Dodge Ram Truck 2002-2004 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Model Years Covered: 2002, 2003, 2004 Platform: Third Generation Ram (DR/DH/D1) 👋 Introduction Market Position Segment: Full-size Pickup Truck Competitive Analysis Key Competitors: Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra Key Features Design: Bold, distinctive styling; robust construction; three cab configurations (Regular, Quad Cab, Mega Cab); two bed lengths (6.3 ft, 8 ft) Powertrain Options: Renowned for powerful engine choices, including V8 gasoline and Cummins turbodiesel Capability: Strong towing and hauling capabilities, available 4x4 drivetrain 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive Service and Repair Diagnostic Coverage: Extensive troubleshooting and diagnostic procedures Maintenance Coverage: Scheduled maintenance, fluid changes, filter replacements Repair Coverage: Detailed step-by-step repair instructions for all major systems Page Count Estimated Page Count: 2000+ Manual Type Manual Type: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, cooling system, lubrication system, fuel system, ignition system, exhaust system Transmission: Automatic Transmission (42RE, 44RE, 45RFE, 48RE) and Manual Transmission (NV3500, NV4500) service, overhaul, diagnostics Drivetrain: Front axle, rear axle, differentials, driveshafts, U-joints, 4WD system operation and service Suspension: Front independent suspension (IFS), rear leaf spring suspension, steering system, wheel alignment specifications Brakes: Front disc brakes, rear drum/disc brakes, ABS system operation and diagnosis, parking brake system Electrical: Battery, charging system, starting system, lighting system, instrumentation, power accessories, fuses, relays, wiring diagrams HVAC: Heating, ventilation, and air conditioning system diagnosis and repair Body: Body panels, doors, windows, seats, interior trim, exterior trim, glass, bumpers Chassis: Frame, crossmembers, exhaust system mounting Procedures Included General Repair: Component removal and installation, disassembly and reassembly Engine Overhaul: Engine rebuild procedures, torque specifications, piston ring end gap, bearing clearance Transmission Rebuild: Automatic and manual transmission component replacement and adjustment Diagnostics Troubleshooting: Systematic troubleshooting guides, DTC (Diagnostic Trouble Code) lookup and interpretation Wiring Diagrams: Complete electrical schematics for all systems, color-coded and detailed Technical Depth Depth Level: Expert-level detail suitable for professional technicians and advanced DIYers Data Accuracy: Factory-level specifications and procedures 📊 Manual Specifications File Format Digital Format: PDF (Searchable, Printable) Print Quality Image Clarity: High-resolution images and diagrams Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Option 1: 4.7L Magnum V8 (PZEV Certified in some states) Engine Option 1 Power: 235 hp @ 4500 rpm Engine Option 1 Torque: 295 lb-ft @ 3200 rpm Engine Option 2: 5.9L Cummins I-6 Turbo Diesel Engine Option 2 Power: 250 hp @ 2900 rpm (later models up to 325 hp) Engine Option 2 Torque: 460 lb-ft @ 1400 rpm (later models up to 555 lb-ft) Engine Option 3: 5.7L HEMI V8 (introduced in 2003 model year) Engine Option 3 Power: 345 hp @ 5400 rpm Engine Option 3 Torque: 375 lb-ft @ 4000 rpm Fuel System Fuel Delivery Gasoline: Sequential Electronic Fuel Injection (SEFI) Fuel Delivery Diesel: Direct Injection (High-Pressure Common Rail - HPCR) for Cummins Performance Emission Controls: Catalytic converters, O2 sensors, EGR (diesel) 🔧 Transmission Standard Standard Transmission: 4-speed Automatic (42RE for 4.7L, 45RFE/48RE for 5.7L HEMI and some 4.7L, 44RE for earlier 5.9L V8) Optional Optional Transmission: 5-speed Manual (NV3500 for lighter duty, NV4500 for heavy duty applications with Cummins) Features 4X4 System: Part-time 4WD system with electronic transfer case shift (241DHD) Transmission Fluid: ATF+4 (for automatic transmissions), GL-5 gear oil (for