🏷️ Basic Information

Make:

Dodge

Model:

Ram Truck 2500 / 3500

Year:

2002

Market Segment:

Heavy-Duty Pickup Truck

👋 Introduction

Positioning:

The Dodge Ram 2500/3500 series for 2002 was a significant player in the heavy-duty truck segment, known for its robust build, towing capabilities, and powerful engine options. It competed directly with offerings from Ford (Super Duty F-250/F-350) and Chevrolet/GMC (Silverado/Sierra 2500/3500).

Key Competitors:

Ford F-250 Super Duty, Ford F-350 Super Duty, Chevrolet Silverado 2500HD, Chevrolet Silverado 3500, GMC Sierra 2500HD, GMC Sierra 3500.

Towing Capacity:

Designed for heavy towing and hauling with robust frames and powertrain options.

Engine Options:

Offered powerful V8 gasoline and inline-6 diesel engines, a hallmark of its heavy-duty credentials.

Durability:

Built with heavy-duty components to withstand demanding work and commercial use.

📋 Manual Details

Diagnostic Codes:

Yes, includes extensive OBD-II diagnostic trouble codes (DTCs) and troubleshooting procedures.

Component Coverage:

All major mechanical and electrical components, bodywork, and chassis systems.

Engine Coverage:

Covers all engine variants offered for the 2002 model year.

Transmission Coverage:

Manual and automatic transmission overhauls and diagnostics.

Chassis Coverage:

Suspension, steering, brakes, driveline, and exhaust systems.

Electrical Coverage:

Wiring diagrams, component testing, and troubleshooting for all electrical systems including HVAC, lighting, and body control modules.

Total Pages:

Hundreds of pages (specific count not provided, but indicative of a comprehensive factory manual).

Type:

Workshop Service Repair Manual (Factory OEM)

Language:

English

Format:

Downloadable Digital Format (typically PDF)

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, inspection, repair, and reassembly for all engine types.

Engine Performance:

Fuel delivery, ignition system, emission control systems, engine diagnostics, and tuning.

Transmission Mechanical:

Detailed procedures for manual and automatic transmission repair, clutch service, and driveline components (driveshafts, U-joints).

Brake System:

Brake component diagnosis, repair, replacement (pads, rotors, calipers, lines, master cylinder), ABS system troubleshooting.

Suspension Steering:

Front and rear suspension component inspection and replacement (shocks, struts, control arms, ball joints, springs), steering gear and linkage repair.

Electrical Controls:

Body control modules (BCM), power windows, door locks, interior and exterior lighting, horn, wiper systems.

HVAC System:

Air conditioning, heating, ventilation system diagnosis, refrigerant handling, component replacement (compressor, condenser, evaporator).

Body And Frame:

Body panel repair, door and latch mechanisms, interior trim, exterior trim, frame inspection and repair.

Cooling System:

Radiator, cooling fan, thermostat, water pump, coolant fluid specifications, and leak detection.

Fuel System:

Fuel pump, fuel filter, injectors, fuel lines, fuel tank service, and pressure testing.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, pipes, and hangers replacement and repair.

Charging Starting:

Alternator, battery, starter motor testing and replacement.

Routine Maintenance:

Oil changes, filter replacements, fluid checks, tire rotations, belt inspections, spark plug replacement.

Troubleshooting Diagnostics:

Systematic diagnostic procedures for common and uncommon drivability issues, electrical faults, and mechanical failures.

Component Replacement:

Step-by-step instructions for replacing virtually every component on the vehicle.

Rebuilding Overhauls:

Detailed overhaul procedures for engines, transmissions, and differentials.

Special Tools:

Lists and descriptions of necessary special tools for specific procedures.

Torque Specifications:

Precise torque values for critical fasteners across all systems.

Wiring Diagrams:

Comprehensive electrical wiring schematics for all vehicle systems.

Depth:

Comprehensive factory-level coverage, suitable for professional technicians and advanced DIY mechanics. Includes detailed diagnostics, repair procedures, and specifications for complete overhauls.

📊 Manual Specifications

Format:

Digital Download (Likely PDF)

Searchability:

Typically searchable text within PDF format, allowing quick access to information.

Quality:

High-quality digital reproduction of original factory documentation, suitable for printing.

Type:

Not applicable for digital download. If printed, would be professional binding.

Type:

Not applicable for digital download. Original manuals typically printed on durable paper stock.

⚙️ Engine Specifications

Gasoline Engine 1:

8.0L OHV V10 (488 cubic inch), Magnum Series

Gasoline Engine 1 Hp:

305 hp @ 4000 rpm

Gasoline Engine 1 Torque:

450 lb-ft @ 3200 rpm

Gasoline Engine 2:

5.9L OHV V8 (360 cubic inch), Magnum Series

Gasoline Engine 2 Hp:

245 hp @ 4000 rpm

Gasoline Engine 2 Torque:

345 lb-ft @ 3200 rpm

Diesel Engine 1:

5.9L Cummins I6 Turbo Diesel (359 cubic inch)

Diesel Engine 1 Hp:

235 hp @ 2600 rpm (approximate, varied by tune)

Diesel Engine 1 Torque:

460 lb-ft @ 1400 rpm (approximate, varied by tune)

Gasoline Fuel System:

Multi-point Fuel Injection (MPI)

Diesel Fuel System:

Direct Injection, Bosch VP44 Injection Pump (for most 2002 models)

Cooling Capacity:

Approximately 20-25 quarts (V10/Cummins), 16-18 quarts (V8 gasoline), depending on specific configuration.

