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Dodge Ram Truck 3500 Series 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck 3500 Series Year: 2002 Product Type: Service Repair Manual 👋 Introduction Market Position Market Segment: Heavy-duty pickup truck, designed for commercial, towing, and heavy hauling applications. Competitive Analysis Competitors: Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD. Key Features Vehicle Attributes: Robust chassis, powerful engine options, high towing and payload capacities, suitable for demanding tasks. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive vehicle service, repair, and maintenance Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Factory Authorized Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: All gasoline and diesel engine variants, including troubleshooting, diagnostics, disassembly, assembly, and specifications. Transmission: Manual and automatic transmissions, including NV4500, NV5600, and 48RE/47RE, with repair procedures and torque specifications. Drivetrain: Four-wheel drive systems (NV241DHD, NV273DHD), transfer case, axles, differentials, driveshafts, and CV joints. Brakes: Front and rear brake systems (disc, drum), ABS, hydraulic systems, parking brake, and related components. Suspension Steering: Front and rear suspension, steering components, power steering system, alignment specifications, and wheel bearings. Electrical Electronics: Complete electrical schematics, wiring diagrams, battery, charging system, starting system, lighting, instrument cluster, power accessories, and control modules. HVAC: Heating, ventilation, and air conditioning system diagnosis, repair, and refrigerant handling. Fuel System: Fuel tank, fuel pump, fuel injectors, diesel fuel system (if applicable), and emission controls. Cooling System: Radiator, water pump, thermostat, coolant specifications, and cooling fan operation. Exhaust System: Exhaust manifold, catalytic converter, mufflers, and emissions control systems. Body Chassis: Body panels, doors, windows, interior trim, bumpers, frame, and corrosion protection. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks, and tire rotation. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, and common fault identification. Repair: Detailed step-by-step repair procedures for all major vehicle systems, including torque specifications and special tool requirements. Diagnostics: OBD-II diagnostic trouble codes (DTCs), sensor data interpretation, and diagnostic tool usage. Disassembly Assembly: Complete instructions for component removal, reassembly, and adjustment for all major systems. Technical Depth Technical Depth: Comprehensive, covering from basic preventative maintenance to complete engine and transmission overhauls, electrical system diagnostics, and body repair. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval. Printability: Printable pages for workshop use. Print Quality Image Resolution: High-resolution diagrams and illustrations. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Options: 8.0L V10 Triton gasoline, 5.9L Cummins Turbo Diesel. Performance 8.0L V10 Horsepower: 305 hp @ 4000 rpm 8.0L V10 Torque: 450 lb-ft @ 3200 rpm 5.9L Cummins Turbo Diesel Horsepower: 235 hp @ 2600 rpm (depending on configuration) 5.9L Cummins Turbo Diesel Torque: 460 lb-ft @ 1400 rpm (depending on configuration) Fuel System Gasoline Fuel System: Multi-point fuel injection Diesel Fuel System: High-pressure common rail (later models) or direct injection with Bosch VP44 injection pump (early 5.9L variants). 🔧 Transmission Standard Standard Transmission: NV4500 5-speed manual transmission (common with diesel). Optional Optional Transmission Automatic: 47RE or 48RE 4-speed automatic transmission (common with V10 and diesel). Optional Transmission Manual: NV5600 6-speed manual transmission (available on higher trims). Features Transmission Fluid Spec Auto: ATF+4 (MS-9602) or equivalent. Transmission Fluid Spec Manual: NV4500: Manual Transmission Fluid (MTF) - consult manual for specific viscosity. NV5600: Manual Transmission Fluid (MTF) - consult manual for specific viscosity. 📐 Dimensions Exterior Wheelbase Options: 134.2 inches (standard cab), 154.6 inches (quad cab 4x2), 159.0 inches (quad cab 4x4), 177.3 inches (long bed). Weights Gvwr: Over 10,000 lbs, varying by configuration (e.g., up to 11,500 lbs or higher). Curb Weight: Approx. 6,000 - 7,000 lbs depending on configuration. Towing Capacity: Up to 13,000 - 14,000 lbs (with proper equipment and configuration). Payload Capacity: Up to 4,000 - 5,000 lbs (depending on configuration). 