Dodge Ram Truck 2002-2004 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Model Generation: Third Generation (DR/DH/D3) Codes Platform Codes: DR/DH/D3 👋 Introduction Market Position Positioning: A robust and capable full-size pickup truck known for its towing and hauling capabilities, comfort, and versatility, serving both commercial and personal use markets. Competitive Analysis Competitors: Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra, Nissan Titan. Key Features Vehicle Appeal: Strong V8 engine options, spacious cabin, available four-wheel drive, reputation for durability and work capability. Manual Value Proposition Value For Owner: Empowers owners and independent repair shops with factory-level information to maintain, diagnose, and repair their vehicle accurately, saving time and money compared to dealership services. 📋 Manual Details Coverage Areas Years Covered: 2002, 2003, 2004 Regions Covered: North America (Primary, but generally applicable worldwide with regional adaptations) Page Count Estimated Pages: 1500+ Manual Type Type: Workshop Service Repair Manual (Factory Official) Language Language: English Format Format: Downloadable Digital Format (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, engine control systems (ECM/PCM), cooling system, lubrication system, manual transmission, automatic transmission, transfer case, driveline, axles, differentials. Chassis: Suspension (front and rear), steering system, brake system (front, rear, parking brake, ABS), wheels and tires. Electrical: Battery, charging system, starting system, lighting system, instrument cluster, gauges, warning lamps, body control module (BCM), power windows, power locks, mirrors, wipers, horn, audio system, climate control blower, airbags (SRS), anti-theft system, cruise control, trailer towing electrical. Body: Body structure, exterior panels, doors, hood, tailgate, bumpers, glass, interior trim, seats, HVAC system (operation and diagnosis), climate control components, fuel tank, filler neck. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, lubrication, tire rotation, battery maintenance. Repair And Rebuild: Engine overhaul, transmission overhaul, brake caliper replacement, suspension component replacement, steering gear service, electrical component repair, body panel repair, HVAC component repair. Diagnostics: Troubleshooting charts, diagnostic trouble codes (DTCs), circuit diagrams, component testing procedures, symptom-based diagnostics. Specifications And Tolerances: Engine torques, bearing clearances, piston ring gaps, valve lash, fastener torque specifications, alignment specifications. Technical Depth Depth: Comprehensive. Covers everything from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Printability: High resolution for clear printing of text, diagrams, and illustrations. Printable in its entirety or by individual sections. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Options: 4.7L Magnum V8 (P/N 5011848AA), 5.9L Magnum V8 (P/N 5011849AA), 5.9L Cummins Turbo Diesel I6 (P/N 3964568) Performance 4.7L V8 Horsepower: Approx. 235 hp @ 4,500 rpm 4.7L V8 Torque: Approx. 305 lb-ft @ 3,200 rpm 5.9L V8 Horsepower: Approx. 245-250 hp @ 4,000 rpm 5.9L V8 Torque: Approx. 330-335 lb-ft @ 3,200 rpm 5.9L Cummins Horsepower: Approx. 235-250 hp @ 2,700 rpm (depending on model year/tune) 5.9L Cummins Torque: Approx. 460-555 lb-ft @ 1,400-1,600 rpm (depending on model year/tune) Fuel System Fuel Type: Unleaded Gasoline (for V8s), Diesel Fuel (for Cummins) Injection System: Multi-port Fuel Injection (MPI) for V8s, High-Pressure Common Rail (HPCR) for later Cummins (this generation likely uses Bosch VP44 injection pump for early models, and HPCR introduced later). Engine Codes Engine Identifier: R = 4.7L V8, Y = 5.9L V8, C = 5.9L Cummins Diesel 🔧 Transmission Standard Transmission Options: 4-speed automatic (45RFE/48RE for V8s, 47RE for 5.9L Gas V8), 6-speed manual (NV5600 for Cummins, G360 for older gas). Optional Optional Transmissions: 5-speed manual (NV4500 for Cummins, G56 for later Cummins), 5-speed automatic (available on some models). Features Transfer Case Options: Electronic Shift-On-The-Fly (ESOF) or part-time manual transfer case. Fluid Specifications Atf Type: ATF+3 or ATF+4 (check specific model year/transmission, ATF+4 generally recommended for later production within this range) Manual Gear Oil: API GL-4 or GL-5 gear lubricant (SAE 75W-90 or 80W-90, depending on temperature) 📐 Dimensions Exterior Wheelbase Options: 131.3 inches (standard cab), 153.3 inches (extended cab), 160.3 inches (Mega Cab) Overall Length Range: Approx. 