🔧 Transmission

Manual Transmission:

NV4500 5-speed manual (common with diesel and V10 engines)

Automatic Transmission 1:

48RE 4-speed Automatic (common with diesel and V10 engines)

Automatic Transmission 2:

47RE 4-speed Automatic (common with V8 gasoline engines)

Transfer Case:

Part-time 4WD system with a 2-speed transfer case (NV241 or NV271 depending on configuration).

48Re Fluid:

Chrysler ATF+4 (MS-9602) or equivalent.

Nv4500 Fluid:

GL-3 or GL-4 rated manual transmission fluid, often a 5W-30 or 75W-90 synthetic.

📐 Dimensions

Wheelbase Std:

134.5 inches (standard cab, short bed)

Wheelbase Long:

140.5 inches (standard cab, long bed), 160.5 inches (crew cab, long bed)

Overall Length:

Varies by configuration, typically 229-261 inches.

Overall Width:

Approx. 79.8 inches (without mirrors)

Overall Height:

Approx. 76.9 inches

Bed Length Short:

6.3 feet

Bed Length Long:

8.0 feet

Curb Weight Approx:

5,800 - 7,500 lbs (depending on configuration and powertrain)

Gvwr:

Ranges from 8,800 lbs (2500) to 10,000+ lbs (3500)

🛡️ Safety Features

NHTSA Side Impact:

Not typically rated by NHTSA for side impact at this time due to vehicle type and era. Focus was on front impact and rollover.

Rollover Resistance:

Rated for rollover resistance, with higher ratings generally achieved by 4WD models due to lower center of gravity.

ABS:

Standard Anti-lock Braking System (ABS) on all wheels.

Trailer Brake Controller:

Available factory-installed trailer brake controller (integrated into dash).

Airbags:

Driver and passenger front airbags.

Seatbelts:

Three-point height-adjustable front seat belts; shoulder belts in rear (if equipped).

💡 Technology Features

Audio System:

Factory AM/FM/Cassette or AM/FM/CD players, optional premium sound systems.

Navigation:

No factory integrated navigation systems available for this model year.

Cruise Control:

Standard cruise control system.

Parking Assist:

No factory parking assist sensors or cameras available.

Auxiliary Input:

No factory auxiliary audio input jacks or USB ports.

🔧 Maintenance

Oil Change Gasoline:

Every 3,000-5,000 miles or 3-6 months, depending on driving conditions (severe vs. normal).

Oil Change Diesel:

Every 5,000-7,500 miles or 6 months for Cummins Diesel, using appropriate diesel-specific oil.

Transmission Fluid Auto:

Every 30,000-60,000 miles, or as specified by severe duty use.

Transmission Fluid Manual:

Inspect every 30,000 miles, change typically at 60,000-100,000 miles.

Coolant Flush:

Every 30,000-50,000 miles or 2-3 years.

Engine Oil Gasoline:

API Service SN or SP, SAE 5W-30 (preferred for V10 and 360 V8) or 10W-30 depending on ambient temperature.

Engine Oil Diesel:

API Service CI-4 or CK-4 (or earlier suitable spec like CH-4), SAE 15W-40 (preferred for Cummins).

Coolant Type:

Ethylene Glycol based, meeting Chrysler MS-7170 specification (typically a green coolant).

Brake Fluid:

DOT 3 or DOT 4.

Vp44 Pump Diesel:

The Bosch VP44 injection pump is known for potential failure, often exacerbated by low fuel pressure or contaminated fuel. The manual will detail testing and replacement procedures.

Automatic Transmission Overheating:

Older 47RE/48RE transmissions can overheat under heavy towing. Manual will cover upgrades like auxiliary coolers.

Power Steering Pump Leaks:

Common on many vehicles of this era, the manual provides diagnostic steps and replacement instructions.

Radiator Corrosion Diesel:

Diesel models can sometimes experience radiator corrosion or leaks over time. Manual covers inspection and replacement.

📚 Vehicle History

Dodge Trucks:

Dodge has a long history of producing trucks, dating back to the early 20th century, establishing a reputation for ruggedness and utility.

Second Generation Ram:

The 2002 model falls within the second generation (1994-2001) or early third generation (2002-2008) depending on the specific release phase of the update. This generation saw significant updates in styling, powertrain, and interior comfort.

Manufacturing Location:

Saltillo Truck Assembly Plant, Mexico, and Warren Truck Assembly Plant, Michigan, USA.

Production Run:

The second generation Ram trucks were produced from 1994 to 2001, with a significant refresh in 1998. The 2002 model year marked the beginning of the third generation, which brought a more distinctive styling and further powertrain enhancements.

🏆 Awards & Recognition

Diesel Engine Award:

The Cummins 5.9L inline-6 turbo-diesel engine consistently received high marks for reliability and torque, often cited as a benchmark in the segment.

Towing Leader:

The Ram 2500/3500 series was frequently recognized for its competitive towing and hauling capabilities within its class.

Emissions Compliance:

Vehicles are designed to meet EPA emissions standards for the model year.