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4-star (2002 model year review). NHTSA Frontal Impact Passenger: 4-star (2002 model year review). Active Features ABS: Standard Anti-lock Braking System (ABS) on all wheels. Passive Features Airbags: Driver and passenger front airbags. Seatbelts: Three-point front and rear seat belts. 💡 Technology Features Infotainment Infotainment System: Basic AM/FM radio with CD player, optional cassette player, available premium audio systems. Driver Assistance Driver Assistance Features: Limited by modern standards; primarily relies on ABS for braking assistance. Connectivity Connectivity Options: No integrated Bluetooth or advanced connectivity features. Optional trailer brake controller. 🔧 Maintenance Service Intervals Oil Change Interval Gasoline: Every 3,000 - 7,500 miles or 6 months, depending on driving conditions and oil type (consult manual for specific recommendations). Oil Change Interval Diesel: Every 7,500 - 15,000 miles or 6 months (depending on oil quality and driving conditions, with Cummins often recommending 15,000 miles with synthetic oil). Engine Air Filter Replacement: Every 15,000 - 30,000 miles or as needed based on inspections. Fuel Filter Replacement Diesel: Every...
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Dodge Ram Truck 3500 Series 2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram Truck 3500 Series
Year:
2002
Product Type:
Service Repair Manual
👋 Introduction
Market Position
Market Segment:
Heavy-duty pickup truck, designed for commercial, towing, and heavy hauling applications.
Competitive Analysis
Competitors:
Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD.
Key Features
Vehicle Attributes:
Robust chassis, powerful engine options, high towing and payload capacities, suitable for demanding tasks.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive vehicle service, repair, and maintenance
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Factory Authorized Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
All gasoline and diesel engine variants, including troubleshooting, diagnostics, disassembly, assembly, and specifications.
Transmission:
Manual and automatic transmissions, including NV4500, NV5600, and 48RE/47RE, with repair procedures and torque specifications.
Drivetrain:
Four-wheel drive systems (NV241DHD, NV273DHD), transfer case, axles, differentials, driveshafts, and CV joints.
Brakes:
Front and rear brake systems (disc, drum), ABS, hydraulic systems, parking brake, and related components.
Suspension Steering:
Front and rear suspension, steering components, power steering system, alignment specifications, and wheel bearings.
Electrical Electronics:
Complete electrical schematics, wiring diagrams, battery, charging system, starting system, lighting, instrument cluster, power accessories, and control modules.
HVAC:
Heating, ventilation, and air conditioning system diagnosis, repair, and refrigerant handling.
Fuel System:
Fuel tank, fuel pump, fuel injectors, diesel fuel system (if applicable), and emission controls.
Cooling System:
Radiator, water pump, thermostat, coolant specifications, and cooling fan operation.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, and emissions control systems.
Body Chassis:
Body panels, doors, windows, interior trim, bumpers, frame, and corrosion protection.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks, and tire rotation.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides, and common fault identification.
Repair:
Detailed step-by-step repair procedures for all major vehicle systems, including torque specifications and special tool requirements.
Diagnostics:
OBD-II diagnostic trouble codes (DTCs), sensor data interpretation, and diagnostic tool usage.
Disassembly Assembly:
Complete instructions for component removal, reassembly, and adjustment for all major systems.
Technical Depth
Technical Depth:
Comprehensive, covering from basic preventative maintenance to complete engine and transmission overhauls, electrical system diagnostics, and body repair.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick information retrieval.
Printability:
Printable pages for workshop use.
Print Quality
Image Resolution:
High-resolution diagrams and illustrations.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Options:
8.0L V10 Triton gasoline, 5.9L Cummins Turbo Diesel.
Performance
8.0L V10 Horsepower:
305 hp @ 4000 rpm
8.0L V10 Torque:
450 lb-ft @ 3200 rpm
5.9L Cummins Turbo Diesel Horsepower:
235 hp @ 2600 rpm (depending on configuration)
5.9L Cummins Turbo Diesel Torque:
460 lb-ft @ 1400 rpm (depending on configuration)
Fuel System
Gasoline Fuel System:
Multi-point fuel injection
Diesel Fuel System:
High-pressure common rail (later models) or direct injection with Bosch VP44 injection pump (early 5.9L variants).