229.7 to 260.1 inches Cargo Bed Lengths: 6.3 feet (short bed), 8.0 feet (long bed) Weights Curb Weight Range: Approx. 4,700 - 6,500 lbs Towing Capacity: Up to ~10,000 lbs (depending on configuration, engine, and axle ratio) 🛡️ Safety Features Ratings NHTSA Front Impact: Not extensively rated by NHTSA for this specific generation, but generally considered robust for its class. Active Features Active Safety: Anti-lock Braking System (ABS) standard on all models, optional Traction Control System (TCS) on some configurations. Passive Features Passive Safety: Front airbags, three-point seat belts, reinforced body structure, available side-impact beams. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional cassette, available premium Infinity sound system. Radio display often prone to pixel failure. Driver Assistance Assistance Features: Cruise control. Limited advanced driver-assistance systems available for this era. Parking sensors were not common....
A robust and capable full-size pickup truck known for its towing and hauling capabilities, comfort, and versatility, serving both commercial and personal use markets.
Competitive Analysis
Competitors:
Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra, Nissan Titan.
Key Features
Vehicle Appeal:
Strong V8 engine options, spacious cabin, available four-wheel drive, reputation for durability and work capability.
Manual Value Proposition
Value For Owner:
Empowers owners and independent repair shops with factory-level information to maintain, diagnose, and repair their vehicle accurately, saving time and money compared to dealership services.
📋 Manual Details
Coverage Areas
Years Covered:
2002, 2003, 2004
Regions Covered:
North America (Primary, but generally applicable worldwide with regional adaptations)
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Workshop Service Repair Manual (Factory Official)
Language
Language:
English
Format
Format:
Downloadable Digital Format (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, engine control systems (ECM/PCM), cooling system, lubrication system, manual transmission, automatic transmission, transfer case, driveline, axles, differentials.
Chassis:
Suspension (front and rear), steering system, brake system (front, rear, parking brake, ABS), wheels and tires.
Electrical:
Battery, charging system, starting system, lighting system, instrument cluster, gauges, warning lamps, body control module (BCM), power windows, power locks, mirrors, wipers, horn, audio system, climate control blower, airbags (SRS), anti-theft system, cruise control, trailer towing electrical.
Body:
Body structure, exterior panels, doors, hood, tailgate, bumpers, glass, interior trim, seats, HVAC system (operation and diagnosis), climate control components, fuel tank, filler neck.
Comprehensive. Covers everything from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Printability:
High resolution for clear printing of text, diagrams, and illustrations. Printable in its entirety or by individual sections.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options:
4.7L Magnum V8 (P/N 5011848AA), 5.9L Magnum V8 (P/N 5011849AA), 5.9L Cummins Turbo Diesel I6 (P/N 3964568)
Performance
4.7L V8 Horsepower:
Approx. 235 hp @ 4,500 rpm
4.7L V8 Torque:
Approx. 305 lb-ft @ 3,200 rpm
5.9L V8 Horsepower:
Approx. 245-250 hp @ 4,000 rpm
5.9L V8 Torque:
Approx. 330-335 lb-ft @ 3,200 rpm
5.9L Cummins Horsepower:
Approx. 235-250 hp @ 2,700 rpm (depending on model year/tune)
5.9L Cummins Torque:
Approx. 460-555 lb-ft @ 1,400-1,600 rpm (depending on model year/tune)
Multi-port Fuel Injection (MPI) for V8s, High-Pressure Common Rail (HPCR) for later Cummins (this generation likely uses Bosch VP44 injection pump for early models, and HPCR introduced later).
