🏷️ Basic Information

Make:

Dodge

Model:

Ram 2500 / 3500

Year:

2002

Chassis Code:

DR (Second Generation Ram Pickup)

👋 Introduction

Segment:

Heavy-duty pickup truck segment, known for towing, hauling, and off-road capability.

Competitors 2002:

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

Vehicle Strengths:

Renowned for its robust powertrain options, particularly the Cummins turbodiesel; strong towing and payload capacities; durable chassis and suspension; straightforward mechanical design.

Manual Value Proposition:

Provides authoritative, factory-level repair and maintenance information for owners and independent repair shops, ensuring accurate and efficient servicing of these heavy-duty vehicles.

📋 Manual Details

Engines Covered:

5.9L OHV V8 Magnum (360 ci), 5.9L L6 OHV Cummins Turbo Diesel (359 ci)

Transmission Types Covered:

4-speed Automatic (47RE, 48RE), 5-speed Manual (NV4500, G56)

Drive Configurations Covered:

2WD, 4WD

Estimated Page Count:

Over 1500 pages (estimated for comprehensive factory service manual)

Type:

Factory Service Repair Manual

Language:

English

Format:

Printable (likely PDF or similar digital format for printing)

Digital Delivery:

Typically delivered as a downloadable digital file (PDF) for immediate access and printing.

📖 Manual Coverage

Engine Systems:

Engine mechanical, fuel system (including injection for diesel), cooling system, lubrication system, ignition system (for gasoline), emission control systems, engine diagnostics, torque specifications, engine overhaul procedures.

Transmission Drivetrain Systems:

Automatic transmission (47RE/48RE) overhaul, repair, diagnostics, shifting controls; Manual transmission (NV4500/G56) overhaul, repair, diagnostics; Transfer case operation and repair; Driveshaft and U-joint service; Axle and differential service (Dana 70HD, Dana 80).

Brakes Suspension Steering:

Hydraulic brake system diagnosis and repair, ABS system service, parking brake system, front and rear suspension components, steering system (power steering pump, gearbox, linkage) diagnosis and repair, wheel alignment specifications.

Electrical Electronics:

Charging system (alternator, battery), starting system (starter motor), lighting systems, instrument cluster, power windows, power locks, power seats, audio system, body control modules (BCM), diagnostic trouble codes (DTCs) and their interpretation, wiring diagrams for all major systems, fuse and relay locations.

HVAC Body Chassis:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, body and interior trim removal/installation, door and window mechanisms, exterior body panel repair, chassis frame inspection and repair, exhaust system, fuel tank and lines.

Maintenance Procedures:

Oil and filter changes, fluid level checks and top-offs, filter replacements (air, fuel, cabin), spark plug replacement (gasoline), battery maintenance, tire rotation, brake pad and rotor replacement, belt inspection and replacement.

Repair Procedures:

Engine rebuilding, transmission overhaul, differential rebuilding, suspension component replacement (ball joints, tie rods, shocks/struts), brake caliper and rotor replacement, starter and alternator replacement, fuel pump replacement, HVAC component replacement.

Diagnostics Troubleshooting:

Step-by-step diagnostic flowcharts for common and uncommon issues, diagnostic trouble code (DTC) interpretation, wiring diagram analysis for electrical faults, component testing procedures, symptom-based troubleshooting guides.

Depth:

Comprehensive, covering everything from routine maintenance to complete engine and transmission overhauls. Includes detailed technical specifications, torque values, special tool requirements, and component removal/installation procedures.

Diagnostic Tools Mentioned:

Likely references Chrysler's proprietary diagnostic tools (e.g., DRB III scan tool) for advanced diagnostics and module programming.

📊 Manual Specifications

Digital Format:

Likely PDF. Searchable text is common for factory manuals, enabling quick information retrieval.

Printability:

Designed for printing. Users can print the entire manual or specific sections as needed, providing flexibility for shop use or on-the-go referencing.

Binding:

N/A (if digital, refers to printing/binding by user)

Paper Recommendation:

Standard printer paper (8.5"x11") is suitable for printing. Consider durable paper or a binder for frequent use in a workshop environment.

Manual Scope:

Complete official factory service manual, covering all aspects of vehicle maintenance, diagnosis, repair, and specifications.

⚙️ Engine Specifications

Gasoline Engine:

5.9L (360 cu in) OHV V8 Magnum

Diesel Engine:

5.9L (359 cu in) OHV L6 Cummins Turbo Diesel

Gasoline Horsepower:

Approx. 245 hp @ 4800 rpm (varies slightly by application)

Gasoline Torque:

Approx. 330 lb-ft @ 3200 rpm (varies slightly by application)

Diesel Horsepower:

Approx. 235 hp @ 2600 rpm (for 47RE auto trans application)

Diesel Torque:

Approx. 460 lb-ft @ 1400 rpm (for 47RE auto trans application)

Gasoline Fuel System:

Sequential Multi-Port Fuel Injection (MPI)

Diesel Fuel System:

Bosch Inline Injection Pump (Rotary)

Gasoline Engine Code:

360

Diesel Engine Code:

ISB 5.9L

🔧 Transmission

Standard Transmission Type:

4-speed Automatic (47RE)

Optional Transmission Type:

5-speed Manual (NV4500) or potentially G56 for later models, though NV4500 is more common for '02. Also 48RE automatic option for higher duty applications.

