🏷️ Basic Information

Make:

Dodge

Model:

Ram Truck 3500

Year:

2002

Chassis Code:

DR (Third Generation Ram)

👋 Introduction

Segment:

Heavy-Duty Pickup Truck

Target Audience:

Commercial users, fleet owners, heavy towing/hauling customers, performance enthusiasts

Competitors:

Ford F-Series Super Duty, Chevrolet Silverado HD/GMC Sierra HD

Vehicle Strengths:

Robust chassis, powerful engine options (especially the Cummins diesel), high towing and payload capacities, legendary durability

Manual Value Proposition:

Empowers owners and technicians with the knowledge to perform accurate diagnostics and repairs, maximizing vehicle uptime and performance.

📋 Manual Details

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

Likely Printed Book (typical for this era and description)

Estimated Page Count:

1500-2500+ pages (typical for comprehensive factory service manuals)

📖 Manual Coverage

Engine:

5.9L Magnum V8 (360 ci), 5.9L Cummins Turbo Diesel (24-valve OHV), 8.0L V10 Magnum

Transmission:

48RE Automatic, NV4500 5-Speed Manual, NV5600 6-Speed Manual

Drivetrain:

4x2, 4x4, Transfer Case (NV241DHD/NV273D), Axles (Dana 60 Front, Dana 70HD/80 Rear)

Suspension:

Front: Independent Front Suspension (IFS) on 4x4, Solid Front Axle on 4x2; Rear: Leaf Springs

Brakes:

Front Disc, Rear Disc (standard on 3500, potentially on 2500 depending on configuration), Anti-lock Braking System (ABS)

Electrical:

Body Control Module (BCM), Powertrain Control Module (PCM), Instrument Cluster, Lighting, Power Accessories, Audio System, Security System

HVAC:

Heating, Ventilation, Air Conditioning (manual and automatic climate control where equipped)

Steering:

Power Steering System, Steering Column

Fuel:

Fuel Tank, Fuel Pump, Fuel Lines, Fuel Injection (MPI for gasoline, common rail injection for diesel)

Exhaust:

Catalytic Converter, Muffler, Exhaust Pipes, Emissions Control Systems

Body:

Body Panels, Doors, Hood, Tailgate, Bumpers, Interior Trim, Glass

Maintenance:

Oil Change, Filter Replacement, Fluid Checks/Changes, Tire Rotation, Brake Inspection, Belt/Hose Inspection

Repair:

Engine overhaul, Transmission repair/rebuild, Differential service, Suspension component replacement, Brake system repair, Electrical component diagnosis/replacement, HVAC system repair, Body panel repair

Diagnostics:

Troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation, Component testing procedures, Wiring diagrams

Special Tools:

Identification of required special tools and their usage

Depth Level:

Comprehensive factory-level detail suitable for professional mechanics and advanced DIY enthusiasts

Diagnostic Tools:

Includes procedures for using diagnostic scan tools and interpreting data

Rebuild Procedures:

Detailed rebuild instructions for major components like engines and transmissions

📊 Manual Specifications

Digital Format Details:

If digital, typically PDF. Searchable text is a key feature of quality digital manuals.

Paper Quality:

Typically heavy-duty paper stock designed for workshop environments. Pages are often glossy or semi-gloss to resist grease and dirt.

Binding Type:

Often spiral-bound or case-bound for durability and ease of use, allowing the manual to lay flat.

Diagrams Illustrations:

High-quality, detailed diagrams, exploded views, and illustrations are standard.

⚙️ Engine Specifications

Base Engine Gas:

5.9L (360 ci) Magnum V8 MPI

Optional Engine Diesel:

5.9L 24-Valve Cummins Turbo Diesel I6

Optional Engine Gas:

8.0L (488 ci) Magnum V10 MPI

5.9L V8 Horsepower:

Approx. 235-245 hp @ 4000 rpm

5.9L V8 Torque:

Approx. 330-350 lb-ft @ 3200 rpm

8.0L V10 Horsepower:

Approx. 305-310 hp @ 4000 rpm

8.0L V10 Torque:

Approx. 450-455 lb-ft @ 3200 rpm

5.9L Cummins Horsepower:

Approx. 235-250 hp @ 2500-2700 rpm (depending on specific variant/tuning)

5.9L Cummins Torque:

Approx. 460-505 lb-ft @ 1400-1600 rpm (depending on specific variant/tuning)

Gasoline Injection Type:

Multi-Point Fuel Injection (MPI)

Diesel Injection Type:

High-Pressure Common Rail (HPCR) Fuel System

Required Fuel Diesel:

