2002 Dodge Ram 1500 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram 1500 Year: 2002 Generation Third Generation Codename: DR/DH/D2 Generation Years: 2002-2008 Codes Chassis Code: DR 👋 Introduction Market Position Segment: Full-size Pickup Truck Competitive Analysis Key Competitors: Ford F-150, Chevrolet Silverado 1500, GMC Sierra 1500, Toyota Tundra Key Features Third Gen Highlights: Redesigned exterior and interior, improved ride quality, introduction of HEMI V8 option, enhanced safety features. Manual Value Proposition Benefit To Owner: Enables DIY maintenance and repair, assists in diagnosing issues, provides factory-accurate specifications for optimal performance and longevity. 📋 Manual Details Coverage Areas Primary Focus: Full Factory Service & Repair Page Count Estimated Pages: Over 1500 (typical for full factory manuals) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (PDF, likely printable) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Exhaust System, Cooling System, Drivetrain (RWD/4WD), Transmission (Automatic/Manual), Transfer Case Chassis: Suspension (Front/Rear), Steering System, Brake System (Hydraulic/ABS), Wheels and Tires Electrical: Starting & Charging System, Ignition System, Lighting System, Instrumentation, Body Control Module (BCM), Powertrain Control Module (PCM), Audio System, Power Accessories (Windows, Locks, Mirrors), HVAC Controls, Diagnostic Systems (OBD-II) Body And Trim: Exterior Body Panels, Doors, Hood, Tailgate, Interior Trim, Seats, Bumpers, Glass, Mirrors Procedures Included Maintenance: Scheduled Maintenance, Fluid Checks and Changes, Filter Replacements, Lubrication, Tune-ups Diagnostics: Troubleshooting Charts, Symptom-based Diagnosis, DTC Code Interpretation, Component Testing Procedures Repair: Component Removal and Installation, Component Overhaul, Adjustment Procedures, Wiring Harness Repair, Body Panel Repair, Glass Replacement Technical Data: Torque Specifications, Clearance Specifications, Electrical Schematics, Wiring Diagrams, Vacuum Diagrams, Diagnostic Trouble Codes (DTCs) Technical Depth Depth: Comprehensive from basic fluid changes to complete engine and transmission rebuilds, including electrical troubleshooting and body repair. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Printability: High-resolution, designed for clear printing of individual pages or the entire manual. Binding Type Binding Format: Not Applicable (Digital Format) Paper Type Paper Recommendation: Standard printer paper, durable paper recommended for printed copies. Searchability Text Search: Likely fully searchable text for quick access to specific topics and procedures. Delivery Delivery Method: Instant Digital Download ⚙️ Engine Specifications Primary Engine Engine Options: 4.7L Magnum V8 (235 hp @ 4800 rpm, 295 lb-ft @ 3200 rpm), 5.9L Magnum V8 (360 hp @ 5000 rpm, 450 lb-ft @ 3200 rpm) Engine Codes: 4.7L (EBD), 5.9L (ETC - HO) Performance Horsepower Range: 235-360 hp Torque Range: 295-450 lb-ft Fuel System Injection Type: Multi-point Fuel Injection (MPI) Cooling System Coolant Capacity 4.7L: 12.1 quarts (11.5 liters) Coolant Capacity 5.9L: 14.0 quarts (13.2 liters) Oil Specifications Oil Type 4.7L: SAE 5W-30 (API Certified) Oil Type 5.9L: SAE 5W-30 (API Certified) Oil Capacity Oil Capacity 4.7L: 5.0 quarts (4.7 liters) with filter Oil Capacity 5.9L: 7.0 quarts (6.6 liters) with filter 🔧 Transmission Standard Transmission Type Standard: 4-Speed Automatic (42RE/44RE/45RFE/48RE) Optional Transmission Type Optional: 5-Speed Manual (NV3500 for some applications) Features Automatic Features: Overdrive, Electronic Control Fluid Specifications Automatic Transmission Fluid: ATF+4 (MS-9602) Fluid Capacity Automatic Fluid Capacity: Approx. 