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Dodge Ram Truck 2002-2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Years Covered: 2002, 2003, 2004 Codes Vehicle Generation: Third Generation (2002-2008) 👋 Introduction Market Position Vehicle Segment: Full-size pickup truck Competitive...
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Type: Truck
Vendor:
Sku: 488061
Dodge Ram Truck 2002-2004 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram Truck
Years Covered:
2002, 2003, 2004
Codes
Vehicle Generation:
Third Generation (2002-2008)
👋 Introduction
Market Position
Vehicle Segment:
Full-size pickup truck
Competitive Segment:
Heavy-duty work truck, personal use truck
Competitive Analysis
Key Competitors:
Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra
Key Features
Design Philosophy:
Rugged, durable, powerful, capable of towing and hauling substantial loads, bold styling.
Manual Value Proposition:
Provides essential technical information for maintenance, repair, and diagnosis, empowering owners and technicians to keep the vehicle in optimal condition and reducing reliance on costly dealership services.
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual
Language:
English
Format:
PDF
Page Count
Estimated Page Count:
Extensive (typically 2000+ pages for a full service manual)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanicals (short block, cylinder heads, valvetrain, timing), fuel system (injectors, pump, lines, pressure regulator), ignition system (coils, plugs, sensors), lubrication system (oil pump, filter, passages), cooling system (radiator, water pump, thermostat, fan), exhaust system (manifold, catalytic converter, muffler), emissions control systems (EGR, PCV, evaporative emissions), engine management (PCM, sensors, actuators, diagnostic trouble codes - DTCs).
Transmission Drivetrain:
Automatic transmissions (42RE, 45RFE, 48RE), manual transmissions (NV3500, NV4500), transfer cases (New Process NP241, NP243), drivelines (U-joints, CV joints), axles (front and rear differential, axle shafts, hubs, bearings), brakes (hydraulic system, ABS, power booster, master cylinder, calipers, drums, rotors, parking brake), steering (power steering pump, gearbox/rack, tie rods, steering column), suspension (front independent suspension - torsion bar or coil springs, rear solid axle with leaf springs, shock absorbers, control arms, sway bars).
Electrical Body:
12V electrical system, battery, alternator, starter, lighting (headlights, taillights, interior), wiring diagrams, fuses, relays, Body Control Module (BCM), power windows, power locks, power mirrors, climate control system (HVAC, A/C compressor, heater core, blower motor), instrument cluster, warning lights, airbags, audio systems, body panels, doors, windows, seats, interior trim, exterior trim, bumpers, frame, chassis.
Procedures Included
Maintenance Procedures:
Scheduled maintenance (oil changes, filter replacements, fluid checks/changes, spark plug replacement, belt inspections/replacement), lubrication points, tire rotation, brake inspections.
Repair Procedures:
Engine overhaul and component replacement, transmission removal/installation/rebuild, suspension component replacement, brake caliper/rotor/drum replacement, steering system repairs, electrical component diagnosis and replacement, HVAC system servicing, body panel repair and alignment, interior component servicing.
Diagnostic Procedures:
Troubleshooting guides for common symptoms, diagnostic trouble code (DTC) interpretation and resolution, electrical circuit testing, fuel pressure testing, compression testing, vacuum testing.
Technical Depth
Diagnostic Depth:
Comprehensive diagnostic charts, flowcharts, and symptom-based troubleshooting for all major systems, including in-depth analysis of powertrain control modules (PCM) and body control modules (BCM).
Repair Depth:
Detailed step-by-step repair procedures with torque specifications, special tool requirements, and exploded diagrams for component disassembly and reassembly, suitable for both professional mechanics and skilled DIY enthusiasts.
Specification Detail:
Includes detailed specifications for all components, including clearances, tolerances, fluid capacities, fluid types, electrical values, and performance data.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Searchable text for quick information retrieval.
Printability:
Printable pages for in-workshop use.
Print Quality
Image Resolution:
High-resolution images, diagrams, and illustrations ensuring clarity and detail.
