🏷️ Basic Information

Make:

Dodge

Model:

Ram 2500 Series

Model Years Covered:

2002, 2003, 2004

Generation Designation:

Third Generation (DR/DH/D2 Ram Pickup)

Generation Years:

2002-2008

Chassis Code:

DR/DH/D2 Platform

👋 Introduction

Vehicle Segment:

Heavy-Duty Pickup Truck

Target Audience:

Commercial users, fleet operators, towing enthusiasts, heavy-duty hauling needs.

Key Competitors:

Ford F-250 Super Duty, Chevrolet Silverado 2500HD, GMC Sierra 2500HD.

Truck Platform:

Known for robust construction, strong towing and hauling capabilities, and powerful engine options.

Manual Value Proposition:

Provides essential, factory-authorized technical information crucial for maintaining, diagnosing, and repairing the 2002-2004 Dodge Ram 2500 Series, ensuring optimal performance and longevity.

📋 Manual Details

Primary Coverage:

Service and Repair

Secondary Coverage:

Maintenance, Diagnostics, Troubleshooting, Overhaul

Estimated Page Count:

1500-2000+ pages (typical for this era's comprehensive service manuals)

Manual Type:

Factory Service Manual (FSM) / Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Full coverage of all engine variants, including: engine removal/installation, disassembly, inspection, assembly, torque specifications, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing systems, lubrication system, cooling system.

Engine Performance:

Fuel injection systems (MPI), ignition systems, emissions control systems, engine diagnostics, computer controls (PCM), sensor testing and replacement, performance tuning basics.

Transmission Manual:

Service and repair procedures for manual transmissions (e.g., NV4500), including clutch operation, gearbox disassembly/assembly, component replacement, fluid specifications.

Transmission Automatic:

Service and repair procedures for automatic transmissions (e.g., 48RE, 47RE), including torque converter, valve body, internal components, clutch packs, bands, hydraulic systems, transmission control module (TCM), fluid specifications, cooler system.

Drivetrain:

Front and rear axle service, differential inspection and repair, transfer case operation and service, driveshaft balancing and U-joint replacement, axle shafts, seals, bearings.

Suspension:

Front and rear suspension component identification, inspection, and replacement. Includes: steering knuckles, control arms, ball joints, tie rods, drag links, sway bars, bushings, springs (coil/leaf), shock absorbers/struts, alignment procedures.

Steering:

Power steering system diagnosis and repair, steering gear box, steering column, intermediate shaft, tie rod ends, power steering pump, fluid specifications, bleeding procedures.

Brakes:

Front and rear brake systems (disc/drum), hydraulic system diagnosis, brake lines, master cylinder, power brake booster, ABS system (component testing, sensor diagnosis, module operation), parking brake system, brake fluid specifications, bleeding procedures.

Electrical System:

Complete wiring diagrams, fuse box layout, relay locations, starter system, charging system (alternator, battery), lighting systems (headlights, taillights, interior), horn, wipers, power windows, power locks, power seats, HVAC blower motor, power mirrors.

Body Exterior:

Body panel alignment, door hinge/latch repair, tailgate operation, bumper repair/replacement, exterior trim removal/installation, glass replacement (windshield, side glass), sunroof operation, paint code information (general). Exterior lighting diagnostics.

Body Interior:

Dashboard removal/installation, instrument cluster service, seat removal/installation, carpet replacement, headliner repair, interior trim panel removal/installation, HVAC controls, audio system service (basic).

HVAC:

Heating, ventilation, and air conditioning (HVAC) system diagnosis and repair, refrigerant handling (basic principles), compressor, condenser, evaporator, blower motor, heater core, A/C controls, actuators, diagnostic procedures.

Diagnostics Troubleshooting:

Systematic troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs) with explanations and repair strategies, connector pinouts, component testing procedures.

Preventive Maintenance:

Detailed maintenance schedules, fluid level checks, filter replacement intervals, lubrication points, tire rotation procedures, battery maintenance.

Repair Procedures:

Step-by-step instructions for component removal, installation, adjustment, and repair for all major vehicle systems.

Overhaul Procedures:

Complete engine and transmission overhaul procedures, including disassembly, cleaning, inspection, measurement, and reassembly with specified tolerances.

Diagnostic Procedures:

Guided diagnostic routines for electrical faults, engine performance issues, transmission problems, and other common malfunctions.

Adjustment Procedures:

Wheel alignment specifications and procedures, headlight aim adjustment, throttle cable adjustment, parking brake adjustment.

Depth Of Coverage:

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

Wiring Diagrams:

Detailed, system-specific wiring diagrams with component locations and harness routing.

Torque Specifications:

Extensive list of torque specifications for all critical fasteners across all major systems.

Diagnostic Trouble Codes:

In-depth explanations of OBD-II diagnostic trouble codes (DTCs) and their corresponding diagnostic and repair procedures.

Special Tools:

Identification and usage of specialized tools required for specific repair and diagnostic procedures.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text for quick information retrieval.

Print Resolution:

High-resolution, suitable for clear printing of text and diagrams.

Binding Type:

N/A (Digital PDF Format)

Paper Type:

N/A (Digital PDF Format)

⚙️ Engine Specifications

Engine Options:

5.9L Magnum V8 (230-245 hp, 330-355 lb-ft torque), 5.7L HEMI V8 (345 hp, 375 lb-ft torque - introduced later in the generation, check specific model year), 5.9L Cummins Turbo Diesel I6 (235-250 hp, 460-475 lb-ft torque).

