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Dodge Ram Pick Up 2500 3500 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Pickup 2500 / 3500 Year: 2002 Codes Chassis Code: DR (Third Generation Ram) 👋 Introduction Market Position Vehicle Segment: Heavy Duty Pickup Truck Target Audience: Commercial users, fleet owners, heavy-duty towing and hauling enthusiasts, DIY mechanics Competitive Analysis Competitors: Ford Super Duty F-250/F-350, Chevrolet Silverado 2500HD/3500HD, GMC Sierra 2500HD/3500HD Key Features Vehicle Attributes: Robust construction, high towing and payload capacities, powerful engine options Manual Value Proposition: Provides essential information for maintaining and repairing these heavy-duty trucks, crucial for maximizing uptime and longevity 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop Body Style Coverage: Heavy Duty Pickup Trucks Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Drivetrain, Exhaust Chassis: Suspension, Steering, Brakes, Frame Electrical: Charging System, Starting System, Ignition System, Lighting, Gauges, Body Electrical, Powertrain Control Module (PCM) Body: Body and Frame, Interior, Exterior Trim, Doors, Glass, HVAC Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication Diagnostics: Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting Repair: Component Removal and Installation, Overhaul Procedures, Reassembly Instructions Specifications: Torque Specifications, Clearances, Tolerances, Electrical Schematics Technical Depth Depth: Comprehensive, from basic adjustments to complete engine and transmission overhauls 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable for efficient information retrieval Print Quality Print Readability: Designed for clarity, with detailed diagrams and illustrations Binding Type Binding: Not applicable (digital format) Paper Type Paper Quality: Not applicable (digital format) ⚙️ Engine Specifications Primary Engine Engine Option 1: 8.0L V10 Triton (Gasoline) Engine Option 2: 5.9L Cummins I6 Turbo Diesel (24-Valve) Engine Option 3: 5.7L Magnum V8 (Gasoline) Performance 8.0L V10 Horsepower: 305 hp @ 4000 rpm (approx.) 8.0L V10 Torque: 450 lb-ft @ 3200 rpm (approx.) 5.9L Cummins Horsepower: 235 hp @ 2600 rpm (approx.) 5.9L Cummins Torque: 460 lb-ft @ 1600 rpm (approx.) 5.7L Magnum Horsepower: 300 hp @ 4800 rpm (approx.) 5.7L Magnum Torque: 330 lb-ft @ 3600 rpm (approx.) Fuel System 8.0L V10 Fuel System: Sequential Multi-Port Fuel Injection (MPI) 5.9L Cummins Fuel System: Bosch VP44 High-Pressure Fuel Injection Pump 5.7L Magnum Fuel System: Sequential Multi-Port Fuel Injection (MPI) 🔧 Transmission Standard Transmission Option 1: 6-Speed Manual (NV5600 for diesel, NV4500 for gasoline) Optional Transmission Option 2: 4-Speed Automatic (47RE for diesel/V10, 46RE for V8) Features Transmission Features Diesel: Heavy-duty manual and automatic transmissions designed for high torque loads Transmission Features Gas: Robust transmissions suitable for demanding work 📐 Dimensions Exterior Wheelbase Std: 134.5 inches (approx. for standard cab) Wheelbase Long: 154.5 inches (approx. for standard cab long box or crew cab) Bed Length Options: 6.3 ft (short bed), 8.0 ft (long bed) Weights Gvwr 2500: 8,800 - 9,500 lbs (approx.) Gvwr 3500: 10,000 - 11,500 lbs (approx.) Curb Weight: Varies significantly by configuration (approx. 