Dodge Ram 2002 (2500-3500) Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Model Variant: 2500-3500 Year: 2002 Codes Platform: BR/BE Ram Truck 👋 Introduction Market Position Segment: Heavy-duty pickup truck Target Use: Work, towing, hauling, and general-purpose heavy-duty truck applications. Competitive Analysis Key Competitors: Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD. Key Features Vehicle Strengths: Robust construction, powerful engine options, high towing and payload capacities, proven reliability in heavy-duty applications. Manual Value Proposition: Provides essential, in-depth technical information for maintaining and repairing these robust vehicles, saving time and money on professional service. 📋 Manual Details Coverage Areas General Coverage: Comprehensive workshop service and repair Target Audience: Professional technicians and knowledgeable DIY enthusiasts Page Count Estimated Pages: 2000+ Manual Type Type: Workshop Service Repair Manual (WSRM) Language Language: English Format Format: Downloadable digital format (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: All engine types, including disassembly, inspection, assembly, and torque specifications. Engine Performance: Fuel delivery, ignition system, emission controls, cooling system, lubrication system. Transmission: Manual and automatic transmission repair, diagnosis, fluid specifications, and internal components. Drivetrain: Front and rear axles, differentials, driveshafts, U-joints, transfer case operation and repair. Suspension: Front and rear suspension systems, steering components, wheel alignment procedures. Brakes: Hydraulic brake system, ABS, parking brake, component replacement, bleeding procedures. Electrical System: Battery, charging system, starting system, lighting, instruments, power distribution, wiring diagrams. Body And Chassis: Body panels, doors, windows, interior trim, frame inspection and repair. HVAC: Heating, ventilation, and air conditioning system diagnosis and repair. Diagnostic Troubleshooting: Systematic diagnostic procedures, symptom-based troubleshooting charts, DTC (Diagnostic Trouble Code) interpretations. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and changes, belt and hose inspection/replacement. Component Removal Installation: Detailed, step-by-step instructions for removing and installing virtually all major and minor vehicle components. Rebuilding Procedures: Comprehensive instructions for rebuilding engines, transmissions, and other major assemblies. Wiring Diagrams: Full electrical system wiring diagrams with component locations and circuit descriptions. Technical Depth Depth: Extremely high. Covers everything from basic fluid checks to complete engine and transmission overhauls, including detailed specifications and tolerances. 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF with clear text and legible diagrams. Print Quality Printability: Printable pages, allowing for a physical copy if desired. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Option 1: 8.0L (488ci) V10 OHV 20-Valve (Triton) Engine Option 2: 5.9L (360ci) Magnum V8 OHV 16-Valve Engine Option 3: 5.9L (359ci) Cummins Turbo Diesel I6 OHV 24-Valve Performance V10 Horsepower: 310 hp @ 4000 rpm V10 Torque: 450 lb-ft @ 2400 rpm Magnum V8 Horsepower: 245 hp @ 4800 rpm Magnum V8 Torque: 335 lb-ft @ 3200 rpm Cummins Horsepower: 235 hp @ 2600 rpm (Standard), 275 hp @ 2600 rpm (High Output) Cummins Torque: 460 lb-ft @ 1400 rpm (Standard), 525 lb-ft @ 1400 rpm (High Output) Fuel System V10 Fuel Delivery: Electronic Multi-port Fuel Injection (MPI) Magnum V8 Fuel Delivery: Electronic Multi-port Fuel Injection (MPI) Cummins Fuel Delivery: Bosch High-Pressure Common Rail (HPCR) Direct Injection 🔧 Transmission Standard Transmission Option 1: NV4500 5-Speed Manual (for some diesel and V10 models) Optional Transmission Option 2: 47RE 4-Speed Automatic (for V8 and diesel models) Transmission Option 3: 48RE 4-Speed Automatic (heavy-duty diesel models) Features Overdrive: All automatic transmissions feature overdrive Transfer Case: 2-speed transfer case with electronic shift-on-the-fly (ESOF) or manual shift options. 