Dodge Ram Truck 2002-2004 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Generation: Third Generation (2002-2008) Chassis Code: DR/DH/D5 Applicable Years: 2002, 2003, 2004 👋 Introduction Market Position Vehicle Segment: Full-size pickup truck Competitive Landscape: Competed with Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra, Nissan Titan. Key Features Engine Options: Renowned for its robust Magnum V8 engine options. Durability: Known for its heavy-duty construction and towing capabilities. Styling: Bold, distinctive styling that differentiated it from competitors. 📋 Manual Details Coverage Areas Primary Coverage: Repair and overhaul of Dodge Ram Trucks Trim Level Coverage: All trim levels for the specified model years Body Style Coverage: Includes information relevant to all body styles (e.g., standard cab, crew cab, chassis cab) within the DR/DH/D5 platform Page Count Estimated Page Count: Likely exceeds 1500 pages (typical for comprehensive workshop manuals of this era) Manual Type Manual Category: Workshop Service Repair Manual Target Audience: Professional technicians and experienced DIY mechanics Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (including timing, cylinder head, block), Fuel system, Ignition system, Exhaust system, Cooling system, Lubrication system Transmission Drivetrain: Manual transmissions (NV3500, NV4500), Automatic transmissions (42RE, 44RE, 45RFE, 48RE), Transfer cases (271, 273), Drivelines, Axles (front and rear) Chassis: Suspension (front and rear independent/solid axle), Steering system, Brake system (front and rear disc/drum, ABS), Wheel alignment Electrical Electronics: Battery, Charging system, Starting system, Lighting, Instrument cluster, Body control modules (BCM), Powertrain control modules (PCM), HVAC controls, Power windows/locks/mirrors, Audio systems, Diagnostic trouble codes (DTCs) Body Interior: Body panels, Doors, Hood, Tailgate, Bumpers, Interior trim, Seats, Airbags, Climate control system (HVAC components) Procedures Included Maintenance: Scheduled maintenance, Oil changes, Filter replacements, Fluid level checks and changes, Lubrication, Tire rotation Diagnosis Troubleshooting: System diagnostics, Symptom-based troubleshooting charts, Diagnostic trouble code (DTC) analysis, Electrical circuit testing Repair Overhaul: Engine rebuild procedures, Transmission overhaul, Differential repair, Brake component replacement, Suspension component replacement, Steering system repair, Electrical component repair/replacement Adjustment Calibration: Throttle cable adjustment, Parking brake adjustment, Wheel alignment procedures, Sensor calibration Specification Data: Torque specifications, Clearances, Fluid capacities, Electrical resistance values, Component dimensions Technical Depth Depth Level: Comprehensive, covering from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures. Diagnostic Tools: References to factory diagnostic tools (e.g., DRBIII) and procedures for using scan tools for diagnostics. 📊 Manual Specifications File Format PDF Searchability: Likely text-searchable PDF, allowing for quick information retrieval. PDF Resolution: High resolution for clear diagrams, illustrations, and text. Print Quality Diagram Clarity: Clear, detailed diagrams, schematics, and exploded views. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Option 1: 4.7L Magnum V8 (235 hp @ 4500 rpm, 295 lb-ft @ 3200 rpm) Engine Option 2: 5.9L Magnum V8 (305 hp @ 4800 rpm, 330 lb-ft @ 3200 rpm) - for 2003-2004 models Engine Option 3: 5.7L HEMI V8 (345 hp @ 5400 rpm, 375 lb-ft @ 4000 rpm) - Introduced in 2003 model year Engine Option 4: 4.7L Magnum V8 (Compression Ratio: 9.1:1) Engine Option 5: 5.9L Magnum V8 (Compression Ratio: 9.1:1) Engine Option 6: 5.7L HEMI V8 (Compression Ratio: 9.6:1) Performance Governor Speed Limit: Typically limited electronically, often around 100-115 mph. Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded gasoline (87 octane recommended, higher octane for HEMI may provide slight performance benefit) Fuel Pump Type: In-tank electric fuel pump 🔧 Transmission Standard Standard Transmission 2002: 4-speed automatic (42RE/44RE) or 5-speed manual (NV3500) depending on engine and configuration Standard Transmission 2003 2004: 4-speed automatic (45RFE/48RE) or 5-speed manual (NV3500) or 6-speed manual (NV4500) depending on engine and configuration Optional Optional Transmission 1: 5-speed manual transmission (NV3500) - available with 4.7L V8 and some 5.9L V8 engines Optional Transmission 2: 6-speed manual transmission (NV4500) - typically paired with the 5.9L Cummins Turbo Diesel (not covered in this specific product info, but a common Ram transmission) Optional Transmission 3: 4-speed automatic transmission (45RFE/48RE) - introduced with 4.7L and HEMI V8s, replacing 42RE/44RE Features Overdrive Gears: Automatic transmissions feature overdrive gears (typically 4th gear). Transfer Case Options: Electronic Shift-on-the-Fly (ESOF) part-time 4WD (NV273) or full-time 4WD (NV244) often available. Fluid Specifications Atf Type 42Re 44Re: ATF+3 or ATF+4 (Chrysler/Mopar specification) Atf Type 45Rfe 48Re: ATF+4 (Chrysler/Mopar specification) Manual Transmission Fluid Nv3500: MS-9224 (Dexron III/Mercon equivalent or specific Chrysler specification) 📐 Dimensions Exterior Wheelbase Options: Approx. 130.5 inches (Regular Cab), 140.5 inches (Club Cab/Quad Cab), 160.5 inches (Mega Cab - introduced later but variations exist) Overall Length: Varies by wheelbase and bed length (e.g., ~220-240 inches) Bed Length Options: 6.3 ft (short bed), 8.0 ft (long bed) Weights Curb Weight: Approx. 4,500 - 5,500 lbs depending on configuration Gross Vehicle Weight Rating Gvwr: Ranges from approx. 6,300 lbs to 8,800 lbs depending on model and payload package Towing Capacity: Up...

