Dodge Ram Truck 2500 3500 2002 Service Repair Manual
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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck 2500 / 3500 Year: 2002 👋 Introduction Market Position Segment: Heavy-Duty Pickup Truck Target Audience: Owners and technicians performing maintenance and repairs on 2002 Dodge Ram 2500/3500 trucks Competitive Analysis Competition: Ford Super Duty, Chevrolet Silverado HD, GMC Sierra HD Key Features Vehicle Appeal: Robust construction, powerful engine options (especially the Cummins diesel), towing and hauling capability Manual Value Proposition: Provides the essential technical data required for DIY repairs and professional service, saving time and money. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: All gasoline and diesel engines (5.9L Magnum V8, 8.0L V10, 5.9L Cummins Turbo Diesel) Transmission Systems: Manual and automatic transmissions (NV4500, NV5600, 47RE, 48RE) Chassis Systems: Frame, suspension (front and rear), steering, brakes (front and rear disc, ABS), driveline, axles, exhaust Electrical Systems: Wiring diagrams, battery, charging system, starting system, lighting, instrument cluster, body control module, comfort & convenience systems Body And Interior: Body panels, doors, windows, seats, interior trim, HVAC system, exterior trim Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication Diagnostics: Troubleshooting guides, symptom-based diagnostics, fault code interpretation (OBD-II) Repairs: Component removal and installation, engine overhaul, transmission repair, brake system service, suspension component replacement Adjustments: Alignment specifications, brake adjustments, clutch adjustments Special Tools: Identification and usage of special tools required for specific repairs Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) Diagnostic Capabilities: Detailed diagnostic flowcharts and procedures for identifying and resolving issues Electrical Schematics: Complete wiring diagrams for all electrical systems, including component locations Torque Specifications: Precise torque values for all fasteners and critical components Tolerances: Engine component tolerances for rebuilds and critical measurements 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval Printability: Printable pages for on-site reference Resolution: High-resolution images and diagrams Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine 1 Name: 5.9L Magnum V8 (360 ci) Engine 1 Type: Overhead Valve (OHV), V-Configuration Engine 1 Bore X Stroke: 4.00 in x 3.58 in (101.6 mm x 90.9 mm) Engine 1 Compression Ratio: 8.7:1 Engine 1 Horsepower: 235 hp @ 4000 rpm (approx.) Engine 1 Torque: 330 lb-ft @ 3200 rpm (approx.) Secondary Engine Engine 2 Name: 8.0L V10 Magnum (488 ci) Engine 2 Type: Overhead Valve (OHV), V-Configuration Engine 2 Horsepower: 305 hp @ 4000 rpm (approx.) Engine 2 Torque: 450 lb-ft @ 3200 rpm (approx.) Diesel Engine Engine 3 Name: 5.9L Cummins Turbo Diesel (359 ci) Engine 3 Type: Inline 6-cylinder, Turbocharged, Overhead Valve (OHV) Engine 3 Horsepower: 235 hp @ 2400 rpm (approx.) Engine 3 Torque: 460 lb-ft @ 1400 rpm (approx.) Fuel System Gasoline Fuel System: Multi-point Fuel Injection (MPI) Diesel Fuel System: Direct Injection, Bosch VP44 Injection Pump 🔧 Transmission Standard Transmission 1 Type: 5-Speed Manual (NV4500) Optional Transmission 2 Type: 6-Speed Manual (NV5600 - Heavy Duty) Transmission 3 Type: 4-Speed Automatic (47RE) Transmission 4 Type: 4-Speed Automatic (48RE - with Diesel) Features Transfer Case: Part-time 4WD system with NP241DHD transfer case 📐 Dimensions Exterior Wheelbase Std: 134.1 inches (3406 mm) Wheelbase Long: 154.1 inches (3914 mm) Weights Gvwr 2500: 8,800 - 9,500 lbs (3992 - 4309 kg) depending on configuration Gvwr 3500: 9,700 - 11,500 lbs (4399 - 5216 kg) depending on configuration Cargo Bed Lengths: 6.3 ft (short bed), 8.0 ft (long bed) 🛡️ Safety Features Ratings NHTSA Front Driver Side Impact: Not Rated (Vehicle year predates standardized NHTSA side impact ratings) IIHS Side Impact: Acceptable (for models with side airbags, if equipped) Active Features ABS: Standard Anti-lock Braking System (ABS) on all wheels Traction Control: Optional Traction Control System Passive Features Airbags: Driver and front passenger airbags. Optional side curtain airbags on some trims. 