12-14 quarts (11.4-13.2 liters) for 48RE, varies by model Transfer Case Transfer Case Options: New Process NP231 (2WD/4WD Part-time), NP241DHD (4WD) Transfer Case Fluid Transfer Case Fluid Spec: ATF+4 (MS-9602) or Dexron III 📐 Dimensions Exterior Wheelbase Options: 134.0 inches (3404 mm) for regular cab, 154.8 inches (3932 mm) for club cab/mega cab Overall Length: Varies by cab/bed configuration (approx. 224-244 inches) Weights Curb Weight Range: 4,700 - 5,500 lbs (2,130 - 2,495 kg) Gross Vehicle Weight Rating: 6,000 - 8,500 lbs (2,722 - 3,856 kg), depending on configuration Cargo Bed Length Options: 6.3 feet (standard), 8.0 feet (long bed) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (2002 Model) NHTSA Front Impact Passenger: 4 Stars (2002 Model) IIHS Front Offset Rating: Acceptable (2002 Model) Active Features ABS: Standard on most models Traction Control: Optional (Electronic Traction Assist - ETA) Passive Features Airbags: Driver and Passenger front airbags Seatbelts: Three-point seatbelts with pretensioners 💡 Technology Features Infotainment Audio System Options: Base AM/FM stereo, AM/FM stereo with CD player, AM/FM stereo with CD/Cassette player, Infinity premium audio system. Driver Assistance Cruise Control: Standard on most trims. Connectivity OBD Ii Port: Located under the dashboard on the driver's side, compliant with SAE J1979. 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles or 6 months, or as indicated by the oil change reminder system. Air Filter Replacement: Every 30,000 miles or as needed based on driving conditions. Spark Plug Replacement: 4.7L V8: 100,000 miles (platinum plugs); 5.9L V8: 30,000 miles (copper plugs) Fluid Specifications Brake Fluid: DOT 3 Power Steering Fluid: ATF+4 (MS-9602) or equivalent Known Issues Common Problems Documented: Oil leaks (valve cover gaskets, oil pan gaskets), transmission issues (input/output shaft seals, torque converter clutch shudder), exhaust manifold cracks (especially on 5.9L), ABS sensor failures, power window regulator failures, interior trim creaks. Lubrication...
Base AM/FM stereo, AM/FM stereo with CD player, AM/FM stereo with CD/Cassette player, Infinity premium audio system.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
OBD Ii Port:
Located under the dashboard on the driver's side, compliant with SAE J1979.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months, or as indicated by the oil change reminder system.
Air Filter Replacement:
Every 30,000 miles or as needed based on driving conditions.
Spark Plug Replacement:
4.7L V8: 100,000 miles (platinum plugs); 5.9L V8: 30,000 miles (copper plugs)
Fluid Specifications
Brake Fluid:
DOT 3
Power Steering Fluid:
ATF+4 (MS-9602) or equivalent
Known Issues
Common Problems Documented:
Oil leaks (valve cover gaskets, oil pan gaskets), transmission issues (input/output shaft seals, torque converter clutch shudder), exhaust manifold cracks (especially on 5.9L), ABS sensor failures, power window regulator failures, interior trim creaks.
Lubrication
Grease Points:
Front suspension ball joints, tie rod ends, driveshaft U-joints (if equipped with grease fittings).
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, dating back to the early 20th century. The Ram nameplate was introduced in 1981.
Model Evolution
Third Gen Introduction:
The 2002 model year marked the debut of the third generation Dodge Ram (2002-2008), significantly re-engineered with a new chassis, updated styling, and the introduction of the powerful 5.7L HEMI V8 for 2003 model year, though not available for the 2002 1500 model itself.
Production
Assembly Locations:
Saltillo, Mexico; Warren, Michigan, USA
🏆 Awards & Recognition
Recognitions
Kbb Consumer Ratings Overall:
Generally positive for its class during its production years, praised for power and towing capacity.
Truck Of The Year Contenders:
Often a contender in various 'Truck of the Year' awards from automotive publications for its respective model year.