Automatic Transmission Features:

Lock-up torque converter, electronically controlled shifts (for 48RE), overdrive gear.

Manual Transmission Features:

Dual-mass flywheel (NV4500), robust gear sets, capable of handling high torque.

Automatic Transmission Fluid:

Chrysler ATF+4 (MS-9602)

Manual Transmission Fluid:

NV4500: SAE 75W-90 Synthetic Gear Lubricant. G56: SAE 75W-85 Synthetic Gear Lubricant.

📐 Dimensions

Wheelbase Options:

Various, including 134.0", 140.5", 154.5", 162.0" (depending on cab and bed configuration)

Bed Length Options:

6.3 ft (standard bed), 8.0 ft (long bed)

Gvwr Range:

Up to 11,500 lbs (2500 series) and 13,500 lbs (3500 series)

Curb Weight Range:

Approx. 6,000 - 7,500 lbs (depending on configuration)

🛡️ Safety Features

NHTSA Rollover Resistance:

Typically 3-star for 2WD, 3-star for 4WD (as rated by NHTSA for this generation).

Active Safety Features:

Four-wheel Anti-lock Braking System (4W-ABS), rear-wheel anti-lock (on some configurations).

Passive Safety Features:

Front airbags for driver and passenger, seat belts with pretensioners, side impact door beams.

💡 Technology Features

Infotainment Options:

Basic AM/FM/Cassette/CD player, optional premium audio systems, simple HVAC controls. No integrated navigation or advanced touchscreen interfaces.

Driver Assistance Features:

Limited by 2002 standards. Primarily ABS. No electronic stability control, traction control, adaptive cruise control, or lane-keeping assist.

Connectivity Features:

Basic power accessory outlets (cigarette lighter). Optional towing mirrors. No Bluetooth or USB connectivity from the factory.

🔧 Maintenance

Oil Change Interval:

Every 3,000-7,500 miles or 6 months, depending on usage and oil type. Refer to manual for specific conditions.

Diesel Oil Change Interval:

Every 7,500 miles or 6 months with conventional oil, potentially extended with synthetic oil and bypass filtration. Crucial to follow manufacturer recommendations.

Tire Rotation Interval:

Every 7,500 miles

Engine Oil Gasoline:

SAE 5W-30 or 10W-30 (depending on ambient temperature, consult manual) API SJ or higher.

Engine Oil Diesel:

API CH-4 or CI-4 rated 15W-40 diesel engine oil. Consult manual for specific viscosity and API rating.

Coolant:

Chrysler Preferred Mopar Antifreeze/Coolant (5 year/100,000 mile)

Brake Fluid:

DOT 3

Common Wear Items:

Ball joints, tie rod ends, U-joints, exhaust system components, fuel injectors (diesel), lift pump (diesel), power steering components.

Common Diesel Issues:

Cracked cylinder head (earlier models, less common on 2002), fuel supply issues, injector pump wear, turbocharger issues (less common but possible).

Common Gasoline Issues:

Spark plug failure, distributor issues, intake manifold gasket leaks, occasional transmission cooler leaks.

Air Filter Part Number Example:

Fram CA8711 (example, specific part number depends on filter manufacturer)

Oil Filter Part Number Example Gas:

Mopar MO-099 or Fram PH8A (example, specific part number depends on filter manufacturer)

Oil Filter Part Number Example Diesel:

Mopar MO-209 or Fleetguard LF9009 (bypass filter) / LF667 (full flow) (example)

Fuel Filter Diesel Part Number Example:

Mopar FS20024 or Fleetguard FS1000 (example)

Engine Oil Capacity Gas:

5.9L V8: Approx. 5 quarts (with filter)

Engine Oil Capacity Diesel:

5.9L L6 Cummins: Approx. 12 quarts (with filter)

Coolant Capacity:

Approx. 23.5 quarts (depending on engine and radiator size)

📚 Vehicle History

Dodge Truck Legacy:

Dodge has a long history of producing robust and capable trucks, with the Ram nameplate becoming synonymous with powerful workhorses.

Second Generation Ram:

The 2002 model year is part of the second generation (1994-2001, with significant updates in 1994 and facelift in 2002), characterized by its distinctive 'Big Rig' styling and introduction of the 5.9L Cummins turbodiesel into the Ram lineup.

Manufacturing Location:

Saltillo, Mexico; Warren, Michigan, USA

🏆 Awards & Recognition

Cummin Diesel Reputation:

The 5.9L Cummins turbodiesel engine used in this generation of Ram trucks gained a legendary reputation for durability, reliability, and performance, making it highly sought after.

Segment Awards:

While specific awards for the 2002 model year are not readily available, the Dodge Ram line consistently received accolades for its towing capabilities and overall value within the heavy-duty truck market during this era.