Dodge Ram 1500 2002-2004 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 1500 Generation: Third Generation (DR/DH/D1) Codes Platform Code: DR 👋 Introduction Market Position Segment: Full-size Pickup Truck Target Audience: DIY Mechanics, Professional...

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Taper: Truck

Distributeur:

UGS: 448982

Mots clés: 2002 2003 2004 Cars Dodge Misc Ram 1500 Truck

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram 1500

Generation:

Third Generation (DR/DH/D1)

Codes

Platform Code:

👋 Introduction

Market Position

Segment:

Full-size Pickup Truck

Target Audience:

DIY Mechanics, Professional Technicians, Fleet Maintenance

Competitive Analysis

Key Competitors:

Ford F-150, Chevrolet Silverado 1500, GMC Sierra 1500, Toyota Tundra

Key Features

Vehicle Highlights:

Robust construction, strong engine options, towing capability, comfortable interior for its class

Manual Value Proposition:

Provides detailed repair and maintenance information, empowering owners to perform complex tasks and reduce repair costs.

📋 Manual Details

Coverage Areas

Covered Years:

2002, 2003, 2004

Vehicle Types:

Pickup Truck

Page Count

Estimated Pages:

~3000+

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

File Format

File Quality:

High-resolution, searchable PDF

Printable:

Yes, designed for printing specific sections or the entire manual

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

📖 Manual Coverage

Systems Covered

Engine:

3.7L Magnum V6, 4.7L Magnum V8, 5.7L HEMI V8

Transmission:

4-Speed Automatic (42RE, 45RFE, 48RE), 5-Speed Manual (NV3500)

Drivetrain:

RWD, 4WD (Part-time, Full-time)

Brakes:

Front Disc, Rear Disc (with ABS)

Suspension:

Front Independent (Short/Long Arm), Rear Solid Axle (Leaf Springs)

Steering:

Power Rack and Pinion

Electrical:

Starting & Charging, Ignition, Lighting, Gauges, Body Controls, HVAC, Power Accessories

Body:

Exterior Panels, Interior Trim, Glass, Seats, Bumpers

HVAC:

Air Conditioning, Heater, Climate Control

Restraint Systems:

Airbags, Seat Belts

Procedures Included

Maintenance:

Oil Changes, Filter Replacements, Fluid Checks and Replacements, Tune-Ups

Troubleshooting:

Diagnostic Flowcharts, Symptom-based Diagnostics, Electrical Schematics

Repair:

Engine Reassembly, Transmission Overhaul, Brake System Repair, Suspension Component Replacement, Electrical Component Diagnosis and Repair

Overhaul:

Complete Engine Rebuilds, Transmission Rebuilds, Differential Rebuilds

Diagnostics:

OBD-II Scans, Component Testing, Circuit Diagnosis

Adjustments:

Parking Brake Adjustment, Clutch Adjustment (Manual)

Specifications:

Torque Specifications, Fluid Capacities, Clearances

Technical Depth

Depth:

Comprehensive, from basic maintenance to full engine and transmission rebuilds

Diagnostic Level:

Advanced (including wiring diagrams and diagnostic procedures)

⚙️ Engine Specifications

Primary Engine

Engine 1 Type:

3.7L Magnum V6

Engine 1 Displacement:

3687 cc

Engine 1 Horsepower:

215 hp @ 5200 rpm

Engine 1 Torque:

235 lb-ft @ 4000 rpm

Engine 2 Type:

4.7L Magnum V8

Engine 2 Displacement:

4701 cc

Engine 2 Horsepower:

240-245 hp @ 4800-5000 rpm

Engine 2 Torque:

300-310 lb-ft @ 3200-3600 rpm

Engine 3 Type:

5.7L HEMI V8 (Introduced mid-2003)

Engine 3 Displacement:

5654 cc

Engine 3 Horsepower:

345-349 hp @ 5000-5200 rpm

Engine 3 Torque:

375-377 lb-ft @ 4000-4200 rpm

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Engine Design

Valve Train:

Overhead Valve (OHV) for Magnum V6/V8, Hemispherical Combustion Chamber (HEMI) OHV for 5.7L V8

Cooling System

Coolant Type:

50/50 Ethylene Glycol Antifreeze

Oil Specifications

Engine Oil Viscosity:

SAE 5W-30 (recommended for most conditions)

Engine Oil Capacity:

5.0-7.0 quarts (depending on engine)

🔧 Transmission

Standard

Transmission 1 Type:

4-Speed Automatic (42RE - used with 3.7L V6)

Transmission 2 Type:

4-Speed Automatic (45RFE/48RE - used with 4.7L V8 and 5.7L HEMI)

Optional

Transmission 3 Type:

