Dodge Ram 2002-2004 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Model Generation: Third Generation (DR/DH/D2) Covered Years: 2002, 2003, 2004 Codes Chassis Codes: DR/DH/D2 👋 Introduction Market Position Target Audience: Dodge Ram owners, DIY mechanics, professional automotive technicians Value Proposition: Cost-effective solution for maintaining and repairing the vehicle, empowering users with factory-level information Competitive Analysis Competitor Manuals: Haynes, Chilton (often less detailed than factory WSRM) Key Features Primary Benefit: Empowers users to perform complex repairs and diagnostics accurately Information Source: Based on official Chrysler/Dodge factory service information Comprehensiveness: Covers virtually all mechanical and electrical aspects of the vehicle 📋 Manual Details Coverage Areas Primary Coverage: Full Service and Repair Trim Level Coverage: All available trim levels for the specified years Body Style Coverage: All body styles including 1500, 2500, 3500; Regular Cab, Quad Cab, Mega Cab (where applicable for model year) Page Count Estimated Pages: Over 2000 (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Service Repair Manual (WSRM) Language Language: English Format Format: Digital (likely PDF), searchable 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel injection, ignition, exhaust, emission control systems Transmission: Manual transmission (NV3500, NV4500), Automatic transmission (45RFE, 48RE, 47RE) Drivetrain: Transfer case, front and rear axles, drive shafts, CV joints, differential systems Brakes: Front disc brakes, rear drum/disc brakes (depending on model/GVWR), ABS, parking brake system Suspension: Front independent suspension (SLA on some models), rear leaf spring suspension, steering components Steering: Power steering system, steering column, tie rods, linkage Electrical: Battery, charging system, starting system, lighting, instrument cluster, power accessories, Body Control Module (BCM) HVAC: Heating, ventilation, and air conditioning (HVAC) system diagnosis and repair Body: Body panels, doors, windows, interior trim, bumpers, tailgate, frame Chassis: Frame construction, mounting points, underbody components Diagnostics: Diagnostic Trouble Codes (DTCs), diagnostic procedures, OBD-II system Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication points Routine Repair: Component replacement (e.g., water pump, alternator, starter, spark plugs) Major Repair: Engine overhaul, transmission overhaul, brake system rebuilding Troubleshooting: Step-by-step diagnostic flowcharts for various symptoms Special Tools: Identification and usage of specialized tools for specific repair procedures Wiring Diagrams: Detailed electrical wiring schematics for all systems Specifications: Torque specifications, clearances, tolerances, fluid capacities Reassembly: Detailed instructions for component disassembly and reassembly Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds Diagnostic Level: Advanced, including sensor data interpretation, electrical circuit testing, and system-level diagnostics Detail Level: High, with clear exploded views, diagrams, and step-by-step instructions 📊 Manual Specifications File Format Digital Format: PDF Searchability: Searchable text for quick information retrieval Printability: Printable pages for hands-on workshop use Print Quality Image Quality: High-resolution illustrations and diagrams Binding Type Physical Binding: N/A (Digital Format) Paper Type Physical Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Options: 4.7L Magnum V8 (P-Code), 5.7L HEMI V8 (4th Gen, late 2003/2004 models), 5.9L Magnum V8 (2500/3500 models), 4.7L Magnum V8 (2500/3500 models), 5.9L Cummins Turbo Diesel (2500/3500 models) Engine Displacement 1500: 4.7L (285 cu in), 5.7L (345 cu in) Engine Displacement 2500 3500: 4.7L (285 cu in), 5.9L (359 cu in), 5.9L Turbo Diesel (359 cu in) Performance Horsepower 4.7L V8: Approx. 235-240 hp Torque 4.7L V8: Approx. 295-300 lb-ft Horsepower 5.7L Hemi V8: Approx. 345-348 hp Torque 5.7L Hemi V8: Approx. 375-380 lb-ft Horsepower 5.9L Magnum V8: Approx. 245-250 hp Torque 5.9L Magnum V8: Approx. 330-335 lb-ft Horsepower 5.9L Cummins Diesel: Approx. 235-250 hp (depending on tuning) Torque 5.9L Cummins Diesel: Approx. 460-505 lb-ft (depending on tuning) Fuel System Injection Type: Multi-port Fuel Injection (MPI) for gasoline engines, Common Rail Direct Injection (CRDI) for Cummins Diesel Fuel Type: Unleaded Gasoline (87 octane recommended), Diesel Fuel (for Cummins) 🔧 Transmission Standard Standard Transmission: 5-Speed Manual (NV3500 on 1500, NV4500 on 2500/3500) Optional Optional Transmission 1500: 4-Speed Automatic (45RFE) Optional Transmission 2500 3500: 4-Speed Automatic (47RE, 48RE) Features Transfer Case: Part-time 4WD (NV243, NV244), Full-time 4WD (NV271, NV273), 2WD available Transmission Fluid Spec Auto: ATF+4 (Chrysler) Transmission Fluid Spec Manual: NV3500: Manual Transmission Fluid (API GL-4, SAE 75W-90), NV4500: Manual Transmission Fluid (API GL-3, SAE 75W-90 or 80W-90) 📐 Dimensions Exterior Wheelbase Regular Cab: 134.0 inches Wheelbase Quad Cab: 154.7 inches Wheelbase Mega Cab: 160.5 inches Bed Lengths: 6.3 ft (Standard Bed), 8.0 ft (Long Bed) Weights Curb Weight 1500: Approx. 4,500 - 5,500 lbs (varies by configuration) Gvwr 1500: Approx. 6,000 - 6,500 lbs Curb Weight 2500 3500: Approx. 5,500 - 7,500+ lbs (varies significantly by configuration and engine) Gvwr 2500: Approx. 7,000 - 8,500 lbs Gvwr 3500: Approx. 8,800 - 11,000+ lbs (including dually configurations) 🛡️ Safety Features Ratings NHTSA Frontal Driver 2002: Five Stars (NHTSA) NHTSA Frontal Passenger 2002: Five Stars (NHTSA) IIHS Frontal Offset 2002: Good (IIHS - Insurance Institute for Highway Safety) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional...
