Dodge Ram Truck 3500 Series 2002 Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck 3500 Series Year: 2002 Product Type: Service Repair Manual 👋 Introduction Market Position Market Segment: Heavy-duty pickup truck, designed for commercial, towing, and heavy hauling applications. Competitive Analysis Competitors: Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD. Key Features Vehicle Attributes: Robust chassis, powerful engine options, high towing and payload capacities, suitable for demanding tasks. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive vehicle service, repair, and maintenance Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Factory Authorized Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: All gasoline and diesel engine variants, including troubleshooting, diagnostics, disassembly, assembly, and specifications. Transmission: Manual and automatic transmissions, including NV4500, NV5600, and 48RE/47RE, with repair procedures and torque specifications. Drivetrain: Four-wheel drive systems (NV241DHD, NV273DHD), transfer case, axles, differentials, driveshafts, and CV joints. Brakes: Front and rear brake systems (disc, drum), ABS, hydraulic systems, parking brake, and related components. Suspension Steering: Front and rear suspension, steering components, power steering system, alignment specifications, and wheel bearings. Electrical Electronics: Complete electrical schematics, wiring diagrams, battery, charging system, starting system, lighting, instrument cluster, power accessories, and control modules. HVAC: Heating, ventilation, and air conditioning system diagnosis, repair, and refrigerant handling. Fuel System: Fuel tank, fuel pump, fuel injectors, diesel fuel system (if applicable), and emission controls. Cooling System: Radiator, water pump, thermostat, coolant specifications, and cooling fan operation. Exhaust System: Exhaust manifold, catalytic converter, mufflers, and emissions control systems. Body Chassis: Body panels, doors, windows, interior trim, bumpers, frame, and corrosion protection. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks, and tire rotation. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, and common fault identification. Repair: Detailed step-by-step repair procedures for all major vehicle systems, including torque specifications and special tool requirements. Diagnostics: OBD-II diagnostic trouble codes (DTCs), sensor data interpretation, and diagnostic tool usage. Disassembly Assembly: Complete instructions for component removal, reassembly, and adjustment for all major systems. Technical Depth Technical Depth: Comprehensive, covering from basic preventative maintenance to complete engine and transmission overhauls, electrical system diagnostics, and body repair. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval. Printability: Printable pages for workshop use. Print Quality Image Resolution: High-resolution diagrams and illustrations. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Options: 8.0L V10 Triton gasoline, 5.9L Cummins Turbo Diesel. Performance 8.0L V10 Horsepower: 305 hp @ 4000 rpm 8.0L V10 Torque: 450 lb-ft @ 3200 rpm 5.9L Cummins Turbo Diesel Horsepower: 235 hp @ 2600 rpm (depending on configuration) 5.9L Cummins Turbo Diesel Torque: 460 lb-ft @ 1400 rpm (depending on configuration) Fuel System Gasoline Fuel System: Multi-point fuel injection Diesel Fuel System: High-pressure common rail (later models) or direct injection with Bosch VP44 injection pump (early 5.9L variants). 🔧 Transmission Standard Standard Transmission: NV4500 5-speed manual transmission (common with diesel). Optional Optional Transmission Automatic: 47RE or 48RE 4-speed automatic transmission (common with V10 and diesel). Optional Transmission Manual: NV5600 6-speed manual transmission (available on higher trims). Features Transmission Fluid Spec Auto: ATF+4 (MS-9602) or equivalent. Transmission Fluid Spec Manual: NV4500: Manual Transmission Fluid (MTF) - consult manual for specific viscosity. NV5600: Manual Transmission Fluid (MTF) - consult manual for specific viscosity. 📐 Dimensions Exterior Wheelbase Options: 134.2 inches (standard cab), 154.6 inches (quad cab 4x2), 159.0 inches (quad cab 4x4), 177.3 inches (long bed). Weights Gvwr: Over 10,000 lbs, varying by configuration (e.g., up to 11,500 lbs or higher). Curb Weight: Approx. 6,000 - 7,000 lbs depending on configuration. Towing Capacity: Up to 13,000 - 14,000 lbs (with proper equipment and configuration). Payload Capacity: Up to 4,000 - 5,000 lbs (depending on configuration). 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4-star (2002 model year review). NHTSA Frontal Impact Passenger: 4-star (2002 model year review). Active Features ABS: Standard Anti-lock Braking System (ABS) on all wheels. Passive Features Airbags: Driver and passenger front airbags. Seatbelts: Three-point front and rear seat belts. 💡 Technology Features Infotainment Infotainment System: Basic AM/FM radio with CD player, optional cassette player, available premium audio systems. Driver Assistance Driver Assistance Features: Limited by modern standards; primarily relies on ABS for braking assistance. Connectivity Connectivity Options: No integrated Bluetooth or advanced connectivity features. Optional trailer brake controller. 🔧 Maintenance Service Intervals Oil Change Interval Gasoline: Every 3,000 - 7,500 miles or 6 months, depending on driving conditions and oil type (consult manual for specific recommendations). Oil Change Interval Diesel: Every 7,500 - 15,000 miles or 6 months (depending on oil quality and driving conditions, with Cummins often recommending 15,000 miles with synthetic oil). Engine Air Filter Replacement: Every 15,000 - 30,000 miles or as needed based on inspections. Fuel Filter Replacement Diesel: Every...