manual transmissions) 📐 Dimensions Exterior Wheelbase Regular Cab: 134.4 inches (3414 mm) Wheelbase Quad Cab: 148.9 inches (3782 mm) Bed Length Standard: 78.0 inches (1981 mm) / 6.5 ft Bed Length Long: 98.3 inches (2497 mm) / 8 ft Weights Curb Weight Approx: 4,500 - 6,000+ lbs (depending on configuration and engine) Gross Vehicle Weight Rating Gvw: 6,000 - 10,500+ lbs (depending on model and configuration) 🛡️ Safety Features Ratings NHTSA Front Impact: 4-star driver, 4-star passenger (for 2002-2004 models) IIHS Frontal Offset: Acceptable (for 2002-2004 models) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional Traction Control System (TCS) on some models Passive Features Airbags: Standard front airbags Seatbelts: Three-point seatbelts for all occupants 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional Infinity premium audio system, satellite radio readiness Navigation: Optional factory navigation system available on some higher trims Driver Assistance Cruise Control: Standard cruise control Connectivity Auxiliary Input: Optional auxiliary input jack for external audio devices 🔧 Maintenance Service Intervals Oil Change Interval Gasoline: Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specific recommendation) Oil Change Interval Diesel: Every 5,000-7,500 miles or 6 months for Cummins (refer to manual for specific recommendation) Transmission Fluid Interval: Every 30,000-60,000 miles or 2-3 years, depending on transmission type and usage (consult manual) Engine Coolant Flush: Every 30,000-100,000 miles or 2-5 years, depending on coolant type (refer...
Optional factory navigation system available on some higher trims
Driver Assistance
Cruise Control:
Standard cruise control
Connectivity
Auxiliary Input:
Optional auxiliary input jack for external audio devices
🔧 Maintenance
Service Intervals
Oil Change Interval Gasoline:
Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specific recommendation)
Oil Change Interval Diesel:
Every 5,000-7,500 miles or 6 months for Cummins (refer to manual for specific recommendation)
Transmission Fluid Interval:
Every 30,000-60,000 miles or 2-3 years, depending on transmission type and usage (consult manual)
Engine Coolant Flush:
Every 30,000-100,000 miles or 2-5 years, depending on coolant type (refer to manual)
Fluid Specifications
Engine Oil Gasoline:
SAE 5W-30 or SAE 10W-30 (depending on temperature), API Certified (e.g., MS-6395 for 4.7L)
Engine Oil Diesel:
API CI-4 or CJ-4 rated 15W-40 synthetic or synthetic blend (for Cummins)
Transmission Fluid Automatic:
Mopar ATF+4 (MS-9602)
Differential Fluid Front:
SAE 75W-90 synthetic gear lubricant (API GL-5), friction modifier may be required for limited-slip differentials
Differential Fluid Rear:
SAE 75W-90 synthetic gear lubricant (API GL-5), friction modifier may be required for limited-slip differentials
Known Issues
Common Wear Items:
Ball joints, tie rod ends, wheel bearings, front suspension components, brake pads/rotors
Powertrain Specific Issues:
Valve spring issues on early 5.7L HEMI engines, potential injector issues on early Cummins models, radiator leaks
Electrical Gremlins:
Intermittent issues with power windows, door locks, or instrument cluster can occur, often related to grounding or connector corrosion
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing durable and powerful trucks, with the Ram nameplate dating back to 1981.
Model Evolution
Third Generation Introduction:
The third generation Ram (DB/DH/DM) was introduced for the 2002 model year, marking a significant redesign with a larger, more imposing presence and an updated interior.
Key Updates 2002 2004:
2003 saw the introduction of the powerful 5.7L HEMI V8 and the Mega Cab option. The 5.9L Cummins received power upgrades in subsequent years.
While specific awards for the 2002-2004 model years are varied, the Ram series generally received positive reviews for its styling and capability in automotive publications of the era.
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