Dodge Ram Truck 3500 Series 2002 Workshop Service Repair Manual
Normaalihinta
$133.00
Myyntihinta
$133.00
Normaalihinta
Yksikköhinta
/ kohti
Alennusmyynti
Loppuunmyyty
🏷️ Basic Information Identification Make: Dodge Model: Ram Truck 3500 Series Year: 2002 Vehicle Type: Heavy-Duty Pickup Truck Codes Chassis Code: DR (Third Generation Ram Pickup) 👋 Introduction Market Position Segment: Heavy-Duty Pickup Truck, primarily for commercial, towing, and heavy hauling applications. Competitive Analysis Key Competitors: Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD. Key Features Target Audience: Owners of 2002 Dodge Ram 3500, independent repair shops, fleet managers, DIY mechanics. Value Proposition: Provides authoritative, detailed information essential for accurate diagnosis, maintenance, and repair, reducing labor costs and ensuring vehicle longevity. 📋 Manual Details Coverage Areas Coverage: All Models/Engine Variants Page Count Estimated Pages: Varies by specific document, typically 1500-3000+ pages for comprehensive factory service manuals Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (Gasoline & Diesel), Transmission (Automatic & Manual), Drivetrain (4x4 systems, axles, differentials), Fuel System, Exhaust System Chassis: Suspension (Front & Rear), Steering, Brakes (ABS, hydraulics, components), Wheels & Tires Electrical System: Battery, Charging System, Starting System, Lighting, Instrumentation, Power Accessories, Wiring Diagrams, Fuses & Relays, Body Control Modules (BCM) Body & Interior: Body Panels, Doors, Windows, Seats, HVAC System, Dashboard, Trim, Bumpers, Glass Procedures Included Maintenance: Scheduled Maintenance Intervals, Oil Changes, Filter Replacements, Lubrication Points, Fluid Checks and Replacements Diagnosis & Troubleshooting: Symptom-based diagnostics, Diagnostic Trouble Codes (DTCs), Electrical Schematics interpretation, Component Testing Procedures Repair Procedures: Component Removal and Installation, Rebuilding Procedures, Adjustments, Torque Specifications, Alignment Procedures Technical Specifications: Engine tolerances, Piston ring end gap, Valve lash, Spark plug gap, Fluid capacities, Torque values for all fasteners, Wheel alignment specifications Technical Depth Depth: Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls, including detailed electrical diagnostics and wiring diagrams. 📊 Manual Specifications File Format PDF Quality: High-resolution, typically scannable text for searchability, often with bookmarks for easy navigation. Print Quality Printable: Printable pages for on-site use in a workshop environment. Binding Type Binding: Not Applicable (Digital PDF Download) Paper Type Paper Quality: Not Applicable (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Gasoline Option 1: 8.0L OHV V10 (488 ci) Gasoline Option 1 Power: 305 hp @ 4000 rpm Gasoline Option 1 Torque: 450 lb-ft @ 3200 rpm Diesel Option 1: 5.9L OHV I6 Cummins Turbo Diesel (360 ci) Diesel Option 1 Power: 235 hp @ 2600 rpm (for manual transmission), 250 hp @ 2600 rpm (for automatic transmission) Diesel Option 1 Torque: 460 lb-ft @ 1600 rpm (for manual transmission), 475 lb-ft @ 1600 rpm (for automatic transmission) Fuel System Gasoline Fuel Delivery: Multi-Point Fuel Injection (MPI) Diesel Fuel Delivery: Bosch High-Pressure Common Rail (HPCR) Injection System Cooling System Coolant Type: Mopar Antifreeze/Coolant (OAT - Organic Additive Technology), or equivalent HOAT (Hybrid Organic Additive Technology) meeting Chrysler MS-9769 Lubrication Oil Type Gasoline: API SN or newer, SAE 5W-30 or 10W-30 (depending on temperature, refer to manual) Oil Type Diesel: API CJ-4 or newer (or older specs like CI-4 Plus), SAE 15W-40 (low