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Dodge Ram 2002-2004 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Model Line: Ram Pickup Covered Years: 2002, 2003, 2004 Codes Platform Code: DR (Third Generation Ram) 👋 Introduction Market Position Segment: Full-size pickup truck Target Audience: Owners seeking to perform their own maintenance and repairs, independent repair shops, automotive enthusiasts Competitive Analysis Competitors: Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra Key Features Manual Value Proposition: Provides authoritative, detailed information essential for proper maintenance and repair, saving time and money compared to professional service. Vehicle Strengths: Renowned for durability, powerful engine options, robust towing and hauling capabilities, and a comfortable ride for a full-size truck. 📋 Manual Details Coverage Areas Primary Coverage: Full Service, Repair, Maintenance, Rebuilding, Refurbishing, Restoration Vehicle Types Covered: All configurations including 1500, 2500, 3500 models (Light Duty, Heavy Duty) Page Count Estimated Page Count: 2000+ Manual Type Type: Factory Service Manual (FSM) Equivalent / Comprehensive Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, transmission (automatic and manual), transfer case (4x4 models) Chassis: Suspension (front and rear), steering system, braking system (including ABS), driveline (axles, driveshafts) Electrical: Wiring diagrams, electrical components, charging system, starting system, lighting, instruments and gauges, power accessories, body control module (BCM), Powertrain Control Module (PCM) diagnostics Body: Body construction, interior trim, exterior trim, doors, windows, seats, climate control system (HVAC), safety restraints (airbags) Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Repair: Engine overhaul, transmission repair, brake caliper replacement, suspension component replacement, electrical diagnostics and repair Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics Special Tools: Identification and usage of special tools required for specific procedures Technical Depth Depth: Comprehensive from basic maintenance to complete engine/transmission rebuilds, including detailed torque specifications, alignment procedures, and electrical circuit tracing 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval Printability: Printable pages for on-site workshop use Print Quality Quality: High-resolution scans with clear diagrams and text Binding Type Binding: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Options: 4.7L Magnum V8 (PZEV option), 5.7L HEMI V8, 5.9L Cummins Turbo Diesel (2500/3500 models) Engine Options Engine Code 4.7L: EHA Engine Code 5.7L: HEMI Engine Code 5.9L Diesel: ISB Performance 4.7L Horsepower: 235 hp @ 4,500 rpm Torque: 295 lb-ft @ 3,200 rpm Performance 5.7L Horsepower: 345 hp @ 5,000 rpm Torque: 375 lb-ft @ 4,000 rpm Performance 5.9L Diesel Horsepower: 250-325 hp @ 2,900 rpm (depending on year/tune) Torque: 475-555 lb-ft @ 1,600 rpm (depending on year/tune) Fuel System Injection Type Gas: Sequential Multi-Port Fuel Injection (MPI) Injection Type Diesel: High-Pressure Common Rail (HPCR) Fuel Type Gas: Unleaded gasoline (87 octane recommended) Fuel Type Diesel: Diesel fuel (ULSD required for later models, check specific year) Engine Management ECU: PCM (Powertrain Control Module) 🔧 Transmission Standard Transmission Options: 4-speed Automatic (42RE, 45RFE, 48RE), 5-speed Manual (NV3500, NV4500/G360 for diesel) Optional Transfer Case: New Process (NV) 241 DHD (part-time 4WD), NV244 (full-time 4WD on some models) Features Automatic Features: Electronically controlled, torque converter lock-up Manual Features Diesel: Heavy-duty design for diesel torque management Fluid Specifications Automatic Transmission Fluid: ATF+4 (Chrysler Material Standard MS-9602) Manual Transmission Fluid: Mopar Manual Transmission Lubricant or equivalent (API GL-3/GL-4, check specific manual) 📐 Dimensions Exterior Wheelbase Options: 131.3 in (Standard Cab), 145.1 in (Club Cab/Quad Cab), 160.5 in (Mega Cab - later availability) Bed Length Options: 6.3 ft (standard), 8.0 ft (long bed) Weights Gvwr Range: 6,020 lbs (1500) to 12,000 lbs (3500) Curb Weight Range: Approx. 4,500 lbs to 7,000+ lbs depending on configuration 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: Four Stars (2002) NHTSA Frontal Impact Passenger: Four Stars (2002) IIHS Frontal Offset: Good (for models equipped with optional side airbags) Active Features ABS: Standard on most models, integrated with brake system Traction Control: Optional on some models Passive Features Airbags: Driver and front passenger airbags standard, optional side curtain airbags on some trims Seatbelts: Three-point seat belts with pretensioners 💡 Technology Features Infotainment Audio System Options: AM/FM stereo with CD player, optional cassette, premium Infinity sound system Navigation: Optional factory navigation system available on higher trims Driver Assistance Cruise Control: Standard on most trims Trailer Tow Features: Integrated trailer brake controller wiring, optional trailer mirrors Connectivity Power Outlets: 12V accessory power outlets Remote Keyless Entry: Optional 🔧 Maintenance Service Intervals Oil Oil Change Interval: Every 3,000-5,000 miles or 6 months, whichever comes first (check manual for specific engine/oil type) Service Intervals Filters Air Filter Replacement: Inspect every 15,000 miles, replace as needed or every 30,000 miles Fuel Filter Replacement: Gasoline: Every 30,000 miles. Diesel: Check manual, often integrated with water separator. Service Intervals Fluids Coolant Flush: Every 30,000 miles or 2 years (conventional coolant) or 100,000 miles/5 years (HOAT...