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Tipo: Truck

Fabricante:

Sku: 449191

Coleções: ALL Dodge

Disponibilidade: Em estoque

Tag: 2002 2003 2004 Cars Dodge Misc Ram Truck

Variantes do produto

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram Truck

Generation:

Third Generation (2002-2008)

Chassis Code:

DR/DH/D5

Applicable Years:

2002, 2003, 2004

👋 Introduction

Market Position

Vehicle Segment:

Full-size pickup truck

Competitive Landscape:

Competed with Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra, Nissan Titan.

Key Features

Engine Options:

Renowned for its robust Magnum V8 engine options.

Durability:

Known for its heavy-duty construction and towing capabilities.

Styling:

Bold, distinctive styling that differentiated it from competitors.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair and overhaul of Dodge Ram Trucks

Trim Level Coverage:

All trim levels for the specified model years

Body Style Coverage:

Includes information relevant to all body styles (e.g., standard cab, crew cab, chassis cab) within the DR/DH/D5 platform

Page Count

Estimated Page Count:

Likely exceeds 1500 pages (typical for comprehensive workshop manuals of this era)

Manual Type

Manual Category:

Workshop Service Repair Manual

Target Audience:

Professional technicians and experienced DIY mechanics

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical (including timing, cylinder head, block), Fuel system, Ignition system, Exhaust system, Cooling system, Lubrication system

Transmission Drivetrain:

Manual transmissions (NV3500, NV4500), Automatic transmissions (42RE, 44RE, 45RFE, 48RE), Transfer cases (271, 273), Drivelines, Axles (front and rear)

Chassis:

Suspension (front and rear independent/solid axle), Steering system, Brake system (front and rear disc/drum, ABS), Wheel alignment

Electrical Electronics:

Battery, Charging system, Starting system, Lighting, Instrument cluster, Body control modules (BCM), Powertrain control modules (PCM), HVAC controls, Power windows/locks/mirrors, Audio systems, Diagnostic trouble codes (DTCs)