Good (IIHS - Insurance Institute for Highway Safety)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Electronic Stability Program (ESP) available on some models
Passive Features
Airbags:
Driver and front passenger airbags; optional side airbags available
Seatbelts:
Three-point front and rear seatbelts
💡 Technology Features
Infotainment
Infotainment Systems:
Base AM/FM/CD player, optional premium Infinity sound system, available navigation systems (less common in this era), rear-seat entertainment systems (rare)
Driver Assistance
Driver Assistance Features:
Anti-lock Brakes (ABS) standard, optional traction control (ESP)
Connectivity
Connectivity Options:
Basic connectivity; features like Bluetooth, USB, or AUX inputs were not standard and typically aftermarket additions.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles or 6 months (depending on oil type and driving conditions)
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on visual inspection
Spark Plug Replacement Gasoline:
4.7L Magnum: 100,000 miles (platinum plugs); 5.7L HEMI: 100,000 miles (platinum plugs)
Coolant Flush:
Every 60,000 - 100,000 miles or 5 years (depending on coolant type)
Transmission Fluid Service:
Every 30,000 - 60,000 miles for automatic transmissions (depending on towing and driving conditions)
Fluid Specifications
Engine Oil 4.7L V8:
SAE 5W-30 (API certified)
Engine Oil 5.7L Hemi:
SAE 5W-20 (API certified)
Engine Oil 5.9L Cummins:
CJ-4 rated Diesel Engine Oil, SAE 15W-40
Coolant:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, Blue (50/50 mix)
Brake Fluid:
DOT 3
Known Issues
4.7L Magnum V8:
Head gasket failures (especially early models), intake manifold gasket leaks, spark plug blow-out
5.7L Hemi V8:
Exhaust manifold cracks, lifter/camshaft wear (multi-displacement system issues in later years of this gen, less common in 03-04)
5.9L Cummins Diesel:
VP44 injection pump failure (mid-life issue), lifting of cylinder head (especially with higher performance tunes), aging fuel lines
Transmissions:
Overheating and failure of automatic transmissions (especially 47RE/48RE under heavy load), manual transmission synchro issues (NV3500)
Suspension Steering:
Ball joint wear, tie rod end wear, front sway bar end link issues
Electrical:
Instrument cluster failures, TIPM (Totally Integrated Power Module) issues (more common in later years of this generation)
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, establishing the Ram nameplate as a serious contender in the pickup market.
Model Evolution
Third Generation Introduction:
The third generation Ram (DN/DM platform) debuted for the 2002 model year, featuring a significant redesign with a bolder, more muscular exterior and a more refined interior. Introduced a larger cab configuration (Mega Cab) and the HEMI V8 engine.
Key Changes 2002:
Complete redesign, new chassis, introduction of Quad Cab and Mega Cab options, 4.7L V8 standard on most 1500 models, 5.9L V8 and Cummins Diesel available on heavier duty models.
Key Changes 2003:
Introduction of the 5.7L HEMI V8 engine, offering a significant power upgrade.
Key Changes 2004:
Minor refinements, further availability of HEMI engine across trims, potential minor feature packaging changes.
Production
Manufacturing Locations:
Saltillo Truck Assembly, Mexico; Warren Truck Assembly, Michigan, USA
Production Period:
2002-2008 (for the third generation platform)
🏆 Awards & Recognition
Recognitions
Segment Recognition:
Consistently ranked among the top heavy-duty pickups for its towing and hauling capabilities.
Engine Awards:
5.7L HEMI V8 often cited for its power and performance.
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