6,000 - 7,500 lbs) 🛡️ Safety Features Ratings NHTSA Frontal Driver: 4 Stars (for 2002 model year, varies by configuration) NHTSA Frontal Passenger: 4 Stars (for 2002 model year, varies by configuration) Active Features ABS: Standard Anti-lock Braking System (ABS) Passive Features Airbags: Driver and Passenger Airbags Seatbelts: Three-point seatbelts 💡 Technology Features Infotainment Infotainment System Type: Basic AM/FM/CD or Cassette player with optional premium audio system Display: Simple LCD or LED display Driver Assistance Cruise Control: Available Trailer Brake Controller: Optional factory-installed Connectivity Connectivity Options: Limited; primarily analog systems, optional satellite radio 🔧 Maintenance Service Intervals Oil Change Interval: Typically 3,000-7,500 miles, depending on engine and oil type (refer to manual for specifics) Transmission Fluid Interval: Recommended fluid change every 30,000-60,000 miles, depending on usage (refer to manual) Diesel Fuel Filter Interval: Recommended replacement every 15,000 miles (for Cummins) Fluid Specifications Engine Oil Gasoline: API SN/SP, SAE 5W-30 or 10W-30 (check manual for specific engine) Engine Oil Cummins: API CJ-4 or CK-4, SAE 15W-40 (heavy-duty diesel engine oil) Transmission Fluid Auto: ATF+4 (Automatic Transmission Fluid) Transmission Fluid Manual Nv4500: GM Synchromesh or equivalent Transmission Fluid Manual Nv5600: Mopar Manual Transmission Lubricant or equivalent Coolant: Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, Prediluted Known Issues Common Issue Cummins: VP44 injection pump failure, injector issues, steering gear wear Common Issue V10: Spark plug ejection (torque specifications critical), exhaust manifold cracks Common Issue General: Ball joint wear, differential issues, HVAC blower motor failure, transfer case issues 📚 Vehicle History Brand Heritage Dodge Truck Legacy: Dodge has a long history of producing robust and capable trucks, with the Ram line being a staple in the commercial and personal use markets. Model Evolution Third Generation Ram: The 2002 model year belongs to the third generation (2002-2008) of the Dodge Ram, which introduced significant styling and mechanical updates. Production Manufacturing Location: Warren Truck Assembly Plant, Warren, Michigan 🏆 Awards & Recognition Recognitions Truck Of The...
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Dodge Ram Pick Up 2500 3500 2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram Pickup 2500 / 3500
Year:
2002
Codes
Chassis Code:
DR (Third Generation Ram)
👋 Introduction
Market Position
Vehicle Segment:
Heavy Duty Pickup Truck
Target Audience:
Commercial users, fleet owners, heavy-duty towing and hauling enthusiasts, DIY mechanics
Competitive Analysis
Competitors:
Ford Super Duty F-250/F-350, Chevrolet Silverado 2500HD/3500HD, GMC Sierra 2500HD/3500HD
Key Features
Vehicle Attributes:
Robust construction, high towing and payload capacities, powerful engine options
Manual Value Proposition:
Provides essential information for maintaining and repairing these heavy-duty trucks, crucial for maximizing uptime and longevity
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Workshop
Body Style Coverage:
Heavy Duty Pickup Trucks
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Drivetrain, Exhaust
Chassis:
Suspension, Steering, Brakes, Frame
Electrical:
Charging System, Starting System, Ignition System, Lighting, Gauges, Body Electrical, Powertrain Control Module (PCM)
Body:
Body and Frame, Interior, Exterior Trim, Doors, Glass, HVAC
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication
Diagnostics:
Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting
Repair:
Component Removal and Installation, Overhaul Procedures, Reassembly Instructions
Specifications:
Torque Specifications, Clearances, Tolerances, Electrical Schematics
Technical Depth
Depth:
Comprehensive, from basic adjustments to complete engine and transmission overhauls
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable for efficient information retrieval
Print Quality
Print Readability:
Designed for clarity, with detailed diagrams and illustrations
Binding Type
Binding:
Not applicable (digital format)
Paper Type
Paper Quality:
Not applicable (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Option 1:
8.0L V10 Triton (Gasoline)
Engine Option 2:
5.9L Cummins I6 Turbo Diesel (24-Valve)
Engine Option 3:
5.7L Magnum V8 (Gasoline)
Performance
8.0L V10 Horsepower:
305 hp @ 4000 rpm (approx.)
