Segment:
Heavy Duty Pickup Truck
Target Market:
Commercial Users, Fleet Operators, Towing Enthusiasts, Heavy Haulers
Key Competitors:
Ford Super Duty F-250/F-350, Chevrolet Silverado 2500HD/3500HD, GMC Sierra 2500HD/3500HD
Vehicle Highlights:
Robust Frame, Powerful Cummins Diesel Option, High Towing and Payload Capacities, Solid Axle Front Suspension
Manual Value Proposition:
Comprehensive diagnostic and repair procedures for optimal vehicle maintenance and longevity.
Primary Coverage:
Body, Chassis, Electrical, Diesel Engine
Secondary Coverage:
HVAC, Suspension, Steering, Brakes, Drivetrain, Powertrain
Type:
Service Shop Manual / Workshop Manual
Engine Systems:
Cummins 5.9L 24V Turbo Diesel (ISB), Cooling System, Fuel System (Injection Pump, Injectors, Lines), Exhaust System, Lubrication System, Ignition (Glow Plugs), Air Intake System
Transmission Systems:
NV5600 6-Speed Manual, NV4500 5-Speed Manual, 47RE 4-Speed Automatic, 48RE 4-Speed Automatic, Transfer Case (NV241, NV271, NV273)
Chassis Systems:
Frame, Front Suspension (Solid Axle, Leaf Springs), Rear Suspension (Solid Axle, Leaf Springs), Steering System (Power Steering), Brake System (Front Disc, Rear Disc/Drum), Wheel Bearings, Axles (Front and Rear)
Electrical Systems:
Battery, Starting System, Charging System, Lighting System, Instrument Panel, Body Control Module (BCM), Powertrain Control Module (PCM), HVAC Controls, Power Accessories (Windows, Locks), Audio System, Cruise Control, Trailer Towing Harness
Body Systems:
Exterior Panels (Doors, Hood, Tailgate), Interior Trim, Seats, Glass, Mirrors, Bumpers, Bed Options (Standard, Long)
Diagnostic Procedures:
Troubleshooting Charts, DTC (Diagnostic Trouble Code) Interpretation, Component Testing, Circuit Analysis
Repair Procedures:
Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake Service, Electrical Component Repair, Body Panel Repair, HVAC System Repair
Maintenance Procedures:
Scheduled Maintenance Intervals, Fluid Changes, Filter Replacements, Lubrication Points, Belt Adjustments/Replacement
Technical Specifications:
Torque Specifications, Alignment Specifications, Fuel Pressures, Electrical Voltages, Component Dimensions
Wiring Diagrams:
Comprehensive, System-Specific, Color-Coded Diagrams
Depth Level:
Expert-Level Repair and Diagnostic Information
Target Audience:
Professional Technicians, Serious DIY Mechanics
Engine Code Diesel:
ISB (Cummins 5.9L 24-Valve Turbo Diesel)
Engine Displacement Diesel:
359 cu in (5.9 Liters)
Engine Configuration Diesel:
Inline 6-Cylinder, Turbocharged, Intercooled
Horsepower Diesel 2002:
235 hp @ 2,300 RPM (with HO option, earlier models may vary)
Torque Diesel 2002:
460 lb-ft @ 1,400 RPM (with HO option, earlier models may vary)
Injection Type Diesel:
High-Pressure Common Rail (HPCR) or Rotary Injection Pump (VE/VP)
Transmission Type Standard:
Manual (NV4500 5-Speed or NV5600 6-Speed)
Transmission Type Optional:
Automatic (47RE / 48RE 4-Speed)
Transfer Case Options:
Part-Time 2WD/4WD (NV241DHD, NV271D, NV273D)
Fluid Type Manual:
NV5600: Mopar Manual Transmission Lubricant (or equivalent GL-3/GL-4) / NV4500: SAE 5W-30 Synthetic
Fluid Type Automatic:
Mopar ATF+4 (MS-9602)
Wheelbase Regular Cab:
134.5 inches (3,416 mm)
Wheelbase Extended Cab:
160.5 inches (4,077 mm)
Wheelbase Crew Cab:
160.5 inches (4,077 mm)
Bed Length Standard:
8.0 feet (2.4 m)
Bed Length Long:
9.25 feet (2.8 m)
Gvwr 2500:
Up to 9,000 lbs (4,082 kg)
Gvwr 3500:
Up to 11,500 lbs (5,216 kg)
Gcwr Diesel:
Up to 23,000 lbs (10,433 kg) (with proper towing package)
NHTSA Frontal Driver:
Not Rated (N/A) for 2002 model year trucks of this class.
NHTSA Frontal Passenger:
Not Rated (N/A) for 2002 model year trucks of this class.
IIHS Frontal Offset:
Good (for similar year Dodge Ram models tested)
ABS:
Standard (4-wheel disc/rear drum configurations)
Traction Control:
Optional
Airbags:
Driver and Passenger Front Airbags
Seatbelts:
3-point front and rear seatbelts
Audio System Options:
AM/FM Cassette/CD Player, Premium Audio System Available
Navigation:
Not available from factory
Cruise Control:
Standard or Optional depending on trim
Trailer Brake Controller:
Optional factory-installed or aftermarket
Auxiliary Inputs:
Typically not present on base models; aftermarket solutions available.
Oil Change Diesel:
Every 7,500 miles or 6 months, or based on oil condition monitoring.
Fuel Filter Diesel:
Every 15,000 miles or 12 months.
Transmission Fluid Auto:
Every 30,000 to 60,000 miles, depending on usage and fluid condition.
Coolant Flush Diesel:
Every 30,000 miles or 24 months (with OAT coolant).
Engine Oil Diesel:
Cummins CES 20081 approved 15W-40 Diesel Engine Oil
Engine Oil Capacity Diesel:
11 Quarts (10.4 Liters)
Coolant Type:
OAT (Organic Acid Technology) / Mopar OAT, or equivalent
Diesel Injection Pump:
VP44 injection pump failure (especially on earlier models in this generation) due to fuel quality or lifting pump issues.
Automatic Transmission:
Torque converter shudder, governor pressure issues in the 47RE/48RE transmission.
Suspension Components:
Wear on ball joints and tie rod ends due to heavy-duty use.
Electrical Systems:
Intermittent issues with instrument cluster, HVAC controls.
Dodge Trucks:
Dodge has a long-standing reputation for building tough and capable trucks.
Third Generation Ram:
The 2002 Ram marked the beginning of the third generation (2002-2008), featuring a significant redesign.
Key Redesign Elements:
New interior, more aerodynamic exterior, improved chassis and suspension components, introduction of the 48RE transmission.
Manufacturing Plant:
Saltillo, Mexico; Warren, Michigan, USA