ash content recommended for emissions systems) 🔧 Transmission Standard Transmission Type: NV4500 5-speed manual transmission (for some engine/drivetrain configurations) Optional Transmission Type: 47RE 4-speed automatic transmission (with V10 gasoline) Features Manual Fluid: NV4500: Manual Transmission Fluid (MTF) meeting Chrysler spec MS-9224, typically a GL-3 or GL-4 rated fluid (e.g., 75W-90 or 75W-140) Automatic Fluid: 48RE/47RE: ATF+4 (MS-9602) or equivalent. Drivetrain Drivetrain Options: 2WD (Rear Wheel Drive) and 4WD (Four-Wheel Drive) 📐 Dimensions Exterior Wheelbase Standard: Approximately 134.7 inches (Regular Cab), 144.5 inches (Club Cab/Quad Cab) Overall Length Approx: Approximately 229.7 inches (Standard Bed) Cargo Bed Length Options: 6.3 ft (Standard Bed), 8.0 ft (Long Bed) Weights Gvwr Min: Approximately 10,000 lbs Gvwr Max: Up to 11,500 lbs (depending on configuration) Gcwr Max: Up to 20,000 lbs (when properly equipped) Towing Max Towing Capacity: Up to 13,200 lbs (properly equipped, varies by configuration) Payload Max Payload Capacity: Up to 5,000 lbs (varies by configuration) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: Often rated 3-star for rollover resistance (typical for high-center-of-gravity trucks of this era) Active Features ABS: Standard 4-wheel Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System (TCS) on some models. Passive Features Airbags: Driver and Passenger Frontal Airbags Seatbelts: Three-point seat belts with pretensioners. 💡 Technology Features Infotainment Audio System Options: Factory AM/FM/CD player, optional cassette player, premium audio systems available on higher trims. Auxiliary input jack may be present. Driver Assistance Cruise Control: Standard cruise control on most trims. Connectivity Trailer Brakes: Provisions for integrated or aftermarket trailer brake controllers were common due to the truck's intended use. 🔧 Maintenance Service Intervals Oil Change Gasoline: Typically every 3,000-5,000 miles or 6 months, depending on usage and oil type (refer to manual for exact recommendations). Oil Change Diesel: Typically every 7,500-15,000 miles or 12 months with synthetic oil and filter, but strongly...
Provides authoritative, detailed information essential for accurate diagnosis, maintenance, and repair, reducing labor costs and ensuring vehicle longevity.
📋 Manual Details
Coverage Areas
Coverage:
All Models/Engine Variants
Page Count
Estimated Pages:
Varies by specific document, typically 1500-3000+ pages for comprehensive factory service manuals
Engine tolerances, Piston ring end gap, Valve lash, Spark plug gap, Fluid capacities, Torque values for all fasteners, Wheel alignment specifications
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls, including detailed electrical diagnostics and wiring diagrams.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, typically scannable text for searchability, often with bookmarks for easy navigation.
Print Quality
Printable:
Printable pages for on-site use in a workshop environment.
Binding Type
Binding:
Not Applicable (Digital PDF Download)
Paper Type
Paper Quality:
Not Applicable (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Gasoline Option 1:
8.0L OHV V10 (488 ci)
Gasoline Option 1 Power:
305 hp @ 4000 rpm
Gasoline Option 1 Torque:
450 lb-ft @ 3200 rpm
Diesel Option 1:
5.9L OHV I6 Cummins Turbo Diesel (360 ci)
Diesel Option 1 Power:
235 hp @ 2600 rpm (for manual transmission), 250 hp @ 2600 rpm (for automatic transmission)
NV4500: Manual Transmission Fluid (MTF) meeting Chrysler spec MS-9224, typically a GL-3 or GL-4 rated fluid (e.g., 75W-90 or 75W-140)
Automatic Fluid:
48RE/47RE: ATF+4 (MS-9602) or equivalent.
