Segment:
Full-size Pickup Truck
Key Competitors:
Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra
Vehicle Strengths:
Rugged construction, powerful engine options, excellent towing and hauling capabilities, spacious cabin (Quad Cab variants)
Primary Coverage:
Mechanical and Electrical Systems, Body and Frame
Secondary Coverage:
Maintenance, Troubleshooting, Repair Procedures
Estimated Page Count:
1500+
Type:
Factory Service Manual (FSM)
Powertrain:
Engine, Transmission, Drivetrain (RWD/4WD), Differentials, Transfer Case
Chassis:
Suspension (Front & Rear), Steering, Brakes (ABS, Hydraulic, Parking), Wheels & Tires
Electrical:
Battery, Charging System, Starting System, Ignition System, Lighting, Instrumentation, Powertrain Control Module (PCM), Body Control Module (BCM), HVAC Controls, Audio System, Power Accessories, Wiring Diagrams
Body:
Exterior Body Panels, Interior Trim, Seats, Glass, Doors, Latches, Bumpers, Body Sealing
Maintenance:
Fluid Changes, Filter Replacements, Inspections, Lubrication Schedules, Belt Replacement, Spark Plug Replacement
Repair:
Engine Overhaul, Transmission Rebuild, Brake System Repair, Suspension Component Replacement, Steering Gear Rebuild, Electrical Component Diagnosis and Replacement, Body Panel Repair
Diagnostics:
Troubleshooting charts, Diagnostic Trouble Codes (DTCs), Symptom-based diagnostics, Component testing procedures
Depth:
Comprehensive, including detailed component removal/installation, specifications, torque values, and diagnostic flowcharts.
Engine Options:
4.7L Magnum V8 (16V, P-Code), 5.9L Magnum V8 (16V, R-Code), 5.9L Cummins Turbo Diesel I6 (24V, ISB)
4.7L V8 Horsepower:
235 hp @ 4,800 rpm
4.7L V8 Torque:
295 lb-ft @ 3,200 rpm
5.9L V8 Horsepower:
245 hp @ 4,000 rpm
5.9L V8 Torque:
345 lb-ft @ 3,200 rpm
5.9L Cummins Horsepower:
235 hp @ 2,900 rpm
5.9L Cummins Torque:
460 lb-ft @ 1,600 rpm
Fuel Delivery:
Multi-Point Fuel Injection (MPI) for gasoline engines; Direct Injection (High-Pressure Common Rail) for Cummins diesel
Fuel Type:
Unleaded Gasoline (87 octane recommended), Diesel Fuel (for Cummins)
Standard Transmission Gas:
4-Speed Automatic (46RE/48RE)
Standard Transmission Diesel:
5-Speed Manual (NV4500), 4-Speed Automatic (47RE)
Optional Transmission Gas:
5-Speed Manual (NV4500 for select applications)
Drivetrain Options:
Rear-Wheel Drive (RWD), Part-Time Four-Wheel Drive (4WD)
Transfer Case 4Wd:
New Process (NP241 DLD, NP241 HD) or Magna Powertrain NV241 DHD
Wheelbase Std Cab:
134.9 inches
Wheelbase Ext Cab:
154.9 inches
Bed Lengths:
6.3 ft (Standard Bed), 8.0 ft (Long Bed)
Curb Weight Range:
Approx. 4,500 - 6,500 lbs (depending on configuration)
Gvwr Range:
Approx. 6,300 - 10,000+ lbs (depending on model and configuration)
NHTSA Driver Front Impact:
4 Stars (Early models, variations may exist)
NHTSA Passenger Front Impact:
4 Stars (Early models, variations may exist)
ABS:
Standard on most trims, 4-wheel disc brakes available on some models
Airbags:
Driver and Passenger Airbags (SRS)
Seatbelts:
3-point front seatbelts, 3-point rear seatbelts (Quad Cab)
Audio System:
Factory AM/FM/CD player, optional cassette, speaker configurations vary by trim.
Cruise Control:
Available
Tow Haul Mode:
Available on automatic transmissions for improved towing performance
Auxiliary Input:
Not standard, aftermarket solutions available
Oil Change Interval:
Every 3,000-7,500 miles or 6 months (depending on oil type and driving conditions, refer to manual for specifics)
Transmission Fluid Change:
Every 30,000-60,000 miles or 2-4 years (depending on transmission type and usage)
Engine Oil 4.7L:
API SL, SAE 5W-30, 5 Quarts (with filter)
Engine Oil 5.9L V8:
API SL, SAE 10W-30 or 5W-30, 5 Quarts (with filter)
Engine Oil 5.9L Cummins:
API CI-4, SAE 15W-40, 10 Quarts (with filter)
Transmission Fluid 48Re:
Mopar ATF+4 (MS-9602)
Transfer Case Fluid:
Mopar T-Case Lubricant (or equivalent)
Coolant:
Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, 50/50 mix
Common Wear Items:
Ball joints, tie rod ends, wheel bearings, exhaust system components, fuel pumps (especially on early models)
Powertrain Concerns:
Phosphorus wear in 4.7L V8 (early models), potential injector issues with 5.9L Cummins (depending on maintenance), transmission clutch wear
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks dating back to the 1930s.
Second Generation:
The 2002 model year is part of the second generation (1994-2001) refresh, featuring revised styling and improved powertrains. The manual covers the final production year of this successful generation before the 2002.5 refresh and subsequent third generation.
Manufacturing Locations:
Saltillo, Mexico; Warren, Michigan, USA
