Dodge Ram Truck 2500 3500 2002 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Model Variant: 2500 / 3500 Year: 2002 Codes Chassis Code: DR (Second Generation Ram - facelift) 👋 Introduction Market Position Segment: Heavy-duty pickup truck Target Audience: Owners of 2002 Dodge Ram 2500/3500, independent repair shops, fleet maintenance Competitive Analysis Competitors: Ford Super Duty F-250/F-350, Chevrolet Silverado 2500HD/3500HD, GMC Sierra 2500HD/3500HD Key Features Vehicle Strengths: Robust chassis, powerful engine options, towing and hauling capability Manual Value Proposition: Provides essential factory data for maintaining and repairing a capable heavy-duty truck 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive service, maintenance, and troubleshooting Specific Models Covered: Dodge Ram 2500, Dodge Ram 3500 Engine Coverage: All Engines (specific engine types TBD by internal documentation) Transmission Coverage: All Transmissions (specific transmission types TBD by internal documentation) Body Style Coverage: All Body Styles (TBD by internal documentation) Page Count Estimated Page Count: Likely 1000+ pages (typical for comprehensive factory service manuals) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul for gasoline and diesel engines Transmission: Service and repair for manual and automatic transmissions Drivetrain: Front axle, rear axle, driveshafts, transfer case (4WD models) Suspension: Front and rear suspension components, steering system Brakes: Hydraulic system, ABS, parking brake, component replacement Electrical: Wiring diagrams, lighting, ignition, charging system, starting system, body electrical, instrumentation Fuel System: Fuel delivery, injection systems (gasoline), fuel injection (diesel), fuel tank and lines Cooling System: Radiator, water pump, thermostat, fan, heater system Exhaust System: Catalytic converter, mufflers, pipes, emission controls HVAC: Heating, Ventilation, and Air Conditioning system components and service Body: Body panels, doors, glass, trim, structural components Chassis: Frame, engine mounting, suspension mounting points Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, tire rotation Troubleshooting: Diagnostic procedures, symptom-based troubleshooting guides Repair Procedures: Step-by-step instructions for component replacement and repair Diagnostics: On-board diagnostics (OBD-II) information, diagnostic trouble codes (DTCs) Rebuilding: Engine and transmission rebuilding specifications and procedures Specifications: Torque specifications, clearances, alignments, electrical specifications Technical Depth Depth: Factory-level detail, suitable for professional technicians and experienced DIYers Scope: Covers all aspects from basic maintenance to major overhauls and diagnostics 📊 Manual Specifications File Format Compatibility: Compatible with all PDF readers Print Quality Resolution: High-resolution scans for clear text and diagrams Searchable: Likely searchable text (depending on OCR quality of original scan) Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Common Gas Engine: 8.0L V10 Magnum (450 cu in) - Estimated 305-310 hp / 450-455 lb-ft torque Common Diesel Engine: 5.9L Cummins I6 Turbo Diesel (359 cu in) - Estimated 235-250 hp / 460-470 lb-ft torque Performance Power Delivery: Emphasis on low-end torque for towing and hauling Fuel System Gasoline Injection: Multi-point fuel injection (MPI) Diesel Injection: High-pressure common rail (HPCR) for Cummins engines Engine Code Example V10 Gas: V10 (specific engine ID depends on exact configuration) Cummins Diesel: 5.9L ISB Cummins (specific engine ID depends on exact configuration) 🔧 Transmission Standard Standard Transmission Type: 5-speed manual (NV4500 for some applications) Optional Optional Automatic Transmission: 4-speed automatic (47RE / 48RE for gasoline and diesel) Features 4Wd System: Part-time 4WD with manual transfer case lever or electronic shift on the fly (ESOF) 📐 Dimensions Exterior Wheelbase Options: Varies by cab and bed configuration (e.g., 130.5", 140.5", 154.5" for 2500) Bed Length Options: Standard Bed (approx. 6.3 ft), Long Bed (approx. 8 ft) Weights Gvwr Range: Starts around 8,800 lbs for 2500, up to 11,500+ lbs for 3500 Curb Weight Range: Varies significantly by configuration, typically 6,000-7,500 lbs Towing Capacity Max Conventional Towing: Up to ~10,000 - 12,000 lbs (depending on configuration and axle ratio) Max Gooseneck Towing: Up to ~13,000 - 16,000 lbs (depending on configuration and axle ratio, typically 3500 DRW) 🛡️ Safety Features Ratings NHTSA Front Crash: NHTSA frontal crash ratings are generally good for trucks of this era, specific score varies by configuration. Active Features ABS: Anti-lock Braking System (ABS) standard on all wheels Trailer Brake Controller Provision: Provision for factory or aftermarket trailer brake controller Passive Features Airbags: Driver and passenger front airbags Seatbelts: Three-point front seat belts with pretensioners, rear seat belts 💡 Technology Features Infotainment Audio System: Base AM/FM radio with cassette player and optional CD player. Higher trims may offer premium audio. Display: Minimal central display for basic information, no integrated touchscreens typical for this era. Driver Assistance Cruise Control: Standard on most trims Tow Haul Mode: Available on automatic transmissions to optimize shifting for towing. Connectivity Auxiliary Inputs: No factory auxiliary audio input or USB ports typically. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 3,000-5,000 miles or 6 months for gasoline, 5,000-7,500 miles or 6 months for diesel, depending on severe/normal service. Transmission Fluid Change: Automatic: 30,000-50,000 miles. Manual: Inspect at...