Binding Type
Binding Type For Digital:
N/A (Digital PDF)
Paper Type
Paper Type For Digital:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Option 1:
4.7L Magnum V8 (P/N 53021545-AA)
Engine Option 1 Displacement:
4.7 liters / 287 cubic inches
Engine Option 1 Configuration:
Overhead Valve (OHV), 16-valve, V8
Engine Option 1 Horsepower:
Approx. 235-245 hp @ 4800-5000 rpm (depending on year/tune)
Engine Option 1 Torque:
Approx. 295-310 lb-ft @ 3200-3600 rpm (depending on year/tune)
Engine Option 2:
5.9L Magnum V8 (P/N 5003804-AA)
Engine Option 2 Displacement:
5.9 liters / 360 cubic inches
Engine Option 2 Configuration:
Overhead Valve (OHV), 16-valve, V8
Engine Option 2 Horsepower:
Approx. 245-250 hp @ 4000-4400 rpm
Engine Option 2 Torque:
Approx. 335-345 lb-ft @ 3200-3600 rpm
Engine Option 3:
8.0L V10 Magnum (P/N 53020247-AB)
Engine Option 3 Displacement:
8.0 liters / 488 cubic inches
Engine Option 3 Configuration:
Overhead Valve (OHV), 20-valve, V10
Engine Option 3 Horsepower:
Approx. 305-310 hp @ 4000-4400 rpm
Engine Option 3 Torque:
Approx. 450-460 lb-ft @ 3200-3400 rpm
Engine Option 4:
5.9L Cummins Turbo Diesel (P/N 5010540-AA)
Engine Option 4 Displacement:
5.9 liters / 359 cubic inches
Engine Option 4 Configuration:
Inline 6-cylinder, Turbocharged Diesel
Engine Option 4 Horsepower:
Approx. 235-250 hp @ 2700-2900 rpm
Engine Option 4 Torque:
Approx. 460-525 lb-ft @ 1400-1600 rpm
Performance
Compression Ratio 47L:
9.1:1
Bore X Stroke 47L:
3.90 in x 3.58 in
Bore X Stroke 59L Gas:
4.02 in x 3.58 in
Bore X Stroke 80L V10:
4.00 in x 3.88 in
Bore X Stroke 59L Diesel:
4.02 in x 4.72 in
Fuel System
Fuel Delivery Gas:
Sequential Multiport Fuel Injection (MPI)
Fuel Type Gas:
Unleaded gasoline (87 octane recommended)
Fuel System Diesel:
Direct Injection, Bosch VP44 Injection Pump (early models), Common Rail (later models - check specific build date for 2004/2005)
Fuel Type Diesel:
Diesel fuel (#2 Diesel recommended)
🔧 Transmission
Standard
Transmission Option 1 Type:
42RE 4-Speed Automatic
Transmission Option 1 Applicability:
Typically paired with 4.7L V8, 5.9L V8 (2WD)
Optional
Transmission Option 2 Type:
45RFE/48RE 4-Speed Automatic
Transmission Option 2 Applicability:
Typically paired with 4.7L V8 (4WD), 5.9L V8 (4WD), 8.0L V10, 5.9L Cummins Diesel (48RE is heavy-duty variant)
Transmission Option 3 Type:
NV3500 5-Speed Manual
Transmission Option 3 Applicability:
Optional on 4.7L V8, 5.9L V8 (2WD/4WD)
Transmission Option 4 Type:
NV4500 5-Speed Manual (Heavy Duty)
Transmission Option 4 Applicability:
Typically paired with 5.9L Cummins Diesel, 8.0L V10
Features
Transmission Fluid 42Re 45Rfe:
ATF+4 (Mopar P/N 05013457AA or equivalent)
Transmission Fluid 48Re:
ATF+4 (Mopar P/N 05013457AA or equivalent)
Transfer Case 4Wd Models:
New Process NP243 (Part-time, electronically shifted)
📐 Dimensions
Exterior
Wheelbase Regular Cab:
134.0 inches
Wheelbase Extended Cab:
148.1 inches
Wheelbase Crew Cab:
160.0 inches
Bed Length Standard:
6.3 feet (76.0 inches)
Bed Length Long:
8.0 feet (95.2 inches)
Weights
Curb Weight Range:
Approx. 4,800 - 6,500 lbs (depending on configuration)
Gross Vehicle Weight Rating Gvwr Range:
Approx. 6,000 - 10,000+ lbs (depending on model and configuration)
Towing Capacity Max:
Up to ~10,000+ lbs (depending on engine, axle ratio, and configuration)
Payload Capacity Max:
Up to ~3,000+ lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Good (for models with side airbags)
NHTSA Frontal Impact Passenger:
Good (for models with side airbags)
IIHS Front Overlap Barrier:
Acceptable (typical for the era, varies by specific test)
IIHS Side Impact:
Good (for models with side airbags)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional (often part of Electronic Stability Program - ESP on later models, or integrated into ABS for 2WD)
Passive Features
Airbags Standard:
Driver and Passenger front airbags
Airbags Optional:
Side curtain airbags (often part of premium packages)
Seatbelts:
3-point seatbelts with pretensioners
💡 Technology Features
Infotainment
Audio System Options:
Base AM/FM radio, AM/FM with CD player, premium Infinity audio system with subwoofer.