8.0L V10 Torque:
450 lb-ft @ 3200 rpm (approx.)
5.9L Cummins Horsepower:
235 hp @ 2600 rpm (approx.)
5.9L Cummins Torque:
460 lb-ft @ 1600 rpm (approx.)
5.7L Magnum Horsepower:
300 hp @ 4800 rpm (approx.)
5.7L Magnum Torque:
330 lb-ft @ 3600 rpm (approx.)
Fuel System
8.0L V10 Fuel System:
Sequential Multi-Port Fuel Injection (MPI)
5.9L Cummins Fuel System:
Bosch VP44 High-Pressure Fuel Injection Pump
5.7L Magnum Fuel System:
Sequential Multi-Port Fuel Injection (MPI)
🔧 Transmission
Standard
Transmission Option 1:
6-Speed Manual (NV5600 for diesel, NV4500 for gasoline)
Optional
Transmission Option 2:
4-Speed Automatic (47RE for diesel/V10, 46RE for V8)
Features
Transmission Features Diesel:
Heavy-duty manual and automatic transmissions designed for high torque loads
Transmission Features Gas:
Robust transmissions suitable for demanding work
📐 Dimensions
Exterior
Wheelbase Std:
134.5 inches (approx. for standard cab)
Wheelbase Long:
154.5 inches (approx. for standard cab long box or crew cab)
Bed Length Options:
6.3 ft (short bed), 8.0 ft (long bed)
Weights
Gvwr 2500:
8,800 - 9,500 lbs (approx.)
Gvwr 3500:
10,000 - 11,500 lbs (approx.)
Curb Weight:
Varies significantly by configuration (approx. 6,000 - 7,500 lbs)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
4 Stars (for 2002 model year, varies by configuration)
NHTSA Frontal Passenger:
4 Stars (for 2002 model year, varies by configuration)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Passive Features
Airbags:
Driver and Passenger Airbags
Seatbelts:
Three-point seatbelts
💡 Technology Features
Infotainment
Infotainment System Type:
Basic AM/FM/CD or Cassette player with optional premium audio system
Display:
Simple LCD or LED display
Driver Assistance
Cruise Control:
Available
Trailer Brake Controller:
Optional factory-installed
Connectivity
Connectivity Options:
Limited; primarily analog systems, optional satellite radio
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-7,500 miles, depending on engine and oil type (refer to manual for specifics)
Transmission Fluid Interval:
Recommended fluid change every 30,000-60,000 miles, depending on usage (refer to manual)
Diesel Fuel Filter Interval:
Recommended replacement every 15,000 miles (for Cummins)
Fluid Specifications
Engine Oil Gasoline:
API SN/SP, SAE 5W-30 or 10W-30 (check manual for specific engine)
Engine Oil Cummins:
API CJ-4 or CK-4, SAE 15W-40 (heavy-duty diesel engine oil)
Transmission Fluid Auto:
ATF+4 (Automatic Transmission Fluid)
Transmission Fluid Manual Nv4500:
GM Synchromesh or equivalent
Transmission Fluid Manual Nv5600:
Mopar Manual Transmission Lubricant or equivalent
Coolant:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, Prediluted
Known Issues
Common Issue Cummins:
VP44 injection pump failure, injector issues, steering gear wear
Common Issue V10:
Spark plug ejection (torque specifications critical), exhaust manifold cracks
Common Issue General:
Ball joint wear, differential issues, HVAC blower motor failure, transfer case issues
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, with the Ram line being a staple in the commercial and personal use markets.
Model Evolution
Third Generation Ram:
The 2002 model year belongs to the third generation (2002-2008) of the Dodge Ram, which introduced significant styling and mechanical updates.
Production
Manufacturing Location:
Warren Truck Assembly Plant, Warren, Michigan
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
While specific 2002 awards may be hard to pinpoint, the third-generation Ram line generally received positive reviews for its design and capability.
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