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Dodge Ram 1500 2002-2004 Workshop Service Repair Manual

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๐Ÿท๏ธ Basic Information Identification Make: Dodge Model: Ram 1500 Generation: Third Generation (DR/DH/D1) Codes Platform Code: DR ๐Ÿ‘‹ Introduction Market Position Segment: Full-size Pickup Truck Target Audience: DIY Mechanics, Professional Technicians, Fleet Maintenance Competitive Analysis Key Competitors: Ford F-150, Chevrolet Silverado 1500, GMC Sierra 1500, Toyota Tundra Key Features Vehicle Highlights: Robust construction, strong engine options, towing capability, comfortable interior for its class Manual Value Proposition: Provides detailed repair and maintenance information, empowering owners to perform complex tasks and reduce repair costs. ๐Ÿ“‹ Manual Details Coverage Areas Covered Years: 2002, 2003, 2004 Vehicle Types: Pickup Truck Page Count Estimated Pages: ~3000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF File Format File Quality: High-resolution, searchable PDF Printable: Yes, designed for printing specific sections or the entire manual Binding Type Binding: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF) ๐Ÿ“– Manual Coverage Systems Covered Engine: 3.7L Magnum V6, 4.7L Magnum V8, 5.7L HEMI V8 Transmission: 4-Speed Automatic (42RE, 45RFE, 48RE), 5-Speed Manual (NV3500) Drivetrain: RWD, 4WD (Part-time, Full-time) Brakes: Front Disc, Rear Disc (with ABS) Suspension: Front Independent (Short/Long Arm), Rear Solid Axle (Leaf Springs) Steering: Power Rack and Pinion Electrical: Starting & Charging, Ignition, Lighting, Gauges, Body Controls, HVAC, Power Accessories Body: Exterior Panels, Interior Trim, Glass, Seats, Bumpers HVAC: Air Conditioning, Heater, Climate Control Restraint Systems: Airbags, Seat Belts Procedures Included Maintenance: Oil Changes, Filter Replacements, Fluid Checks and Replacements, Tune-Ups Troubleshooting: Diagnostic Flowcharts, Symptom-based Diagnostics, Electrical Schematics Repair: Engine Reassembly, Transmission Overhaul, Brake System Repair, Suspension Component Replacement, Electrical Component Diagnosis and Repair Overhaul: Complete Engine Rebuilds, Transmission Rebuilds, Differential Rebuilds Diagnostics: OBD-II Scans, Component Testing, Circuit Diagnosis Adjustments: Parking Brake Adjustment, Clutch Adjustment (Manual) Specifications: Torque Specifications, Fluid Capacities, Clearances Technical Depth Depth: Comprehensive, from basic maintenance to full engine and transmission rebuilds Diagnostic Level: Advanced (including wiring diagrams and diagnostic procedures) โš™๏ธ Engine Specifications Primary Engine Engine 1 Type: 3.7L Magnum V6 Engine 1 Displacement: 3687 cc Engine 1 Horsepower: 215 hp @ 5200 rpm Engine 1 Torque: 235 lb-ft @ 4000 rpm Engine 2 Type: 4.7L Magnum V8 Engine 2 Displacement: 4701 cc Engine 2 Horsepower: 240-245 hp @ 4800-5000 rpm Engine 2 Torque: 300-310 lb-ft @ 3200-3600 rpm Engine 3 Type: 5.7L HEMI V8 (Introduced mid-2003) Engine 3 Displacement: 5654 cc Engine 3 Horsepower: 345-349 hp @ 5000-5200 rpm Engine 3 Torque: 375-377 lb-ft @ 4000-4200 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Engine Design Valve Train: Overhead Valve (OHV) for Magnum V6/V8, Hemispherical Combustion Chamber (HEMI) OHV for 5.7L V8 Cooling System Coolant Type: 50/50 Ethylene Glycol Antifreeze Oil Specifications Engine Oil Viscosity: SAE 5W-30 (recommended for most