Diagnostic flowcharts, symptom-based troubleshooting guides, and common fault identification.
Repair:
Detailed step-by-step repair procedures for all major vehicle systems, including torque specifications and special tool requirements.
Diagnostics:
OBD-II diagnostic trouble codes (DTCs), sensor data interpretation, and diagnostic tool usage.
Disassembly Assembly:
Complete instructions for component removal, reassembly, and adjustment for all major systems.
Technical Depth
Technical Depth:
Comprehensive, covering from basic preventative maintenance to complete engine and transmission overhauls, electrical system diagnostics, and body repair.
Over 10,000 lbs, varying by configuration (e.g., up to 11,500 lbs or higher).
Curb Weight:
Approx. 6,000 - 7,000 lbs depending on configuration.
Towing Capacity:
Up to 13,000 - 14,000 lbs (with proper equipment and configuration).
Payload Capacity:
Up to 4,000 - 5,000 lbs (depending on configuration).
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4-star (2002 model year review).
NHTSA Frontal Impact Passenger:
4-star (2002 model year review).
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Passive Features
Airbags:
Driver and passenger front airbags.
Seatbelts:
Three-point front and rear seat belts.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio with CD player, optional cassette player, available premium audio systems.
Driver Assistance
Driver Assistance Features:
Limited by modern standards; primarily relies on ABS for braking assistance.
Connectivity
Connectivity Options:
No integrated Bluetooth or advanced connectivity features. Optional trailer brake controller.
🔧 Maintenance
Service Intervals
Oil Change Interval Gasoline:
Every 3,000 - 7,500 miles or 6 months, depending on driving conditions and oil type (consult manual for specific recommendations).
Oil Change Interval Diesel:
Every 7,500 - 15,000 miles or 6 months (depending on oil quality and driving conditions, with Cummins often recommending 15,000 miles with synthetic oil).
Engine Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on inspections.
Fuel Filter Replacement Diesel:
Every 15,000 - 30,000 miles (crucial for diesel longevity).
Fluid Specifications
Engine Oil Spec Gasoline:
API SN/SP, ILSAC GF-6A compliant. Viscosity: 5W-30 (preferred for V10).
Engine Oil Spec Diesel:
API CJ-4/CK-4 or newer, SAE 15W-40 (conventional) or 5W-40 (synthetic for colder climates/extended intervals).
Coolant Spec:
Mopar OAT (Organic Additive Technology) or HOAT (Hybrid Organic Additive Technology) Antifreeze/Coolant, typically a long-life pink or orange formulation.
Known Issues
Common Issues Diesel:
VP44 injection pump failures (if equipped with older 5.9L), injector issues, vacuum pump leaks, potential for cylinder head lifting on high-output tunes.
Common Issues Gasoline:
Spark plug issues (if not replaced on schedule), occasional transmission solenoid issues, exhaust manifold leaks.
Common Issues General:
Rust on body panels (especially around wheel wells and cab corners), rear axle seal leaks, ball joint wear, HVAC blend door actuator failures.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long-standing history in the truck market, known for robust and capable vehicles, culminating in the development of the Ram brand in 1994.
Model Evolution
Third Generation Ram:
The 2002 model year falls within the third generation of the Dodge Ram (DN platform, 2002-2008), which introduced significant chassis and styling updates, including a more integrated frame and suspension design.
Production
Manufacturing Location:
Saltillo Truck Assembly, Mexico.
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
While specific awards for the 2002 model year might vary, Dodge Ram trucks consistently received accolades for their styling, capability, and value within the heavy-duty segment.