or MO-899 (check specific engine/filter type). Fluid Specifications Coolant Coolant Type: Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Blue (Mopar P/N 05103532AA or equivalent). Fluid Specifications Brake Brake Fluid Type: DOT 3 Fluid Specifications Power Steering Power Steering Fluid: ATF+4 (Mopar P/N 05013457AA or equivalent) or designated power steering fluid. Known Issues Common Problems Typical: Cracked exhaust manifolds (especially 4.7L), fuel pump failures, transmission...
Instructions for replacing common wear items and components like spark plugs, brake pads, belts, hoses, and more.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds.
Detail Level:
Factory-level detail with illustrations and diagrams.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Searchable text for quick information retrieval.
Print Quality
Illustrations:
High-quality, detailed illustrations and diagrams.
Binding Type
Physical Binding:
N/A (Digital format)
Paper Type
Physical Paper:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine 1:
4.7L Magnum V8 (P) (VIN Z)
Engine 2:
5.9L Magnum V8 (Q) (VIN 6)
Engine 3:
5.7L HEMI V8 (D) (VIN T) - Introduced in 2003 model year, but some early production could be present.
Performance 4.7L
Horsepower 4.7L:
245 hp @ 4800 rpm
Torque 4.7L:
300 lb-ft @ 3200 rpm
Performance 5.9L
Horsepower 5.9L:
245 hp @ 4000 rpm
Torque 5.9L:
335 lb-ft @ 3200 rpm
Fuel System
Fuel Delivery:
Sequential Multiport Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Technical Specs
Bore Stroke 4.7L:
3.70 in x 3.38 in
Bore Stroke 5.9L:
3.90 in x 3.91 in
Engine Management
ECM:
NGC (Next Generation Controller) or similar.
🔧 Transmission
Standard Transmission
Automatic Std 1500:
48RE 4-Speed Automatic (for 5.9L)
Optional Transmission
Automatic Opt 1500:
45RFE 4-Speed Automatic (for 4.7L)
Manual Transmission:
NV3500 5-Speed Manual (Less Common on 1500 models, more frequent on 2500)
Features
Overdrive:
All automatics feature overdrive.
Fluid Specs
Auto Fluid 45Rfe:
ATF+4 (Mopar P/N 05013457AA or equivalent)
Auto Fluid 48Re:
ATF+4 (Mopar P/N 05013457AA or equivalent)
Manual Fluid:
MS-9224 spec manual transmission fluid
📐 Dimensions
Exterior 1500
Wheelbase:
134.0 inches (Standard Bed)
Wheelbase Long:
134.0 inches (2002 - Crew Cab introduced with 134.0" wb, Regular/Quad Cab w/ standard box)
Bed Length Options:
6.3 ft (standard), 8.0 ft (long bed)
Weights 1500
Gvwr Start:
Approx. 6,350 lbs (varies by configuration)
Curb Weight Start:
Approx. 4,700 lbs (varies by configuration)
Towing Capacity
Max Towing 1500:
Up to 8,750 lbs (depending on engine, axle ratio, and configuration)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver 2002:
Five-star
NHTSA Frontal Passenger 2002:
Five-star
IIHS Frontal Offset:
Good
Active Features
ABS:
Standard on all models.
Traction Control:
Optional on some models.
Passive Features
Airbags:
Driver and passenger front airbags.
Seatbelts:
Three-point seat belts in all seating positions.
💡 Technology Features
Infotainment
Audio Options:
Base AM/FM, AM/FM/CD, AM/FM/Cassette/CD, optional Infinity premium sound system.
Navigation:
Rare factory navigation system available on higher trims.
Driver Assistance
Cruise Control:
Standard on most models.
Connectivity
Onboard Diagnostics:
OBD-II compliant for emissions and diagnostic scanning.
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 3,000 miles or 3 months (severe service) or 6,000 miles/6 months (normal service), refer to manual for specific recommendation based on oil type.
Oil Filter Part Number:
Mopar: MO-090 or MO-899 (check specific engine/filter type).
Fluid Specifications Coolant
Coolant Type:
Chrysler HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Blue (Mopar P/N 05103532AA or equivalent).
Fluid Specifications Brake
Brake Fluid Type:
DOT 3
Fluid Specifications Power Steering
Power Steering Fluid:
ATF+4 (Mopar P/N 05013457AA or equivalent) or designated power steering fluid.
Known Issues
Common Problems Typical:
Cracked exhaust manifolds (especially 4.7L), fuel pump failures, transmission solenoid issues, brake wear, rust in certain climates, potential for front suspension wear on higher mileage vehicles.
Specific Issues 4.7L:
Valve seat recession, piston slap, oil consumption, and camshaft issues have been reported on some 4.7L engines.
Maintenance Schedule Highlights
Spark Plugs:
Replace every 100,000 miles (check manual for specific plug type and gap).
Drive Belt:
Inspect at regular intervals, replace as needed or every 60,000-100,000 miles.
Transmission Fluid Service:
Recommended every 60,000-100,000 miles, depending on service conditions.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks dating back to the 1930s.
Model Evolution
Third Gen Ram Introduction:
The 2002 model year marked the introduction of the third generation Dodge Ram (2002-2008), a significant redesign with updated styling, improved aerodynamics, and enhanced chassis dynamics.
Key Changes 2002:
New exterior styling, revised interior, independent front suspension (IFS) for 1500 models, updated engine options, and the introduction of the Quad Cab configuration.