Horsepower Range:

230 - 345 hp (depending on engine option)

Torque Range:

330 - 475 lb-ft (depending on engine option)

Fuel Delivery Gas:

Multi-point Fuel Injection (MPI)

Fuel Delivery Diesel:

High-pressure Common Rail (HPCR) fuel injection system for the Cummins.

Gasoline Engine Codes:

260 (5.9L Magnum V8), EZH (5.7L HEMI V8)

Diesel Engine Codes:

230 (5.9L Cummins I6)

Cooling System Type:

Pressurized, liquid-cooled system

Oil Capacity 5.9L Gas:

7 quarts (with filter)

Oil Capacity 5.7L Hemi:

7 quarts (with filter)

Oil Capacity 5.9L Cummins:

11 quarts (with filter)

🔧 Transmission

Standard Transmission:

5-speed manual transmission (e.g., NV4500)

Optional Transmission:

4-speed automatic transmission (e.g., 48RE, 47RE)

Transfer Case:

Part-time 4WD system with electronic or manual engagement (depending on trim/options).

Automatic Transmission Fluid:

Chrysler ATF+4 (Mopar Material Standard MS-9602)

Manual Transmission Fluid:

Typically GL-3 or GL-4 gear oil, specific grade varies by transmission model (consult manual for exact spec, e.g., 75W-90)

Automatic Transmission Fluid Capacity:

Approximately 11-13 quarts (refer to manual for precise capacity)

📐 Dimensions

Body Styles:

Regular Cab, Extended Cab (Club Cab), Crew Cab

Bed Lengths:

6.3 ft (short bed), 8.0 ft (long bed)

Wheelbase Options:

Various wheelbases depending on cab and bed configuration (e.g., 134.0", 140.5", 160.5")

Gross Vehicle Weight Rating Gvwr:

Typically 8,800 lbs to 9,500 lbs depending on configuration

Curb Weight:

Varies significantly by configuration, generally 5,500 lbs - 7,000+ lbs

Max Towing Capacity:

Up to 13,000+ lbs (with appropriate configuration, engine, axle ratio, and towing package)

Max Payload Capacity:

Up to 3,000+ lbs (with appropriate configuration)

🛡️ Safety Features

NHTSA Front Impact Rating:

Not fully representative of modern testing, but generally considered robust for its class.

IIHS Crash Test Ratings:

Good in frontal offset crash tests by IIHS (Insurance Institute for Highway Safety) for some configurations.

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Available traction control system (often standard on higher trims or diesel models)

Airbags:

Standard driver and front passenger airbags.

Seat Belts:

Three-point seat belts with pretensioners for front occupants.

💡 Technology Features

Audio Systems:

Factory AM/FM/CD or Cassette player, with optional premium Infinity sound systems. Auxiliary input jacks (on some models) or early Bluetooth connectivity (rare for base models).

ABS System:

Four-wheel Anti-lock Braking System (ABS).

OBD Ii Port:

Standard OBD-II diagnostic port for emissions and engine management system diagnostics.

🔧 Maintenance

Oil Change Interval:

Typically 3,000-7,500 miles for gasoline engines, 3,000-5,000 miles for the Cummins Turbo Diesel (depending on oil type and driving conditions).

Filter Replacement Interval:

Engine oil filter, fuel filter (diesel), air filter should be replaced at or before oil change intervals, or as per driving conditions.

Transmission Fluid Change:

Automatic transmission fluid and filter: typically every 30,000-60,000 miles for heavy-duty use. Manual transmission fluid: inspect periodically, change around 60,000-100,000 miles.

Coolant Change:

Initial change at 5 years/100,000 miles, then every 2-5 years/30,000-100,000 miles depending on coolant type.

Engine Oil Gas 5.9L:

API Service SG, SH, SJ, or SL rated, SAE 5W-30 or 10W-30 depending on ambient temperature.

Engine Oil Gas 5.7L Hemi:

Chrysler MS-6395 approved SAE 5W-20 (check owner's manual for confirmation).

Engine Oil Diesel 5.9L Cummins:

API Service CH-4 or CI-4 rated, SAE 15W-40 heavy-duty diesel engine oil.

Coolant:

Mopar OAT (Organic Additive Technology) coolant, pink color (or equivalent meeting Chrysler MS-9769).

Brake Fluid:

DOT 3 brake fluid.

Common Diesel Issues:

Lift pump failure (in-tank), VP44 injection pump failure (early models), grid heater issues, exhaust manifold leaks, crankcase blow-by.

Common Gasoline Issues:

Lifter tick (especially in early HEMI), ignition coil failures, transmission cooler line leaks (common for 48RE), exhaust system rust.

Common Chassis Issues:

Ball joint wear, tie rod end wear, steering stabilizer failure, u-joint wear, exhaust system rust, brake component wear (rotors, pads).

📚 Vehicle History

Dodge Truck Legacy:

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

Third Generation Introduction:

The third generation (DR/DH/D2) was introduced for the 2002 model year, marking a significant redesign with a more modern interior, improved chassis, and updated styling compared to the preceding second generation.

Key Updates 2002-2004:

Introduction of the HEMI 5.7L V8 engine in 2003, further enhancing performance for gasoline models. Subtle styling tweaks and feature enhancements across the model years.

Manufacturing Locations:

Saltillo, Mexico; Warren, Michigan, USA

🏆 Awards & Recognition

Truck Of The Year:

While specific awards vary by year and publication, the Ram trucks from this era were consistently recognized for their capability and towing prowess.

Diesel Engine Recognition:

The 5.9L Cummins Turbo Diesel engine is highly regarded in the automotive industry for its durability and power.