conditions) Engine Oil Capacity: 5.0-7.0 quarts (depending on engine) ๐Ÿ”ง Transmission Standard Transmission 1 Type: 4-Speed Automatic (42RE - used with 3.7L V6) Transmission 2 Type: 4-Speed Automatic (45RFE/48RE - used with 4.7L V8 and 5.7L HEMI) Optional Transmission 3 Type: 5-Speed Manual (NV3500 - primarily with V6) Features Transmission Control: Electronic Control Module (ECM) for automatics Fluid Specifications Automatic Transmission Fluid: ATF+4 (Mopar) Fluid Capacities Automatic Transmission Fluid Capacity: Approx. 9-13 quarts (dry fill) Manual Transmission Fluid Manual Transmission Fluid Type: MS-9224 (Synchromesh Manual Transmission Fluid) or equivalent Manual Transmission Fluid Capacity Manual Transmission Fluid Capacity: Approx. 2.3 quarts ๐Ÿ“ Dimensions Exterior Wheelbase: 139.0 inches (Standard Bed), 145.2 inches (Long Bed) Overall Length: 227.0 - 239.0 inches (depending on cab/bed) Overall Width: 79.3 inches Overall Height: 74.4 - 75.1 inches (depending on configuration) Cargo Bed Length: 6'3" (Standard), 8'0" (Long) Bed Width Between Wheelwells: 41.0 inches Weights Curb Weight: 4,500 - 5,500 lbs (approx.) Gross Vehicle Weight Rating Gvwr: 6,400 - 7,200 lbs (depending on configuration) Max Towing Capacity: Up to 8,600 lbs (with appropriate equipment) Max Payload Capacity: Up to 1,650 lbs (approx.) ๐Ÿ›ก๏ธ Safety Features Ratings NHTSA Front Driver Side Impact: โ˜…โ˜…โ˜…โ˜…โ˜… (5-Star) NHTSA Front Passenger Side Impact: โ˜…โ˜…โ˜…โ˜…โ˜… (5-Star) IIHS Frontal Offset Score: Good Active Features ABS: Standard (4-wheel disc brakes with ABS) Traction Control: Available (Electronic Traction Control) Passive Features Airbags: Driver and Passenger Frontal Airbags Seat Belts: Height-adjustable front seat belts with pretensioners ๐Ÿ’ก Technology Features Infotainment Audio System: Available AM/FM stereo with CD player, cassette player (early models), optional premium sound systems. Climate Control: Manual or optional Electronic Dual-Zone Climate Control Driver Assistance Cruise Control: Standard Tow Haul Mode: Available on automatic transmissions to optimize shifting for towing. Connectivity Power Outlets: 12V auxiliary power outlets ๐Ÿ”ง Maintenance Service Intervals Oil Change Interval: Every 3,000 to 7,500 miles (depending on oil type and driving conditions, consult manual for specifics) Engine Air Filter Replacement: Every 15,000 to 30,000 miles or as needed based on inspection Cabin Air Filter Replacement: Every 15,000 to 30,000 miles or as needed Spark Plug Replacement: Varies by engine: 3.7L V6 (~100,000 miles), 4.7L V8 (~100,000 miles),...
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Sku: 448982
Coleรงรตes: ALL Dodge

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Dodge Ram 1500 2002-2004 Workshop Service Repair Manual
๐Ÿท๏ธ Basic Information
Identification
Make:
Dodge
Model:
Ram 1500
Generation:
Third Generation (DR/DH/D1)
Codes
Platform Code:
DR
๐Ÿ‘‹ Introduction
Market Position
Segment:
Full-size Pickup Truck
Target Audience:
DIY Mechanics, Professional Technicians, Fleet Maintenance
Competitive Analysis
Key Competitors:
Ford F-150, Chevrolet Silverado 1500, GMC Sierra 1500, Toyota Tundra
Key Features
Vehicle Highlights:
Robust construction, strong engine options, towing capability, comfortable interior for its class
Manual Value Proposition:
Provides detailed repair and maintenance information, empowering owners to perform complex tasks and reduce repair costs.