Factory-level detail, suitable for professional technicians and experienced DIYers
Scope:
Covers all aspects from basic maintenance to major overhauls and diagnostics
📊 Manual Specifications
File Format
Compatibility:
Compatible with all PDF readers
Print Quality
Resolution:
High-resolution scans for clear text and diagrams
Searchable:
Likely searchable text (depending on OCR quality of original scan)
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Common Gas Engine:
8.0L V10 Magnum (450 cu in) - Estimated 305-310 hp / 450-455 lb-ft torque
Common Diesel Engine:
5.9L Cummins I6 Turbo Diesel (359 cu in) - Estimated 235-250 hp / 460-470 lb-ft torque
Performance
Power Delivery:
Emphasis on low-end torque for towing and hauling
Fuel System
Gasoline Injection:
Multi-point fuel injection (MPI)
Diesel Injection:
High-pressure common rail (HPCR) for Cummins engines
Engine Code Example
V10 Gas:
V10 (specific engine ID depends on exact configuration)
Cummins Diesel:
5.9L ISB Cummins (specific engine ID depends on exact configuration)
🔧 Transmission
Standard
Standard Transmission Type:
5-speed manual (NV4500 for some applications)
Optional
Optional Automatic Transmission:
4-speed automatic (47RE / 48RE for gasoline and diesel)
Features
4Wd System:
Part-time 4WD with manual transfer case lever or electronic shift on the fly (ESOF)
📐 Dimensions
Exterior
Wheelbase Options:
Varies by cab and bed configuration (e.g., 130.5", 140.5", 154.5" for 2500)
Bed Length Options:
Standard Bed (approx. 6.3 ft), Long Bed (approx. 8 ft)
Weights
Gvwr Range:
Starts around 8,800 lbs for 2500, up to 11,500+ lbs for 3500
Curb Weight Range:
Varies significantly by configuration, typically 6,000-7,500 lbs
Towing Capacity
Max Conventional Towing:
Up to ~10,000 - 12,000 lbs (depending on configuration and axle ratio)
Max Gooseneck Towing:
Up to ~13,000 - 16,000 lbs (depending on configuration and axle ratio, typically 3500 DRW)
🛡️ Safety Features
Ratings
NHTSA Front Crash:
NHTSA frontal crash ratings are generally good for trucks of this era, specific score varies by configuration.
Active Features
ABS:
Anti-lock Braking System (ABS) standard on all wheels
Trailer Brake Controller Provision:
Provision for factory or aftermarket trailer brake controller
Passive Features
Airbags:
Driver and passenger front airbags
Seatbelts:
Three-point front seat belts with pretensioners, rear seat belts
💡 Technology Features
Infotainment
Audio System:
Base AM/FM radio with cassette player and optional CD player. Higher trims may offer premium audio.
Display:
Minimal central display for basic information, no integrated touchscreens typical for this era.
Driver Assistance
Cruise Control:
Standard on most trims
Tow Haul Mode:
Available on automatic transmissions to optimize shifting for towing.
Connectivity
Auxiliary Inputs:
No factory auxiliary audio input or USB ports typically.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-5,000 miles or 6 months for gasoline, 5,000-7,500 miles or 6 months for diesel, depending on severe/normal service.
Transmission Fluid Change:
Automatic: 30,000-50,000 miles. Manual: Inspect at 30,000 miles, fluid change typically 60,000-100,000 miles.
Fluid Specifications
Engine Oil Gasoline:
API Certified SAE 10W-30 or 10W-40 (check manual for specific viscosity recommendations and API classifications like CI-4/SL)
Engine Oil Diesel:
API CI-4 rated SAE 15W-40 diesel engine oil (Cummins recommendation)
Transmission Fluid Auto:
ATF+3 or ATF+4 (Chrysler spec)
Transmission Fluid Manual:
API GL-3 or GL-4 SAE 75W-90 gear oil (for NV4500)
Coolant:
Mopar Antifreeze/Coolant (HOAT - Hybrid Organic Acid Technology), typically a 50/50 mix with distilled water
Known Issues
Common Diesel Issue:
VP44 injection pump failures (especially on earlier models with insufficient lift pump pressure), injector issues, front axle U-joint wear.
Common Gas Issue:
Spark plug fouling on V10, exhaust manifold leaks, some transmission hard shifting issues.
Common Chassis Issue:
Frame rust (especially in areas with road salt), ball joint wear, rear axle seal leaks.
Filter Part Numbers
Oil Filter Gasoline:
Mopar MO-090 or equivalent (e.g., Wix 51515, Purolator L20093)
Oil Filter Diesel:
Mopar MO-899 or equivalent (e.g., Wix 57108, Fleetguard LF9009)
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing rugged and capable trucks for work and utility.
Model Evolution
Second Generation Ram:
The 2002 model falls into the second generation (1994-2001) with a facelift for 2002-2003, featuring updated styling (grille, headlights) and interior refinements.
Production
Manufacturing Plant:
Saltillo Truck Plant, Mexico; St. Louis Assembly Plant, Missouri (pre-2004)
🏆 Awards & Recognition
Recognitions
Truck Of The Year Competitors:
While not specific to the 2002 model, the Dodge Ram lineup has historically received accolades for its design and capability.
Ratings
Consumer Reports Reliability:
Reliability ratings for 2002 models can be mixed, often depending on the specific engine and drivetrain. Cummins diesel generally rated higher for durability.
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