Body Interior:

Body panels, Doors, Hood, Tailgate, Bumpers, Interior trim, Seats, Airbags, Climate control system (HVAC components)

Procedures Included

Maintenance:

Scheduled maintenance, Oil changes, Filter replacements, Fluid level checks and changes, Lubrication, Tire rotation

Diagnosis Troubleshooting:

System diagnostics, Symptom-based troubleshooting charts, Diagnostic trouble code (DTC) analysis, Electrical circuit testing

Repair Overhaul:

Engine rebuild procedures, Transmission overhaul, Differential repair, Brake component replacement, Suspension component replacement, Steering system repair, Electrical component repair/replacement

Adjustment Calibration:

Throttle cable adjustment, Parking brake adjustment, Wheel alignment procedures, Sensor calibration

Specification Data:

Torque specifications, Clearances, Fluid capacities, Electrical resistance values, Component dimensions

Technical Depth

Depth Level:

Comprehensive, covering from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.

Diagnostic Tools:

References to factory diagnostic tools (e.g., DRBIII) and procedures for using scan tools for diagnostics.

📊 Manual Specifications

File Format

PDF Searchability:

Likely text-searchable PDF, allowing for quick information retrieval.

PDF Resolution:

High resolution for clear diagrams, illustrations, and text.

Print Quality

Diagram Clarity:

Clear, detailed diagrams, schematics, and exploded views.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Option 1:

4.7L Magnum V8 (235 hp @ 4500 rpm, 295 lb-ft @ 3200 rpm)

Engine Option 2:

5.9L Magnum V8 (305 hp @ 4800 rpm, 330 lb-ft @ 3200 rpm) - for 2003-2004 models

Engine Option 3:

5.7L HEMI V8 (345 hp @ 5400 rpm, 375 lb-ft @ 4000 rpm) - Introduced in 2003 model year

Engine Option 4:

4.7L Magnum V8 (Compression Ratio: 9.1:1)

Engine Option 5:

5.9L Magnum V8 (Compression Ratio: 9.1:1)

Engine Option 6:

5.7L HEMI V8 (Compression Ratio: 9.6:1)

Performance

Governor Speed Limit:

Typically limited electronically, often around 100-115 mph.

Fuel System

Fuel Delivery:

Sequential Multi-Port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (87 octane recommended, higher octane for HEMI may provide slight performance benefit)

Fuel Pump Type:

In-tank electric fuel pump

🔧 Transmission

Standard

Standard Transmission 2002:

4-speed automatic (42RE/44RE) or 5-speed manual (NV3500) depending on engine and configuration

Standard Transmission 2003 2004:

4-speed automatic (45RFE/48RE) or 5-speed manual (NV3500) or 6-speed manual (NV4500) depending on engine and configuration

Optional

Optional Transmission 1:

5-speed manual transmission (NV3500) - available with 4.7L V8 and some 5.9L V8 engines

Optional Transmission 2:

6-speed manual transmission (NV4500) - typically paired with the 5.9L Cummins Turbo Diesel (not covered in this specific product info, but a common Ram transmission)

Optional Transmission 3:

4-speed automatic transmission (45RFE/48RE) - introduced with 4.7L and HEMI V8s, replacing 42RE/44RE

Features

Overdrive Gears:

Automatic transmissions feature overdrive gears (typically 4th gear).

Transfer Case Options:

Electronic Shift-on-the-Fly (ESOF) part-time 4WD (NV273) or full-time 4WD (NV244) often available.