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Dodge Ram 2002-2004 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram
Model Line:
Ram Pickup
Covered Years:
2002, 2003, 2004
Codes
Platform Code:
DR (Third Generation Ram)
👋 Introduction
Market Position
Segment:
Full-size pickup truck
Target Audience:
Owners seeking to perform their own maintenance and repairs, independent repair shops, automotive enthusiasts
Competitive Analysis
Competitors:
Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra
Key Features
Manual Value Proposition:
Provides authoritative, detailed information essential for proper maintenance and repair, saving time and money compared to professional service.
Vehicle Strengths:
Renowned for durability, powerful engine options, robust towing and hauling capabilities, and a comfortable ride for a full-size truck.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service, Repair, Maintenance, Rebuilding, Refurbishing, Restoration
Vehicle Types Covered:
All configurations including 1500, 2500, 3500 models (Light Duty, Heavy Duty)
Page Count
Estimated Page Count:
2000+
Manual Type
Type:
Factory Service Manual (FSM) Equivalent / Comprehensive Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, transmission (automatic and manual), transfer case (4x4 models)
Chassis:
Suspension (front and rear), steering system, braking system (including ABS), driveline (axles, driveshafts)
Electrical:
Wiring diagrams, electrical components, charging system, starting system, lighting, instruments and gauges, power accessories, body control module (BCM), Powertrain Control Module (PCM) diagnostics
Body:
Body construction, interior trim, exterior trim, doors, windows, seats, climate control system (HVAC), safety restraints (airbags)
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Repair:
Engine overhaul, transmission repair, brake caliper replacement, suspension component replacement, electrical diagnostics and repair
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics
Special Tools:
Identification and usage of special tools required for specific procedures
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine/transmission rebuilds, including detailed torque specifications, alignment procedures, and electrical circuit tracing
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval
Printability:
Printable pages for on-site workshop use
Print Quality
Quality:
High-resolution scans with clear diagrams and text
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Type:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Options:
4.7L Magnum V8 (PZEV option), 5.7L HEMI V8, 5.9L Cummins Turbo Diesel (2500/3500 models)
Engine Options
Engine Code 4.7L:
EHA
Engine Code 5.7L:
HEMI
Engine Code 5.9L Diesel:
ISB
Performance 4.7L
Horsepower:
235 hp @ 4,500 rpm
Torque:
295 lb-ft @ 3,200 rpm
Performance 5.7L
Horsepower:
345 hp @ 5,000 rpm
Torque:
375 lb-ft @ 4,000 rpm
Performance 5.9L Diesel
Horsepower:
250-325 hp @ 2,900 rpm (depending on year/tune)
Torque:
475-555 lb-ft @ 1,600 rpm (depending on year/tune)
Fuel System
Injection Type Gas:
Sequential Multi-Port Fuel Injection (MPI)
Injection Type Diesel:
High-Pressure Common Rail (HPCR)
Fuel Type Gas:
Unleaded gasoline (87 octane recommended)
Fuel Type Diesel:
Diesel fuel (ULSD required for later models, check specific year)
Engine Management
ECU:
PCM (Powertrain Control Module)
🔧 Transmission
Standard
Transmission Options:
4-speed Automatic (42RE, 45RFE, 48RE), 5-speed Manual (NV3500, NV4500/G360 for diesel)
Optional
Transfer Case:
New Process (NV) 241 DHD (part-time 4WD), NV244 (full-time 4WD on some models)
Features
Automatic Features:
Electronically controlled, torque converter lock-up
Manual Features Diesel:
Heavy-duty design for diesel torque management
Fluid Specifications
Automatic Transmission Fluid:
ATF+4 (Chrysler Material Standard MS-9602)
Manual Transmission Fluid:
Mopar Manual Transmission Lubricant or equivalent (API GL-3/GL-4, check specific manual)