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, optional premium audio, and cassette player. Navigation: Not available from the factory. Driver Assistance Cruise Control: Standard on most trims. Trailer Brake Controller: Optional integrated trailer brake controller available on some models. Connectivity Phone Integration: Not available. 🔧 Maintenance Service Intervals Oil Change Interval Gas: Every 7,500 miles or 6 months, whichever comes first (synthetic oil recommended) Oil Change Interval Diesel: Every 7,500 miles or 6 months, whichever comes first (or consult manual for severe conditions) Engine Air Filter Replacement: Inspect every 15,000 miles, replace as needed or every 30,000 miles Fuel Filter Replacement Diesel: Every 15,000 miles Fluid Specifications Engine Oil Gas Spec: API SJ or higher, SAE 5W-30 or 10W-30 (refer to manual for specific engine) Engine Oil Diesel Spec: API CI-4 or ACEA E3/E4, SAE 15W-40 (e.g., Cummins CES 20076/7) Transmission Fluid Manual: MS-9224, SAE 75W-90 synthetic (NV4500, NV5600) Transmission Fluid Auto: MS-9224, ATF+4 (47RE, 48RE)...
8,800 - 9,500 lbs (3992 - 4309 kg) depending on configuration
Gvwr 3500:
9,700 - 11,500 lbs (4399 - 5216 kg) depending on configuration
Cargo
Bed Lengths:
6.3 ft (short bed), 8.0 ft (long bed)
🛡️ Safety Features
Ratings
NHTSA Front Driver Side Impact:
Not Rated (Vehicle year predates standardized NHTSA side impact ratings)
IIHS Side Impact:
Acceptable (for models with side airbags, if equipped)
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels
Traction Control:
Optional Traction Control System
Passive Features
Airbags:
Driver and front passenger airbags. Optional side curtain airbags on some trims.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional premium audio, and cassette player.
Navigation:
Not available from the factory.
Driver Assistance
Cruise Control:
Standard on most trims.
Trailer Brake Controller:
Optional integrated trailer brake controller available on some models.
Connectivity
Phone Integration:
Not available.
🔧 Maintenance
Service Intervals
Oil Change Interval Gas:
Every 7,500 miles or 6 months, whichever comes first (synthetic oil recommended)
Oil Change Interval Diesel:
Every 7,500 miles or 6 months, whichever comes first (or consult manual for severe conditions)
Engine Air Filter Replacement:
Inspect every 15,000 miles, replace as needed or every 30,000 miles
Fuel Filter Replacement Diesel:
Every 15,000 miles
Fluid Specifications
Engine Oil Gas Spec:
API SJ or higher, SAE 5W-30 or 10W-30 (refer to manual for specific engine)
Engine Oil Diesel Spec:
API CI-4 or ACEA E3/E4, SAE 15W-40 (e.g., Cummins CES 20076/7)
Transmission Fluid Manual:
MS-9224, SAE 75W-90 synthetic (NV4500, NV5600)
Transmission Fluid Auto:
MS-9224, ATF+4 (47RE, 48RE)
Coolant Spec:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, 50/50 mix with distilled water
Known Issues
Diesel Injector Pump:
VP44 injection pump failures can occur due to fuel quality or lift pump issues.
Automatic Transmission:
47RE/48RE transmissions can experience torque converter issues or solenoid problems with high mileage or heavy use.
Front Suspension:
Ball joint and track bar wear are common due to the heavy nature of the truck and towing.
📚 Vehicle History
Brand Heritage
Dodge Truck History:
Dodge has a long history of producing robust and capable trucks, with the Ram line evolving into a distinct brand.
Model Evolution
Third Generation Ram:
The 2002 model is part of the third generation of Ram trucks (2002-2008), which introduced a significant redesign with improved aerodynamics, a more refined interior, and enhanced safety features.
Production
Production Years:
2002-2008 (Third Generation)
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
While not specific to the 2002 model, Dodge Ram trucks have historically received various 'Truck of the Year' awards from automotive publications.
Ratings
Customer Satisfaction:
Generally well-regarded for their capability and durability, particularly the Cummins diesel models, although some interior and electrical component complaints exist.