Drivetrain
Drivetrain Options:
2WD (Rear Wheel Drive) and 4WD (Four-Wheel Drive)
📐 Dimensions
Exterior
Wheelbase Standard:
Approximately 134.7 inches (Regular Cab), 144.5 inches (Club Cab/Quad Cab)
Overall Length Approx:
Approximately 229.7 inches (Standard Bed)
Cargo
Bed Length Options:
6.3 ft (Standard Bed), 8.0 ft (Long Bed)
Weights
Gvwr Min:
Approximately 10,000 lbs
Gvwr Max:
Up to 11,500 lbs (depending on configuration)
Gcwr Max:
Up to 20,000 lbs (when properly equipped)
Towing
Max Towing Capacity:
Up to 13,200 lbs (properly equipped, varies by configuration)
Payload
Max Payload Capacity:
Up to 5,000 lbs (varies by configuration)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
Often rated 3-star for rollover resistance (typical for high-center-of-gravity trucks of this era)
Active Features
ABS:
Standard 4-wheel Anti-lock Braking System (ABS)
Traction Control:
Optional Traction Control System (TCS) on some models.
Passive Features
Airbags:
Driver and Passenger Frontal Airbags
Seatbelts:
Three-point seat belts with pretensioners.
💡 Technology Features
Infotainment
Audio System Options:
Factory AM/FM/CD player, optional cassette player, premium audio systems available on higher trims. Auxiliary input jack may be present.
Driver Assistance
Cruise Control:
Standard cruise control on most trims.
Connectivity
Trailer Brakes:
Provisions for integrated or aftermarket trailer brake controllers were common due to the truck's intended use.
🔧 Maintenance
Service Intervals
Oil Change Gasoline:
Typically every 3,000-5,000 miles or 6 months, depending on usage and oil type (refer to manual for exact recommendations).
Oil Change Diesel:
Typically every 7,500-15,000 miles or 12 months with synthetic oil and filter, but strongly dependent on operating conditions (heavy towing/idling can reduce interval).
Fuel Filter Diesel:
Recommended replacement every 15,000-30,000 miles for diesel trucks to prevent injection system damage.
Transmission Fluid Change Auto:
Recommended every 30,000-60,000 miles, or more frequently under severe towing conditions.
Transmission Fluid Change Manual:
Inspect and potentially change every 50,000-100,000 miles, depending on manufacturer recommendations and usage.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 Brake Fluid, meeting Chrysler MS-5771.
Power Steering Fluid:
Chrysler Power Steering Fluid (PSF) or Mopar Power Steering Fluid, meeting specification MS-5901.
Transfer Case Fluid:
NV241 DHD/DLD: Mopar NV241 Transfer Case Lubricant or equivalent specification (e.g., Dexron III/VI ATF or specialized transfer case fluid).
Rear Axle Fluid:
API GL-5, SAE 75W-90 or 75W-140 synthetic gear oil. Limited slip differentials require friction modifier additive (check manual).
Known Issues
Diesel Injection Pump:
Early 5.9L Cummins engines can experience issues with the injection pump (VE pump) if not properly maintained or if fuel quality is poor. The 2002 models typically feature the P7100 or early common rail system which are generally robust, but still require good fuel and filter maintenance.
Transmission Overdrive Clutches:
Automatic transmissions (47RE/48RE) can develop issues with overdrive clutch packs or solenoid failures, particularly with higher mileage or heavy use.
Front Suspension Components:
Heavy-duty trucks can experience wear in ball joints, tie rod ends, and steering linkages due to load and use. Regular inspection is crucial.
Cooling System Radiator:
Radiator leaks or core degradation can occur over time, especially in harsh environments or with improper coolant maintenance.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, with the Ram nameplate becoming synonymous with heavy-duty performance and durability.
Model Evolution
Third Generation Ram:
The 2002 model year represents the third generation of the Dodge Ram pickup (DB series, 1994-2001, DR series, 2002-2008). This generation introduced significant styling updates and chassis refinements, with the DR series starting in 2002.
Production
Manufacturing Location:
Saltillo, Coahuila, Mexico and Warren, Michigan, USA.
🏆 Awards & Recognition
Recognitions
Segment Awards:
The Dodge Ram 3500 series consistently received accolades for its strong powertrain options, particularly the Cummins turbodiesel, and its towing capabilities within the heavy-duty truck segment during its production run.