📐 Dimensions
Exterior
Wheelbase Options:
131.3 in (Standard Cab), 145.1 in (Club Cab/Quad Cab), 160.5 in (Mega Cab - later availability)
Bed Length Options:
6.3 ft (standard), 8.0 ft (long bed)
Weights
Gvwr Range:
6,020 lbs (1500) to 12,000 lbs (3500)
Curb Weight Range:
Approx. 4,500 lbs to 7,000+ lbs depending on configuration
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Four Stars (2002)
NHTSA Frontal Impact Passenger:
Four Stars (2002)
IIHS Frontal Offset:
Good (for models equipped with optional side airbags)
Active Features
ABS:
Standard on most models, integrated with brake system
Traction Control:
Optional on some models
Passive Features
Airbags:
Driver and front passenger airbags standard, optional side curtain airbags on some trims
Seatbelts:
Three-point seat belts with pretensioners
💡 Technology Features
Infotainment
Audio System Options:
AM/FM stereo with CD player, optional cassette, premium Infinity sound system
Navigation:
Optional factory navigation system available on higher trims
Driver Assistance
Cruise Control:
Standard on most trims
Trailer Tow Features:
Integrated trailer brake controller wiring, optional trailer mirrors
Connectivity
Power Outlets:
12V accessory power outlets
Remote Keyless Entry:
Optional
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 3,000-5,000 miles or 6 months, whichever comes first (check manual for specific engine/oil type)
Service Intervals Filters
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed or every 30,000 miles
Fuel Filter Replacement:
Gasoline: Every 30,000 miles. Diesel: Check manual, often integrated with water separator.
Service Intervals Fluids
Coolant Flush:
Every 30,000 miles or 2 years (conventional coolant) or 100,000 miles/5 years (HOAT coolant)
Fluid Specifications
Engine Oil Type Gas:
API SN/SP, SAE 5W-20 or 5W-30 (refer to owner's manual for specific engine and temperature range)
Engine Oil Type Diesel:
API CJ-4 or CK-4, SAE 15W-40 (check owner's manual for specific year and climate)
Coolant Type:
Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula (Orange/Pink HOAT)
Fluid Capacities Engine Oil 4.7L
Capacity Quarts:
5.0 quarts (with filter)
Fluid Capacities Engine Oil 5.7L
Capacity Quarts:
7.0 quarts (with filter)
Fluid Capacities Engine Oil 5.9L Diesel
Capacity Quarts:
10.5 quarts (with filter)
Known Issues
Common Wear Item:
Front suspension components (ball joints, tie rod ends, control arm bushings) due to truck's weight and usage.
Common Diesel Issue:
Injector issues, CP3 injection pump failure (though less common on early 3rd gen Cummins compared to later models), radiator cap leaks.
Common Gas Engine Issue:
Spark plug fouling on 4.7L, intake manifold gasket leaks on 5.7L HEMI (early versions).
Transmission Concern:
Torque converter shudder on 45RFE/48RE automatic transmissions (often related to fluid condition or electronics).
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing rugged and capable trucks dating back to the 1930s.
Model Evolution
Third Generation:
The 2002-2004 models represent the third generation of the Ram pickup (DR platform), known for its bold styling and improved amenities over its predecessor.
Key Changes 2002:
Introduction of the third generation, new chassis, updated interior and exterior styling, introduction of the 5.7L HEMI V8.
Production
Assembly Locations:
Warren Truck Assembly Plant, Michigan, USA; Saltillo Truck Assembly Plant, Mexico
🏆 Awards & Recognition
Recognitions
Motor Trend Truck Of The Year:
Ram Pickup was MotorTrend's Truck of the Year for 2003.
Consumer Reports Reliability:
Reliability ratings varied by model year and powertrain; specific details would be in the manual's troubleshooting section.
Ratings
Towing Capacity:
Up to 12,000+ lbs (for properly equipped 3500 models with diesel engine)
Payload Capacity:
Up to 3,000+ lbs (for properly equipped models)
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