๐Ÿ“‹ Manual Details
Coverage Areas
Covered Years:
2002, 2003, 2004
Vehicle Types:
Pickup Truck
Page Count
Estimated Pages:
~3000+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
File Format
File Quality:
High-resolution, searchable PDF
Printable:
Yes, designed for printing specific sections or the entire manual
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
๐Ÿ“– Manual Coverage
Systems Covered
Engine:
3.7L Magnum V6, 4.7L Magnum V8, 5.7L HEMI V8
Transmission:
4-Speed Automatic (42RE, 45RFE, 48RE), 5-Speed Manual (NV3500)
Drivetrain:
RWD, 4WD (Part-time, Full-time)
Brakes:
Front Disc, Rear Disc (with ABS)
Suspension:
Front Independent (Short/Long Arm), Rear Solid Axle (Leaf Springs)
Steering:
Power Rack and Pinion
Electrical:
Starting & Charging, Ignition, Lighting, Gauges, Body Controls, HVAC, Power Accessories
Body:
Exterior Panels, Interior Trim, Glass, Seats, Bumpers
HVAC:
Air Conditioning, Heater, Climate Control
Restraint Systems:
Airbags, Seat Belts
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Fluid Checks and Replacements, Tune-Ups
Troubleshooting:
Diagnostic Flowcharts, Symptom-based Diagnostics, Electrical Schematics
Repair:
Engine Reassembly, Transmission Overhaul, Brake System Repair, Suspension Component Replacement, Electrical Component Diagnosis and Repair
Overhaul:
Complete Engine Rebuilds, Transmission Rebuilds, Differential Rebuilds
Diagnostics:
OBD-II Scans, Component Testing, Circuit Diagnosis
Adjustments:
Parking Brake Adjustment, Clutch Adjustment (Manual)
Specifications:
Torque Specifications, Fluid Capacities, Clearances
Technical Depth
Depth:
Comprehensive, from basic maintenance to full engine and transmission rebuilds
Diagnostic Level:
Advanced (including wiring diagrams and diagnostic procedures)
โš™๏ธ Engine Specifications
Primary Engine
Engine 1 Type:
3.7L Magnum V6
Engine 1 Displacement:
3687 cc
Engine 1 Horsepower:
215 hp @ 5200 rpm
Engine 1 Torque:
235 lb-ft @ 4000 rpm
Engine 2 Type:
4.7L Magnum V8
Engine 2 Displacement:
4701 cc
Engine 2 Horsepower:
240-245 hp @ 4800-5000 rpm
Engine 2 Torque:
300-310 lb-ft @ 3200-3600 rpm
Engine 3 Type:
5.7L HEMI V8 (Introduced mid-2003)
Engine 3 Displacement:
5654 cc
Engine 3 Horsepower:
345-349 hp @ 5000-5200 rpm
Engine 3 Torque:
375-377 lb-ft @ 4000-4200 rpm
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Engine Design
Valve Train:
Overhead Valve (OHV) for Magnum V6/V8, Hemispherical Combustion Chamber (HEMI) OHV for 5.7L V8
Cooling System
Coolant Type:
50/50 Ethylene Glycol Antifreeze
Oil Specifications
Engine Oil Viscosity:
SAE 5W-30 (recommended for most conditions)
Engine Oil Capacity:
5.0-7.0 quarts (depending on engine)
๐Ÿ”ง Transmission
Standard
Transmission 1 Type:
4-Speed Automatic (42RE - used with 3.7L V6)
Transmission 2 Type:
4-Speed Automatic (45RFE/48RE - used with 4.7L V8 and 5.7L HEMI)
Optional
Transmission 3 Type:
5-Speed Manual (NV3500 - primarily with V6)
Features
Transmission Control:
Electronic Control Module (ECM) for automatics
Fluid Specifications
Automatic Transmission Fluid:
ATF+4 (Mopar)
Fluid Capacities
Automatic Transmission Fluid Capacity:
Approx. 9-13 quarts (dry fill)
Manual Transmission Fluid
Manual Transmission Fluid Type:
MS-9224 (Synchromesh Manual Transmission Fluid) or equivalent
Manual Transmission Fluid Capacity
Manual Transmission Fluid Capacity:
Approx. 2.3 quarts
๐Ÿ“ Dimensions
Exterior
Wheelbase:
139.0 inches (Standard Bed), 145.2 inches (Long Bed)
Overall Length:
227.0 - 239.0 inches (depending on cab/bed)
Overall Width:
79.3 inches
Overall Height:
74.4 - 75.1 inches (depending on configuration)
Cargo
Bed Length:
6'3" (Standard), 8'0" (Long)
Bed Width Between Wheelwells:
41.0 inches
Weights
Curb Weight:
4,500 - 5,500 lbs (approx.)