Navigation System:
Available factory-installed navigation system on higher trim levels.
Driver Assistance
Parking Assist:
Available rear parking assist sensors.
Connectivity
Phone Integration:
Early models did not feature integrated Bluetooth or smartphone connectivity as standard. Aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval Gas:
Every 3,000-7,500 miles or 6-12 months, depending on driving conditions and oil type used (refer to owner's manual for specific recommendations).
Oil Change Interval Diesel:
Every 7,500-15,000 miles or 6-12 months, depending on driving conditions and oil type used (refer to owner's manual for specific recommendations).
Air Filter Replacement Interval:
Every 15,000-30,000 miles or annually, or more frequently in dusty conditions.
Spark Plug Replacement Interval 47L:
Approx. 100,000 miles (long-life platinum/iridium plugs).
Spark Plug Replacement Interval 59L Gas:
Approx. 30,000-60,000 miles (standard copper or platinum plugs).
Coolant Flush Interval:
Every 30,000-60,000 miles or 2-4 years.
Fluid Specifications
Engine Oil Type Gas:
SAE 5W-30 or SAE 10W-30 (refer to owner's manual for specific viscosity based on temperature extremes)
Engine Oil Capacity 47L:
Approx. 5.0 quarts (with filter)
Engine Oil Capacity 59L Gas:
Approx. 5.0 quarts (with filter)
Engine Oil Capacity 80L V10:
Approx. 7.0 quarts (with filter)
Engine Oil Type Diesel:
API CJ-4 or CK-4 rated diesel engine oil, SAE 15W-40 recommended (refer to owner's manual)
Engine Oil Capacity 59L Diesel:
Approx. 10.5 quarts (with filter)
Coolant Type:
Chrysler/Mopar OAT (Organic Acid Technology) Antifreeze/Coolant, typically a pink or orange color (P/N 05013457AA or equivalent, 50/50 mix with distilled water)
Brake Fluid Type:
DOT 3
Power Steering Fluid Type:
ATF+4 (Mopar P/N 05013457AA or equivalent)
Known Issues
Common Issue 47L V8:
Cylinder head gasket failures (especially on early versions), intake manifold gasket leaks, plenum gasket leaks, valve spring issues.
Common Issue 59L Diesel:
VP44 injection pump failures (especially on 2001-2003 models), injector line failures, lifting pump failures, crankshaft position sensor issues.
Common Issue Transmission:
Overdrive clutch failure (42RE/45RFE/48RE), torque converter issues, solenoid pack issues.
Common Issue Suspension Steering:
Worn ball joints and tie rod ends, steering gearbox looseness, worn front suspension bushings.
Common Issue Electrical:
Power window motor failures, instrument cluster gauge sweep issues, ABS sensor failures.
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long and established history in the pickup truck market, dating back to the Dodge Power Wagon in the 1940s. The 'Ram' nameplate became a distinct division of Chrysler in 1993.
Model Evolution
Third Generation Introduction:
The third generation of the Dodge Ram Truck debuted for the 2002 model year, marking a significant redesign with a more muscular and aggressive exterior styling, a revamped interior, and updated powertrain options.
Key Updates 2002-2004:
Introduction of the 4.7L Magnum V8 as a primary engine option, updated interior ergonomics and materials, improved ride comfort, and the availability of the 5.9L Cummins Turbo Diesel in certain configurations. Subtle exterior styling tweaks may have occurred between these early years.
Production
Manufacturing Plants:
Primary assembly locations included Warren Truck Assembly Plant (Michigan) and Saltillo Truck Assembly Plant (Mexico).
🏆 Awards & Recognition
Recognitions
Vehicle Awards:
The Dodge Ram Truck has consistently received positive reviews and awards for its towing capability, engine power, and robust design in the full-size pickup segment throughout its lifespan.
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