5-Speed Manual (NV3500 - primarily with V6)

Features

Transmission Control:

Electronic Control Module (ECM) for automatics

Fluid Specifications

Automatic Transmission Fluid:

ATF+4 (Mopar)

Fluid Capacities

Automatic Transmission Fluid Capacity:

Approx. 9-13 quarts (dry fill)

Manual Transmission Fluid

Manual Transmission Fluid Type:

MS-9224 (Synchromesh Manual Transmission Fluid) or equivalent

Manual Transmission Fluid Capacity

Manual Transmission Fluid Capacity:

Approx. 2.3 quarts

📐 Dimensions

Exterior

Wheelbase:

139.0 inches (Standard Bed), 145.2 inches (Long Bed)

Overall Length:

227.0 - 239.0 inches (depending on cab/bed)

Overall Width:

79.3 inches

Overall Height:

74.4 - 75.1 inches (depending on configuration)

Cargo

Bed Length:

6'3" (Standard), 8'0" (Long)

Bed Width Between Wheelwells:

41.0 inches

Weights

Curb Weight:

4,500 - 5,500 lbs (approx.)

Gross Vehicle Weight Rating Gvwr:

6,400 - 7,200 lbs (depending on configuration)

Max Towing Capacity:

Up to 8,600 lbs (with appropriate equipment)

Max Payload Capacity:

Up to 1,650 lbs (approx.)

🛡️ Safety Features

Ratings

NHTSA Front Driver Side Impact:

★★★★★ (5-Star)

NHTSA Front Passenger Side Impact:

★★★★★ (5-Star)

IIHS Frontal Offset Score:

Active Features

Standard (4-wheel disc brakes with ABS)

Traction Control:

Available (Electronic Traction Control)

Passive Features

Airbags:

Driver and Passenger Frontal Airbags

Seat Belts:

Height-adjustable front seat belts with pretensioners

💡 Technology Features

Infotainment

Audio System:

Available AM/FM stereo with CD player, cassette player (early models), optional premium sound systems.

Climate Control:

Manual or optional Electronic Dual-Zone Climate Control

Driver Assistance

Cruise Control:

Standard

Tow Haul Mode:

Available on automatic transmissions to optimize shifting for towing.

Connectivity

Power Outlets:

12V auxiliary power outlets

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 to 7,500 miles (depending on oil type and driving conditions, consult manual for specifics)

Engine Air Filter Replacement:

Every 15,000 to 30,000 miles or as needed based on inspection

Cabin Air Filter Replacement:

Every 15,000 to 30,000 miles or as needed

Spark Plug Replacement:

Varies by engine: 3.7L V6 (~100,000 miles), 4.7L V8 (~100,000 miles), 5.7L HEMI (100,000 miles with specific plugs)

Transmission Fluid Service:

Every 30,000 to 60,000 miles for automatic transmissions (filter and fluid change)

Coolant Flush:

Every 30,000 to 100,000 miles (depending on coolant type, consult manual)

Fluid Specifications

Power Steering Fluid:

ATF+4 or Mopar Power Steering Fluid

Brake Fluid:

DOT 3

Known Issues

Ignition Coils:

Premature failure reported on some models, especially with V8 engines.

Wheel Hubs:

Front wheel hub bearing premature wear/failure can occur.

Transmission Cooler:

Potential for internal transmission cooler leaks (especially in earlier models with integrated radiator coolers) leading to coolant contamination.

Brake Rotors:

Warping or premature wear of brake rotors can be an issue under heavy use.

Rust:

Corrosion on frame, body panels, and exhaust components can be a concern in rust-prone areas.

📚 Vehicle History

Brand Heritage

Dodge Truck Legacy:

Dodge has a long history of producing robust and capable trucks, dating back to the Power Wagon.

Model Evolution

Third Generation Introduction:

The third generation (DB/DC/DM) was a significant redesign introduced for the 2002 model year, featuring a completely new exterior and interior design, and the introduction of the HEMI engine.

Key Updates 2003:

Introduction of the 5.7L HEMI V8 engine for certain models.

Key Updates 2004:

Standardization of 4-wheel disc brakes and ABS on most models, minor interior trim adjustments.

Production

Manufacturing Plant:

St. Louis Assembly, Missouri, USA; Saltillo Truck Plant, Mexico

🏆 Awards & Recognition

Recognitions

Motor Trend Truck Of The Year:

The Ram 1500 (as part of the third-generation redesign) was a contender, though did not win the award during these specific years. It was recognized for its significant improvements.

Ratings

Jdpowe Initial Quality Study:

Ratings varied, but the third-generation Ram generally saw improvements over its predecessor, though often ranked mid-pack in its segment for initial quality.