Gross Vehicle Weight Rating Gvwr:
6,400 - 7,200 lbs (depending on configuration)
Max Towing Capacity:
Up to 8,600 lbs (with appropriate equipment)
Max Payload Capacity:
Up to 1,650 lbs (approx.)
๐Ÿ›ก๏ธ Safety Features
Ratings
NHTSA Front Driver Side Impact:
โ˜…โ˜…โ˜…โ˜…โ˜… (5-Star)
NHTSA Front Passenger Side Impact:
โ˜…โ˜…โ˜…โ˜…โ˜… (5-Star)
IIHS Frontal Offset Score:
Good
Active Features
ABS:
Standard (4-wheel disc brakes with ABS)
Traction Control:
Available (Electronic Traction Control)
Passive Features
Airbags:
Driver and Passenger Frontal Airbags
Seat Belts:
Height-adjustable front seat belts with pretensioners
๐Ÿ’ก Technology Features
Infotainment
Audio System:
Available AM/FM stereo with CD player, cassette player (early models), optional premium sound systems.
Climate Control:
Manual or optional Electronic Dual-Zone Climate Control
Driver Assistance
Cruise Control:
Standard
Tow Haul Mode:
Available on automatic transmissions to optimize shifting for towing.
Connectivity
Power Outlets:
12V auxiliary power outlets
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 to 7,500 miles (depending on oil type and driving conditions, consult manual for specifics)
Engine Air Filter Replacement:
Every 15,000 to 30,000 miles or as needed based on inspection
Cabin Air Filter Replacement:
Every 15,000 to 30,000 miles or as needed
Spark Plug Replacement:
Varies by engine: 3.7L V6 (~100,000 miles), 4.7L V8 (~100,000 miles), 5.7L HEMI (100,000 miles with specific plugs)
Transmission Fluid Service:
Every 30,000 to 60,000 miles for automatic transmissions (filter and fluid change)
Coolant Flush:
Every 30,000 to 100,000 miles (depending on coolant type, consult manual)
Fluid Specifications
Power Steering Fluid:
ATF+4 or Mopar Power Steering Fluid
Brake Fluid:
DOT 3
Known Issues
Ignition Coils:
Premature failure reported on some models, especially with V8 engines.
Wheel Hubs:
Front wheel hub bearing premature wear/failure can occur.
Transmission Cooler:
Potential for internal transmission cooler leaks (especially in earlier models with integrated radiator coolers) leading to coolant contamination.
Brake Rotors:
Warping or premature wear of brake rotors can be an issue under heavy use.
Rust:
Corrosion on frame, body panels, and exhaust components can be a concern in rust-prone areas.
๐Ÿ“š Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, dating back to the Power Wagon.
Model Evolution
Third Generation Introduction:
The third generation (DB/DC/DM) was a significant redesign introduced for the 2002 model year, featuring a completely new exterior and interior design, and the introduction of the HEMI engine.
Key Updates 2003:
Introduction of the 5.7L HEMI V8 engine for certain models.
Key Updates 2004:
Standardization of 4-wheel disc brakes and ABS on most models, minor interior trim adjustments.
Production
Manufacturing Plant:
St. Louis Assembly, Missouri, USA; Saltillo Truck Plant, Mexico
๐Ÿ† Awards & Recognition
Recognitions
Motor Trend Truck Of The Year:
The Ram 1500 (as part of the third-generation redesign) was a contender, though did not win the award during these specific years. It was recognized for its significant improvements.
Ratings
Jdpowe Initial Quality Study:
Ratings varied, but the third-generation Ram generally saw improvements over its predecessor, though often ranked mid-pack in its segment for initial quality.
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