Engine Codes
Engine Identifier:
R = 4.7L V8, Y = 5.9L V8, C = 5.9L Cummins Diesel
🔧 Transmission
Standard
Transmission Options:
4-speed automatic (45RFE/48RE for V8s, 47RE for 5.9L Gas V8), 6-speed manual (NV5600 for Cummins, G360 for older gas).
Optional
Optional Transmissions:
5-speed manual (NV4500 for Cummins, G56 for later Cummins), 5-speed automatic (available on some models).
Features
Transfer Case Options:
Electronic Shift-On-The-Fly (ESOF) or part-time manual transfer case.
Fluid Specifications
Atf Type:
ATF+3 or ATF+4 (check specific model year/transmission, ATF+4 generally recommended for later production within this range)
Manual Gear Oil:
API GL-4 or GL-5 gear lubricant (SAE 75W-90 or 80W-90, depending on temperature)
Up to ~10,000 lbs (depending on configuration, engine, and axle ratio)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not extensively rated by NHTSA for this specific generation, but generally considered robust for its class.
Active Features
Active Safety:
Anti-lock Braking System (ABS) standard on all models, optional Traction Control System (TCS) on some configurations.
Passive Features
Passive Safety:
Front airbags, three-point seat belts, reinforced body structure, available side-impact beams.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional cassette, available premium Infinity sound system. Radio display often prone to pixel failure.
Driver Assistance
Assistance Features:
Cruise control. Limited advanced driver-assistance systems available for this era. Parking sensors were not common.
Connectivity
Connectivity Options:
Limited to factory-installed audio systems. No Bluetooth or USB connectivity from the factory. Trailer brake controller available on some higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions (refer to manual for specific recommendations). Diesel may have different intervals.
Transmission Fluid Change:
Every 30,000-60,000 miles, depending on usage (heavy towing requires more frequent service). Check manual for specific ATF+3/ATF+4 recommendations.
Coolant Flush:
Every 30,000-60,000 miles or 2-3 years.
Fluid Specifications
Engine Oil V8:
5W-20 or 10W-30 (API Certified, refer to manual for exact grade based on ambient temperature).
Engine Oil Cummins:
15W-40 (CI-4 rated diesel engine oil, e.g., Mobil Delvac or equivalent).
Coolant Type:
HOAT (Hybrid Organic Acid Technology) coolant, typically a long-life 50/50 mixture of antifreeze and distilled water (e.g., Mopar Antifreeze/Coolant).
Known Issues
Common Problems V8:
Intake manifold gasket leaks, camshaft position sensor failures, exhaust manifold cracks (especially early 4.7L), rear main seal leaks.
Cracked dashboards (sun exposure), worn suspension components (ball joints, tie rods), HVAC blend door actuator failures, rust on body panels (especially in certain climates).
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long-standing heritage in the pickup truck market, dating back to the 1930s, consistently known for building rugged and powerful trucks.
Model Evolution
Third Gen Introduction:
The third generation Ram debuted for the 2002 model year, marking a significant redesign with a more aggressive, squared-off styling, updated powertrains, and improved interior comfort and features.
Production
Manufacturing Locations:
Saltillo Truck Plant, Mexico; Warren Truck Assembly Plant, Michigan, USA.
🏆 Awards & Recognition
Recognitions
Segment Awards:
While specific awards for the 2002-2004 model years might be less prominent than later generations, the Dodge Ram consistently received positive reviews for its styling, power, and towing capabilities within the competitive full-size truck segment during its tenure.
Ratings
Consumer Reviews:
Generally favorable reviews for engine power and towing. Consumer satisfaction often cited the robust chassis and the availability of the powerful Cummins diesel.
Certifications
Manual Quality:
Official Factory Service Manual – the highest standard for repair and maintenance documentation, providing accurate and detailed information as used by dealership technicians.
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