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Dodge Ram Truck 1500 2002 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram 1500 Year: 2002 Codes Platform Code: DN (Third Generation Ram) 👋 Introduction Market Position Segment: Full-size pickup truck Competitive Analysis Key Competitors:...
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Dodge Ram Truck 1500 2002 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram 1500
Year:
2002
Codes
Platform Code:
DN (Third Generation Ram)
👋 Introduction
Market Position
Segment:
Full-size pickup truck
Competitive Analysis
Key Competitors:
Ford F-150, Chevrolet Silverado 1500, GMC Sierra 1500, Toyota Tundra
Key Features
Design Philosophy:
Robust construction, strong towing and hauling capability, commanding road presence
Third Generation Distinction:
Redesigned exterior and interior, improved aerodynamics, enhanced powertrain options
📋 Manual Details
Coverage Areas
Model Variants Covered:
All models, engines, trims, and transmissions
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system
Drivetrain:
Transmission (automatic and manual), transfer case, driveshafts, differentials, axles
Chassis:
Suspension (front and rear), steering, brakes (front and rear disc, ABS), wheels, tires
Electrical:
Wiring diagrams, charging system, starting system, lighting, instruments, gauges, power accessories, body control modules, powertrain control modules (PCM)
Body:
Exterior body panels, interior trim, doors, windows, seats, HVAC system, body sealing
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnostics
Repair:
Component removal and installation, rebuilding procedures, adjustments, calibration
Special Tools:
Identification and usage of specialized tools required for specific repairs
Technical Depth
Depth:
Comprehensive, from basic maintenance to in-depth engine and transmission rebuilds
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable text, printable
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1 Type:
4.7L Magnum V8 (SOHC)
Engine 1 Displacement:
4.7 Liters / 287 cubic inches
Engine 1 Horsepower:
245 hp @ 4750 RPM
Engine 1 Torque:
305 lb-ft @ 3250 RPM
Engine 1 Block Material:
Cast Iron
Engine 1 Cylinder Head Material:
Aluminum
Engine 1 Fuel System:
Multi-Point Fuel Injection (MPI)
Engine 1 Ignition System:
Distributorless Ignition System (DIS) with coil-on-plug
Engine 1 Oil Capacity:
5.0 US quarts (4.7 Liters)
Engine 1 Oil Type:
API SJ or SL, SAE 5W-30
Optional Engine
Engine 2 Type:
5.9L Magnum V8 (OHV)
Engine 2 Displacement:
5.9 Liters / 360 cubic inches
Engine 2 Horsepower:
245 hp @ 4000 RPM
Engine 2 Torque:
335 lb-ft @ 3200 RPM
Engine 2 Fuel System:
Multi-Point Fuel Injection (MPI)
Engine 2 Oil Capacity:
5.0 US quarts (4.7 Liters)
Engine 2 Oil Type:
API SJ or SL, SAE 5W-30
🔧 Transmission
Standard
Transmission 1 Type:
4-speed Automatic (45RFE/48RE)
Optional
Transmission 2 Type:
5-speed Manual (NV3500/NV4500)
Features
Automatic Transmission Fluid:
ATF+4 (Chrysler Material Standard MS-9602)
Manual Transmission Fluid:
Mopar Manual Transmission Lubricant (or equivalent API GL-3/GL-4)
📐 Dimensions
Exterior
Wheelbase Regular Cab:
131.3 inches (3335 mm)
Wheelbase Extended Cab:
140.5 inches (3569 mm)
Wheelbase Crew Cab:
140.5 inches (3569 mm)
Overall Length Varies:
Varies by cab and bed configuration (approx. 229.7 - 249.8 inches)
Overall Width:
79.1 inches (2009 mm)
Overall Height:
74.5 - 75.1 inches (1892 - 1908 mm)
Cargo
Bed Length Short:
6.3 feet (1.9 m)
Bed Length Long:
8.0 feet (2.4 m)
Weights
Curb Weight Approx:
4700 - 5400 lbs (2130 - 2450 kg)
Gross Vehicle Weight Rating Gvwr:
6400 - 7500 lbs (2900 - 3400 kg)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Not rated (or 'Acceptable' for earlier models depending on configuration)
NHTSA Frontal Impact Passenger:
Not rated (or 'Acceptable' for earlier models depending on configuration)
IIHS Frontal Offset:
Acceptable
Active Features
ABS:
Standard on most models (Anti-lock Braking System)
Passive Features
Airbags:
Driver and passenger front airbags
Seat Belts:
Front and rear seat belts
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional cassette player, optional Infinity premium audio system
Display:
Basic digital display for radio and climate controls
Driver Assistance
Cruise Control:
Standard on most trims
Tow Haul Mode:
Available on automatic transmission models for enhanced towing performance
Connectivity
Auxiliary Input:
Not typically factory-equipped, aftermarket solutions common
Remote Keyless Entry:
Available on higher trims
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first (under normal driving conditions)
Tire Rotation Interval:
Every 7,500 miles or 6 months
Transmission Fluid Change:
Inspect every 30,000 miles, replace fluid and filter at 60,000 miles (for typical usage)
Spark Plug Replacement:
100,000 miles (for 4.7L V8 and 5.9L V8 models)
Fluid Specifications
Engine Coolant:
Mopar Antifreeze/Coolant (HOAT - Hybrid Organic Acid Technology), a 50/50 mix with distilled water
Brake Fluid:
DOT 3
Power Steering Fluid:
ATF+4 or Chrysler Power Steering Fluid
Known Issues
Intake Manifold Gasket Leaks:
Can occur on early 4.7L Magnum V8 engines, leading to coolant or vacuum leaks.
Transmission Hard Shifting:
Some owners report hard shifts or delayed engagement, often related to transmission fluid quality or valve body issues.
Crankshaft Position Sensor:
Failure can cause stalling or no-start conditions.
Oil Filter Adapter Housing Leaks:
Common on the 4.7L V8, requiring replacement of the seal or housing.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long-standing history of producing durable and capable trucks since the early 20th century.
Model Evolution
Third Generation Launch:
The 2002 model year marked the introduction of the third generation of the Dodge Ram pickup truck, a significant redesign from the previous generation.
Production
Manufacturing Location:
Saltillo, Mexico; Warren, Michigan; St. Louis, Missouri (production sites varied)
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
While specific 'Truck of the Year' awards for the 2002 model are not prominently documented, the third-generation Ram was well-received for its styling and capability.
Ratings
Jdpowers Initial Quality:
Varies by year and specific configuration, but generally competitive within its class for the era.
Certifications
Emissions Compliance:
Meets applicable EPA and California emissions standards for its model year.
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