🔧 Transmission
Standard
Standard Transmission:
NV4500 5-speed manual transmission (common with diesel).
Optional
Optional Transmission Automatic:
47RE or 48RE 4-speed automatic transmission (common with V10 and diesel).
Optional Transmission Manual:
NV5600 6-speed manual transmission (available on higher trims).
Features
Transmission Fluid Spec Auto:
ATF+4 (MS-9602) or equivalent.
Transmission Fluid Spec Manual:
NV4500: Manual Transmission Fluid (MTF) - consult manual for specific viscosity. NV5600: Manual Transmission Fluid (MTF) - consult manual for specific viscosity.
📐 Dimensions
Exterior
Wheelbase Options:
134.2 inches (standard cab), 154.6 inches (quad cab 4x2), 159.0 inches (quad cab 4x4), 177.3 inches (long bed).
Weights
Gvwr:
Over 10,000 lbs, varying by configuration (e.g., up to 11,500 lbs or higher).
Curb Weight:
Approx. 6,000 - 7,000 lbs depending on configuration.
Towing Capacity:
Up to 13,000 - 14,000 lbs (with proper equipment and configuration).
Payload Capacity:
Up to 4,000 - 5,000 lbs (depending on configuration).
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4-star (2002 model year review).
NHTSA Frontal Impact Passenger:
4-star (2002 model year review).
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Passive Features
Airbags:
Driver and passenger front airbags.
Seatbelts:
Three-point front and rear seat belts.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio with CD player, optional cassette player, available premium audio systems.
Driver Assistance
Driver Assistance Features:
Limited by modern standards; primarily relies on ABS for braking assistance.
Connectivity
Connectivity Options:
No integrated Bluetooth or advanced connectivity features. Optional trailer brake controller.
🔧 Maintenance
Service Intervals
Oil Change Interval Gasoline:
Every 3,000 - 7,500 miles or 6 months, depending on driving conditions and oil type (consult manual for specific recommendations).
Oil Change Interval Diesel:
Every 7,500 - 15,000 miles or 6 months (depending on oil quality and driving conditions, with Cummins often recommending 15,000 miles with synthetic oil).
Engine Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on inspections.
Fuel Filter Replacement Diesel:
Every 15,000 - 30,000 miles (crucial for diesel longevity).
Fluid Specifications
Engine Oil Spec Gasoline:
API SN/SP, ILSAC GF-6A compliant. Viscosity: 5W-30 (preferred for V10).
Engine Oil Spec Diesel:
API CJ-4/CK-4 or newer, SAE 15W-40 (conventional) or 5W-40 (synthetic for colder climates/extended intervals).
Coolant Spec:
Mopar OAT (Organic Additive Technology) or HOAT (Hybrid Organic Additive Technology) Antifreeze/Coolant, typically a long-life pink or orange formulation.
Known Issues
Common Issues Diesel:
VP44 injection pump failures (if equipped with older 5.9L), injector issues, vacuum pump leaks, potential for cylinder head lifting on high-output tunes.
Common Issues Gasoline:
Spark plug issues (if not replaced on schedule), occasional transmission solenoid issues, exhaust manifold leaks.
Common Issues General:
Rust on body panels (especially around wheel wells and cab corners), rear axle seal leaks, ball joint wear, HVAC blend door actuator failures.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long-standing history in the truck market, known for robust and capable vehicles, culminating in the development of the Ram brand in 1994.
Model Evolution
Third Generation Ram:
The 2002 model year falls within the third generation of the Dodge Ram (DN platform, 2002-2008), which introduced significant chassis and styling updates, including a more integrated frame and suspension design.
Production
Manufacturing Location:
Saltillo Truck Assembly, Mexico.
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
While specific awards for the 2002 model year might vary, Dodge Ram trucks consistently received accolades for their styling, capability, and value within the heavy-duty segment.
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