🏷️ Basic Information Identification Make: Dodge Model: Ram 2500 Year: 2002 Product Name: 2002 Dodge Ram 2500 Service & Repair Manual Official Licensing: Officially Licensed 👋 Introduction Market Position Target User: Professional automotive technicians and advanced DIY enthusiasts. Value Proposition: Provides comprehensive, dealership-level repair information for significant cost savings compared to professional labor. Competitive Analysis Competitors: Haynes, Chilton manuals (often less detailed, may not be official). Key Features Official Source: Officially licensed, indicating accuracy and completeness aligned with manufacturer specifications. Digital Format Benefit: Instant access, portability, searchable content, bookmarking capabilities. 📋 Manual Details Coverage Areas General Coverage: Complete service, repair, maintenance, and diagnostic procedures for the 2002 Dodge Ram 2500. Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: Digital Software (likely PDF or proprietary executable) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, and overhaul for all available engines including gasoline and Cummins diesel. Transmission: Coverage for automatic (48RE, NV4500) and manual transmissions, including repair, adjustments, and fluid services. Drivetrain: Front and rear axle service, differentials, transfer case (NV241DHD/NV243DHD), driveshafts, and U-joints. Suspension: Front and rear suspension components, steering system, shock absorbers, springs, and alignment specifications. Brakes: Hydraulic brake system diagnostics, ABS, front and rear brake component service, parking brake. Electrical System: Comprehensive wiring diagrams, fuse box layouts, lighting, power windows, locks, ignition system, starting and charging systems. HVAC: Air conditioning, heating system, climate control, refrigerant handling, and component replacement. Body And Frame: Exterior trim, interior components, glass, doors, tailgate, and body panel repair, including frame specifications. Fuel System: Fuel tank, pump, lines, injectors, and fuel pressure diagnostics for gasoline and diesel engines. Cooling System: Radiator, coolant, water pump, thermostat, fan clutch, and cooling system diagnostics. Exhaust System: Exhaust manifold, catalytic converter, mufflers, and pipe routing and replacement. Procedures Included Routine Maintenance: Oil changes, fluid checks and top-offs, filter replacements, tire rotations, brake inspections. Diagnostic Procedures: Troubleshooting guides for common and complex issues, using scan tools and symptom-based diagnostics. Component Replacement: Step-by-step instructions for replacing engine parts, transmission components, suspension parts, brake assemblies, sensors, actuators, and more. Rebuild Procedures: Complete overhaul procedures for engines and transmissions. Wiring Diagrams: Detailed, system-specific wiring schematics for easy electrical troubleshooting. Torque Specifications: Precise torque values for all critical fasteners. Specifications And Tolerances: Detailed mechanical specifications and allowable wear tolerances for key components. Technical Depth Depth: Comprehensive, covering everything from basic preventative maintenance to in-depth component overhaul and advanced diagnostics. 📊 Manual Specifications File Format File Type: Digital Software Searchability: Likely fully searchable text content for quick information retrieval. Print Quality Print Option: Printable pages for hard copy reference. Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Gasoline Engine Options: 4.7L Magnum V8 (16V, P-code), 5.9L Magnum V8 (16V, Y-code). Diesel Engine Option: 5.9L Cummins Turbo Diesel (24V ISB, ISB '03 HO). Performance 4.7L V8 Horsepower: Approx. 235 hp @ 4800 rpm 4.7L V8 Torque: Approx. 305 lb-ft @ 3200 rpm 5.9L V8 Horsepower: Approx. 245-250 hp @ 4000 rpm 5.9L V8 Torque: Approx. 330-345 lb-ft @ 2400 rpm 5.9L Cummins Horsepower: Approx. 235-250 hp @ 2700 rpm (Standard/HO) 5.9L Cummins Torque: Approx. 460-505 lb-ft @ 1400-1600 rpm (Standard/HO) Fuel System Gasoline Injection Type: Multi-point fuel injection (MPI) Diesel Injection Type: Bosch VP44 Inline Injection Pump (Standard), Common Rail (HO models variants). Engine Codes 4.7L V8 Code: P 5.9L V8 Code: Y 5.9L Cummins Code: ISB, ISB '03 HO 🔧 Transmission Standard Standard Transmission Gas: NV3500 5-Speed Manual (Light duty 2500) Standard Transmission Heavy Duty: NV4500 5-Speed Manual (Heavy duty 2500) Optional Optional Transmission Gas Diesel: 48RE 4-Speed Automatic Transmission Features Diesel Tow Haul: Integrated Tow/Haul mode on 48RE for improved towing performance. Transfer Case Options: NV241DHD (Heavy Duty 273 HD) and NV243DHD (Electronic Shift). 