📐 Dimensions Exterior Wheelbase 2500: Various (e.g., 134.5 in, 140.5 in, 160.5 in for Regular Cab, Quad Cab, and Long Bed configurations) Wheelbase 3500: Various (e.g., 134.5 in, 140.5 in, 160.5 in for Regular Cab, Quad Cab, and Long Bed configurations, including dually options) Weights Gvwr 2500: 8,800 lbs to 9,500 lbs (depending on configuration) Gvwr 3500: 9,500 lbs to 12,500 lbs (depending on configuration, including dually) Curb Weight: Varies significantly by engine, cab, and bed configuration (typically 6,000 - 7,500+ lbs) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: Varies by configuration, typically 3-star or 4-star. Higher center of gravity for heavy-duty trucks. Active Features ABS: Standard Anti-lock Braking System (ABS) on all wheels. Passive Features Airbags: Driver and front passenger airbags. Seatbelts: Three-point front and rear seat belts. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, with optional cassette and premium audio systems available. Driver Assistance Cruise Control: Standard cruise control on most models. Connectivity Trailer Towing Prep: Wiring harnesses and trailer brake controller provisions often available from the factory. 🔧 Maintenance Service Intervals Oil Change Gasoline: Every 3,000 - 7,500 miles, or 6 months, depending on driving conditions and oil type (consult manual for specifics). Oil Change Diesel: Every 7,500 - 15,000 miles, or 12 months, depending on oil and filter quality, and driving conditions. Fuel Filter Diesel: Recommended every 15,000 miles or annually. Transmission Fluid Auto: Inspect every 30,000 miles, change every 60,000 - 100,000 miles, depending...
Oil changes, filter replacements, fluid checks and changes, belt and hose inspection/replacement.
Component Removal Installation:
Detailed, step-by-step instructions for removing and installing virtually all major and minor vehicle components.
Rebuilding Procedures:
Comprehensive instructions for rebuilding engines, transmissions, and other major assemblies.
Wiring Diagrams:
Full electrical system wiring diagrams with component locations and circuit descriptions.
Technical Depth
Depth:
Extremely high. Covers everything from basic fluid checks to complete engine and transmission overhauls, including detailed specifications and tolerances.
📊 Manual Specifications
File Format
Quality:
High-resolution, searchable PDF with clear text and legible diagrams.
Print Quality
Printability:
Printable pages, allowing for a physical copy if desired.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Option 1:
8.0L (488ci) V10 OHV 20-Valve (Triton)
Engine Option 2:
5.9L (360ci) Magnum V8 OHV 16-Valve
Engine Option 3:
5.9L (359ci) Cummins Turbo Diesel I6 OHV 24-Valve
Performance
V10 Horsepower:
310 hp @ 4000 rpm
V10 Torque:
450 lb-ft @ 2400 rpm
Magnum V8 Horsepower:
245 hp @ 4800 rpm
Magnum V8 Torque:
335 lb-ft @ 3200 rpm
Cummins Horsepower:
235 hp @ 2600 rpm (Standard), 275 hp @ 2600 rpm (High Output)
Chrysler HOAT (Hybrid Organic Acid Technology) Extended Life Antifreeze/Coolant, typically Mopar part # 05013457AA or equivalent.
Known Issues
Cummins Injection Pump Failures:
Early models could experience VP44 injection pump failures due to low fuel pressure or contaminated fuel.
Nv4500 2Nd Gear ப்புகள்:
Some NV4500 transmissions are known for the '2nd gear pop-out' issue, often related to worn synchronizers or linkage.
V10 Oil Consumption:
Some V10 engines may exhibit higher oil consumption, particularly with high mileage.
Automatic Transmission Overheating:
Heavy towing can lead to automatic transmission overheating, necessitating auxiliary coolers.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long-standing history of producing durable and capable trucks, with the Ram nameplate becoming synonymous with strength and utility.
Model Evolution
Third Generation Ram:
The 2002 model year is part of the third generation (2002-2008) of the Dodge Ram, which introduced a completely redesigned chassis and body, offering improved aerodynamics and styling.
Production
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan, USA.
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
While specific awards vary, the Ram line has consistently been recognized for its capability and design in the heavy-duty segment.
Ratings
Consumer Reports Reliability:
Reliability ratings for this generation can vary; the Cummins diesel is generally considered very robust.