ULSD (Ultra-Low Sulfur Diesel) is recommended and required for emission compliance

🔧 Transmission

Manual Transmission Std:

NV4500 5-Speed Manual (typically on lower trims/4x2)

Manual Transmission Opt:

NV5600 6-Speed Manual (typically on higher trims/4x4/diesel)

Automatic Transmission Opt:

48RE 4-Speed Automatic with Overdrive

Transmission Fluid Spec 48Re:

ATF+4 (MS-9602)

Transmission Fluid Spec Nv4500:

Dexron III/Mercon ATF or equivalent manual transmission fluid (check manual for specific recommendation)

Transmission Fluid Spec Nv5600:

GL-4 75W-90 Synthetic Gear Oil (check manual for specific recommendation)

📐 Dimensions

Wheelbase Configurations:

Various, common for 2500/3500: 135.2" (Regular Cab 8' Bed), 154.8" (Club Cab 8' Bed), 164.5" (Regular Cab Long Bed), 172.4" (Club Cab Long Bed), 164.5" (Mega Cab 6.3' Bed)

Body Styles:

2-Door Regular Cab, 4-Door Club Cab, 4-Door Mega Cab

Gvwr Range:

Approx. 8,800 lbs (2500) to 11,500 lbs (3500) or higher, depending on configuration

Curb Weight Range:

Approx. 6,000 lbs to 7,500+ lbs

Bed Lengths:

Approx. 6.3 ft (short bed) and 8.0 ft (long bed)

🛡️ Safety Features

NHTSA Ratings:

Varies by specific test and configuration; typically good frontal ratings for its class and era. Side impact and rollover ratings should be consulted individually.

ABS:

Standard Anti-lock Braking System

Airbags:

Driver and Passenger Front Airbags

Seatbelts:

Three-point front seat belts, rear seat belts for applicable configurations

💡 Technology Features

Audio System:

Factory AM/FM/CD players, optional cassette, Sirius Satellite Radio (late availability).

Navigation:

Generally not available from the factory for this model year, aftermarket solutions common.

Cruise Control:

Standard or optional depending on trim level.

Trailer Brake Controller:

Factory option available for integrated trailer brake control.

Oem Connectivity:

Limited to basic audio inputs and optional satellite radio. No integrated Bluetooth or USB typically.

🔧 Maintenance

Oil Change Interval Gas:

Every 3,000-7,500 miles or 6 months, depending on driving conditions and oil type (refer to manual for exact recommendation).

Oil Change Interval Diesel:

Every 7,500-15,000 miles or 12 months, depending on oil quality and driving conditions (refer to manual for exact recommendation).

Transmission Service Interval:

Automatic: Every 30,000-60,000 miles. Manual: Inspection intervals, fluid changes as needed or at higher mileages (refer to manual).

Engine Oil Spec Gas:

API SN or SP, SAE 5W-30 (preferred for most conditions), or SAE 10W-30 (severe service) - check owner's manual.

Engine Oil Spec Diesel:

API CI-4 or CH-4 rated synthetic diesel engine oil, SAE 15W-40 is common, 5W-40 synthetic for colder climates.

Coolant Spec:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, P-5000 (Orange)

Brake Fluid Spec:

DOT 3 or DOT 4

Common Diesel Issues:

Injector pump issues (VP44 on earlier Cummins models, though this generation primarily uses common rail), turbocharger wear, cracked exhaust manifolds (especially on high-mileage units).

Common Gasoline Issues:

Lifter/camshaft wear (especially on 5.9L Magnum), ignition coil failures, EGR valve issues (if equipped).

Common Transmission Issues:

Torque converter shudder in automatics, clutch wear in manuals, potential synchro issues in older manuals.

Common Suspension Issues:

Wear in ball joints and tie rod ends due to heavy duty usage, potential track bar wear on 4x4 models.

📚 Vehicle History

Dodge Truck Legacy:

Dodge has a long history of producing durable and capable trucks, with the Ram nameplate becoming synonymous with heavy-duty performance.

Third Generation Ram:

The 2002 model is part of the third generation (2002-2008) Ram trucks, which introduced a significant redesign with a bolder, more aggressive styling, improved aerodynamics, and enhanced chassis components.

Manufacturing Plant:

Saltillo Truck Assembly Plant, Mexico; Warren Truck Assembly Plant, Michigan, USA

🏆 Awards & Recognition

Cummins Diesel Reputation:

The 5.9L Cummins Turbo Diesel engine is widely acclaimed for its robust construction, longevity, and performance, often considered one of the best diesel engines ever put in a pickup.