Market Position:
The Dodge Ram series of trucks for 2002 represented a significant offering in the heavy-duty pickup segment, known for its towing and hauling capabilities, particularly with the Cummins diesel option.
Competitive Analysis:
Competed directly with Ford F-Series Super Duty, Chevrolet Silverado HD, and GMC Sierra HD trucks.
Key Features:
Robust chassis, powerful engine options (including the renowned 5.9L Cummins Turbo Diesel), capable for towing and heavy-duty work, variety of configurations (1500, 2500, 3500).
Systems Covered:
Engine (3.7L Magnum V6, 4.7L Magnum V8, 5.9L Cummins Turbo Diesel), Transmission (manual and automatic), Driveline, Suspension, Steering, Brakes (ABS, standard), Fuel System, Exhaust System, Cooling System, HVAC, Electrical System (wiring diagrams, components), Body and Frame, Body Control Modules, Restraint Systems (Airbags).
Procedures Included:
Routine maintenance, scheduled maintenance, troubleshooting, diagnostic procedures, repair procedures, overhaul instructions, component replacement, electrical system diagnosis, bodywork repair, specifications, torque values, wiring diagrams, diagnostic trouble codes (DTCs).
Technical Depth:
Complete rebuilds, advanced diagnostics, detailed troubleshooting, and component-level repair.
Engine 3.7L Coverage:
Detailed procedures for the 3.7L V6 Magnum engine, including diagnosis, repair, timing, cooling, fuel, and exhaust.
Engine 4.7L Coverage:
Comprehensive coverage for the 4.7L V8 Magnum, including specific diagnostics for common issues like manifold cracks and oil consumption.
Engine 5.9L Cummins Coverage:
In-depth coverage for the 5.9L Cummins Turbo Diesel, including fuel system (injectors, injection pump, common rail), turbocharger, exhaust brake (if equipped), and engine management.
Driveline Coverage:
Front and rear axle assembly repair, differential service, transfer case operation and repair, driveshaft and U-joint replacement.
Brakes Coverage:
Front and rear brake system service (disc/disc or disc/drum configurations), ABS system diagnosis and repair, parking brake operation.
Electrical Coverage:
Complete wiring diagrams for all vehicle systems, fuse and relay identification, starter, alternator, battery system, lighting, power windows, locks, and body control modules.
Suspension Steering Coverage
Suspension Steering Coverage:
Front and rear suspension component inspection and replacement (control arms, ball joints, bushings, shocks/struts), steering gear and linkage service, power steering system diagnosis.
Body Coverage:
Body panel alignment and repair, door and tailgate service, interior trim removal and installation, bumper repair, sheet metal repair procedures.
Diagnostics Coverage:
On-Board Diagnostics (OBD-II) system interpretation, diagnostic trouble code (DTC) lookup and troubleshooting procedures, scan tool usage recommendations.
Specifications Data:
Detailed torque specifications for all fasteners, engine and transmission fluid capacities, tire pressure recommendations, alignment specifications, and critical component measurements.
Primary Engine 3.7L:
3.7L (226 cu in) Magnum V6
Primary Engine 4.7L:
4.7L (285 cu in) Magnum V8
Primary Engine 5.9L:
5.9L (359 cu in) Cummins Turbo Diesel I6 (12-valve and 24-valve variants likely for 2002, with 24-valve being more common for this year).
Engine 3.7L Horsepower:
Approx. 205 hp @ 4800 rpm (V6).
Engine 4.7L Horsepower:
Approx. 235 hp @ 4800 rpm (V8).
Engine 5.9L Horsepower:
Approx. 235 hp @ 2400 rpm (24-valve Cummins).
Engine 3.7L Torque:
Approx. 235 lb-ft @ 4000 rpm (V6).
Engine 4.7L Torque:
Approx. 290 lb-ft @ 3200 rpm (V8).
Engine 5.9L Torque:
Approx. 460 lb-ft @ 1600 rpm (24-valve Cummins).
Fuel System 3.7L 4.7L:
Multi-Point Fuel Injection (MPFI).
Fuel System 5.9L:
High-pressure Common Rail (for 24-valve) or P7100 Injection Pump (for 12-valve).
Cooling System Type:
Pressurized liquid cooling system.
Exterior Dimensions Note:
Varies significantly by cab type (Regular Cab, Quad Cab), bed length (6.3 ft, 8.0 ft), and driveline (2WD/4WD). Specific dimensions require model breakdown.
Cargo Bed Options:
6.3 ft and 8.0 ft bed lengths.
Gvwr Note:
Gross Vehicle Weight Rating (GVWR) varies by model (1500, 2500, 3500) and configuration, impacting payload and towing capacity.
Oil Change Interval Gasoline:
Typically every 5,000-7,500 miles or 6 months for gasoline engines, depending on driving conditions.
Oil Change Interval Diesel:
Typically every 7,500-10,000 miles or 6 months for Cummins Turbo Diesel, depending on driving conditions and oil type.
Transmission Fluid Interval:
Refer to manual for specific intervals; generally around 30,000-60,000 miles for automatic transmissions, depending on service type.
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Spark Plug Replacement Gasoline:
Varies by plug type; typically 30,000-100,000 miles for platinum or iridium plugs.
Engine Oil Spec 3.7L 4.7L:
SAE 5W-30, API Certified.
Engine Oil Spec 5.9L Diesel:
API CJ-4 or CK-4 (preferred for modern oils that meet specifications), SAE 15W-40 is common, or 5W-40 synthetic for cold weather.
Coolant Spec:
Mopar Antifreeze/Coolant (HOAT), or equivalent meeting Chrysler MS-9769. Typically a 50/50 mix.
Transmission Fluid Auto Spec:
ATF+4 (Chrysler Material Standard MS-9602).
Transmission Fluid Manual Spec:
Refer to manual; typically GL-3 or GL-4 gear oil for NV3500/NV4500.
Known Issues General:
Common issues can include front suspension wear (ball joints, tie rods), brake component wear, exhaust manifold cracks (especially on 4.7L V8), and potential for rust on older models. Cummins 5.9L can experience injector issues or fuel system wear with high mileage.
Known Issues 4.7L V8:
Exhaust manifold cracks, spark plug blow-out from cylinder head, oil consumption.
Known Issues 5.9L Cummins:
Fuel filter clogging, potential for injector issues (especially if poor fuel quality is used), lift pump failure, occasional turbocharger wear.