Fluid Specifications

Atf Type 42Re 44Re:

ATF+3 or ATF+4 (Chrysler/Mopar specification)

Atf Type 45Rfe 48Re:

ATF+4 (Chrysler/Mopar specification)

Manual Transmission Fluid Nv3500:

MS-9224 (Dexron III/Mercon equivalent or specific Chrysler specification)

📐 Dimensions

Exterior

Wheelbase Options:

Approx. 130.5 inches (Regular Cab), 140.5 inches (Club Cab/Quad Cab), 160.5 inches (Mega Cab - introduced later but variations exist)

Overall Length:

Varies by wheelbase and bed length (e.g., ~220-240 inches)

Bed Length Options:

6.3 ft (short bed), 8.0 ft (long bed)

Weights

Curb Weight:

Approx. 4,500 - 5,500 lbs depending on configuration

Gross Vehicle Weight Rating Gvwr:

Ranges from approx. 6,300 lbs to 8,800 lbs depending on model and payload package

Towing Capacity:

Up to 9,000+ lbs depending on configuration, engine, axle ratio, and towing package

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

4-star rating (2002-2004 models)

NHTSA Frontal Impact Passenger:

4-star rating (2002-2004 models)

Active Features

Standard Anti-lock Braking System (ABS) on all wheels, often with rear-wheel sensing only on base models prior to 2003.

Traction Control:

Optional traction control system, especially on higher trims or with specific packages.

Passive Features

Airbags:

Standard front driver and passenger airbags. Side curtain airbags became available on later models.

Seatbelts:

Three-point seat belts with pretensioners.

💡 Technology Features

Infotainment

Audio Options:

Factory AM/FM/CD players, optional CD changer, and premium Infinity sound systems available.

Navigation:

Dealer-installed or aftermarket navigation systems were common; factory navigation was rare or limited for this period.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Parking Assist:

Optional rear parking assist sensors on some models.

Connectivity

Remote Keyless Entry:

Available on most trim levels.

Power Features:

Power windows, power door locks, and power mirrors were common options.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (consult manual for specifics).

Engine Air Filter:

Replace every 15,000-30,000 miles or as needed based on air quality.

Cabin Air Filter:

Replace every 15,000-30,000 miles or annually.

Spark Plugs:

30,000 miles for copper plugs, 100,000 miles for platinum/iridium plugs (engine dependent).

Fluid Specifications

Engine Oil 4.7L:

5W-30 (API Certified, meeting MS-6395 specification)

Engine Oil 5.7L Hemi:

5W-20 (API Certified, meeting MS-6395 specification)

Coolant:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, Blue (50/50 mix with distilled water)

Brake Fluid:

DOT 3 or DOT 4 brake fluid

Power Steering Fluid:

ATF+4 (Chrysler/Mopar specification)

Known Issues

Common Issue 1:

Cracked exhaust manifolds (especially 4.7L V8) due to heat cycling.

Common Issue 2:

Water pump leaks, particularly the plastic impeller models.

Common Issue 3:

Blend door actuator failures in the HVAC system, leading to improper temperature control.

Common Issue 4:

Electronic Throttle Control (ETC) issues on early HEMI models (often addressed by software updates).

Common Issue 5:

Front suspension wear (ball joints, tie rods) due to vehicle weight and workload.

📚 Vehicle History

Brand Heritage

Dodge Truck Legacy:

Dodge has a long history of building rugged and capable trucks dating back to the 1930s.

Model Evolution

Third Generation Debut:

The third generation of the Ram Truck was introduced for the 2002 model year, featuring a significantly revised exterior and interior design.

Design Philosophy:

The third generation continued the 'big rig' styling theme established by its predecessor but with more sculpted lines and improved aerodynamics.

Production

Manufacturing Location:

Saltillo, Mexico; Warren, Michigan; St. Louis, Missouri (assembly plants varied)

Platform Sharing:

Shared platform and many components with Heavy Duty Ram 2500/3500 models.

🏆 Awards & Recognition

Recognitions

Motor Trend Truck Of The Year:

Dodge Ram Truck was named Motor Trend's Truck of the Year for 2003.

Consumer Reports Ratings:

Ratings varied by model year and engine, but generally received average to above-average ratings for powertrain reliability, with some noted concerns in specific areas.

Certifications

Emissions Compliance:

Compliant with federal emissions standards for the respective model years.