📐 Dimensions Exterior Wheelbase Options: 134.5 inches (Regular Cab), 160.5 inches (Quad Cab/Long Bed). Bed Length Options: 6.3 ft (short bed), 8.0 ft (long bed). Weights Gvwr Range: 8,800 lbs - 9,750 lbs (depending on configuration). Curb Weight Range: Approx. 6,000 - 7,000 lbs. 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Likely 4-star (typical for period trucks, specific data may vary). NHTSA Front Impact Passenger: Likely 4-star (typical for period trucks, specific data may vary). Active Features ABS: Standard Anti-lock Braking System (ABS). Passive Features Airbags: Driver and Passenger front airbags. Seatbelts: Three-point front seat belts, rear seat belts. 💡 Technology Features Infotainment Audio System Options: AM/FM stereo, CD player, cassette player (optional), premium Infinity sound system. User Interface: Basic dashboard layout with physical controls for climate and audio. Driver Assistance Cruise Control: Standard cruise control. Trailer Brake Controller: Optional factory-integrated trailer brake controller on some models. Connectivity Power Accessories: Power windows, power door locks, power mirrors. Remote Keyless Entry: Available on higher trim levels. 🔧 Maintenance Service Intervals...
8,800 lbs - 9,750 lbs (depending on configuration).
Curb Weight Range:
Approx. 6,000 - 7,000 lbs.
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Likely 4-star (typical for period trucks, specific data may vary).
NHTSA Front Impact Passenger:
Likely 4-star (typical for period trucks, specific data may vary).
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Passive Features
Airbags:
Driver and Passenger front airbags.
Seatbelts:
Three-point front seat belts, rear seat belts.
💡 Technology Features
Infotainment
Audio System Options:
AM/FM stereo, CD player, cassette player (optional), premium Infinity sound system.
User Interface:
Basic dashboard layout with physical controls for climate and audio.
Driver Assistance
Cruise Control:
Standard cruise control.
Trailer Brake Controller:
Optional factory-integrated trailer brake controller on some models.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors.
Remote Keyless Entry:
Available on higher trim levels.
🔧 Maintenance
Service Intervals
Oil Change Gasoline:
Every 3,000 - 5,000 miles or 6 months (severe vs. normal duty).
Oil Change Cummins:
Every 7,500 - 15,000 miles or 6-12 months (depending on oil quality and usage).
Transmission Fluid Change Auto:
Every 30,000 - 60,000 miles (depending on towing and conditions).
Transmission Fluid Change Manual:
Every 60,000 - 100,000 miles.
Fluid Specifications
Engine Oil Gasoline:
API Certified SAE 5W-30 or 10W-30 (check owner's manual for exact specification).
Engine Oil Cummins:
API CJ-4 or CK-4 (preferred) SAE 15W-40 Diesel Engine Oil.
Transmission Fluid 48Re:
ATF+4 (Chrysler Material Standard MS-9602).
Transfer Case Fluid:
ATF+4 or compatible fluid.
Differential Fluid:
API GL-5, SAE 75W-90 or 80W-90 (check axle type).
Known Issues
Cummins Vp44 Pump:
Known vulnerability to failure due to fuel pressure issues or contamination.
Gasoline Engine 4.7L Cam Phaser:
Potential issues with cam phaser solenoids leading to rough idle or P0016 codes.
Front Suspension:
Wear on ball joints, tie rod ends, and track bar bushings due to heavy duty use.
Brake Wear:
Premature wear on brake pads and rotors, especially with heavy towing.
Electrical Connectors:
Corrosion or loose connections in wiring harnesses, especially in exposed areas.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable pickup trucks, with the Ram line dating back to the 1980s.
Model Evolution
Third Generation Ram:
The 2002 model is part of the third generation of the Dodge Ram (DB series), launched for the 2002 model year. It featured a significant redesign from the previous generation.
Design Changes:
Third generation introduced a more aggressive styling, a larger cab, and updated powertrains, including the revised Cummins diesel.
Production
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan, USA.
🏆 Awards & Recognition
Recognitions
Cummins Engine Reputation:
The 5.9L Cummins Turbo Diesel engine is highly regarded for its durability and longevity, often considered one of the best diesel engines of its era.
Truck Of The Year:
While not specific to this exact year's manual, the Dodge Ram line has received numerous 'Truck of the Year' awards from various automotive publications throughout its history.