🏷️ Basic Information

Make:

Dodge

Model:

Ram 2500-3500

Year:

2002

Generation Code:

Third Generation (DR/DH/D2)

👋 Introduction

Market Position:

The 2002 Dodge Ram 2500-3500 occupied a significant position in the heavy-duty pickup truck market, known for its robust construction, towing capability, and variety of powertrain options.

Competitive Analysis:

Competed directly with the Ford Super Duty series (F-250, F-350) and Chevrolet Silverado/GMC Sierra HD (2500HD, 3500) of the same era.

Key Features:

Strong chassis, available HEMI V8 engine, Cummins turbodiesel option, heavy-duty towing and payload capacities, spacious interior options.

Key Selling Points Manual:

Provides the exact information needed by technicians and DIY enthusiasts to maintain and repair their 2002 Dodge Ram 2500-3500, saving time and money.

Intended Audience:

Professional automotive technicians, DIY mechanics, fleet managers, and owners who perform their own maintenance and repairs.

📋 Manual Details

Coverage Areas:

All mechanical and electrical systems of the 2002 Dodge Ram 2500 and 3500 pickup trucks.

Page Count:

Not specified, but described as 'complete' and containing 'lots of pictures, diagrams/illustrations, and charts'.

Manual Type:

Service Repair Shop Technical Manual

Language:

English

Format:

PDF

Compatibility Software:

Requires Adobe Acrobat Reader or compatible PDF viewer. Latest version recommended for optimal display.

📖 Manual Coverage

Systems Covered:

Introduction, Lubrication & Maintenance, Suspension, Differential & Driveline, Brakes, Clutch, Cooling, Audio, Chime/Buzzer, Electronic Control Modules, Engine Systems, Heated Systems, Horn, Ignition Control, Instrument Cluster, Lamps, Message Systems, Power Systems, Restraints, Speed Control, Vehicle Theft Security, Wipers/Washers, Wiring, Engine, Exhaust System, Frame & Bumpers, Fuel System, Steering, Transmission and Transfer Case, Tires/Wheels, Body, Heating & Air Conditioning, Emissions Control, Component and System Index.

Procedures Included:

Maintenance, troubleshooting, repair procedures, detailed diagrams, exploded diagrams, drawings, photos, manufacturers specifications.

Technical Depth:

Comprehensive, covering all aspects from routine maintenance to detailed repair of complex systems.

Procedures Included Diagnostics:

Detailed diagnostic procedures for engine, transmission, braking, and electrical systems. Includes troubleshooting charts and common fault codes.

Procedures Included Rebuild:

Comprehensive rebuild procedures for major components such as engines (Cummins, Magnum, HEMI), transmissions, differentials, and transfer cases.

Technical Depth Torque Specs:

Includes precise torque specifications for critical fasteners across all systems, essential for proper assembly and safety.

Technical Depth Schematics:

Extensive wiring diagrams ('Wiring' section) for all electrical circuits, vital for diagnosing and repairing electrical faults.

Procedures Included Alignment:

Front and rear suspension alignment specifications and procedures are included to ensure proper tire wear and vehicle handling.

Procedures Included Ac Recharge:

Detailed instructions for servicing the air conditioning system, including refrigerant types, capacities, and safe handling procedures, found within the 'Heating & Air Conditioning' section.

📊 Manual Specifications

File Format:

PDF

Print Quality:

Printable pages, high-quality resolution for clear diagrams and text.

Binding Type:

Digital download, not physically bound.

Paper Type:

N/A (Digital format).

File Format Compatibility:

Compatible with all versions of Windows, Mac, iOS, Blackberry, Android, and other operating systems supporting PDF viewing.

⚙️ Engine Specifications

Primary Engine Options:

5.9L Cummins Turbo Diesel (24-valve ISB), 5.7L HEMI V8, 4.7L Magnum V8. Specific power outputs varied by configuration and model year updates within 2002.

Performance Diesel:

5.9L Cummins Turbo Diesel: Typically produced around 235-250 horsepower and 450-500 lb-ft of torque, renowned for durability and towing prowess.

Performance Hemi:

5.7L HEMI V8: Introduced for 2003 but initial models might have had earlier V8s. When available, typically produced around 345 horsepower and 375 lb-ft of torque.

Fuel System Diesel:

Common Rail Fuel Injection (CRFI) for the 5.9L Cummins.

Fuel System Gas:

Multi-port fuel injection (MPI) for V8 gasoline engines.

Engine Cooling System:

Pressurized cooling system with thermostatically controlled fan and radiator. Capacity and coolant type detailed in 'Cooling' and 'Lubrication & Maintenance' sections.

Engine Oil Capacity:

Approx. 10-12 quarts for the 5.9L Cummins Diesel, 7 quarts for the 5.7L HEMI V8, and 6 quarts for the 4.7L Magnum V8. Exact capacity specified by engine type.

Engine Block Material:

Cast Iron for all primary engine options (Cummins, Magnum, HEMI).

Engine Head Material:

Cast Iron or Aluminum Alloy, depending on the specific engine variant. 5.9L Cummins uses cast iron.

🔧 Transmission

Standard Transmission:

Varies by engine and trim. Often a 6-speed manual for the Cummins, and a 5-speed manual or 4-speed automatic for gasoline engines.

Optional Transmission:

4-speed automatic transmission (48RE for diesel, 45RFE/47RE for gasoline variants) was a common option, especially for heavier duty applications.

Transfer Case:

Manual or electronic shift-on-the-fly 4WD transfer case (NV241DHD or similar).

Transmission Fluid Capacity:

Automatic transmissions (e.g., 48RE) typically hold around 11-13 quarts when refilling, more for a complete overhaul. Manual transmission capacity varies by model.

Transmission Features:

Heavy-duty construction for both manual and automatic transmissions to handle high torque loads. Overdrive gears for improved fuel economy on the highway.

📐 Dimensions

Wheelbase Options:

Multiple wheelbase options available, including standard, long bed, and crew cab configurations, typically ranging from 134.9 inches to 170.5 inches or more.

Overall Length:

Varies significantly based on cab and bed configuration, but generally longer than standard pickups.

Gross Vehicle Weight Rating Gvwr:

Exceeds 8,500 lbs for 2500 models and can go up to 11,000 lbs or more for 3500 models, depending on configuration.

Tire Size Examples:

Commonly equipped with LT265/70R17, LT275/70R18, or similar heavy-duty rated tires. Specifics vary by trim and axle ratio.

Wheel Bolt Pattern:

Typically 8x6.5 inches (8x165.1 mm) for Ram 2500/3500 models.

🛡️ Safety Features

Ratings:

As a heavy-duty truck, specific crash test ratings (like NHTSA's 5-star) might differ from lighter vehicles. Focus was on structural integrity for towing and payload.

Active Features:

Anti-lock Braking System (ABS) standard on all wheels.

Passive Features:

Front airbags for driver and passenger. Seat belt pre-tensioners.

Braking System:

Power-assisted front disc and rear drum or disc brakes, depending on configuration. ABS is standard. Detailed inspection, service, and fluid replacement procedures are in the 'Brakes' section.

💡 Technology Features

Infotainment:

Basic infotainment systems for the era, often including AM/FM radio, cassette player, and CD player options. Speaker system details are covered in the 'Audio' section.

Driver Assistance:

Limited driver assistance features by modern standards. Primarily focused on ABS. Cruise control is detailed in 'Speed Control'.

Connectivity:

No integrated smartphone connectivity or advanced Bluetooth. Auxiliary inputs for audio might be present on some higher trims.

🔧 Maintenance

Service Intervals Oil:

Typically every 3,000-7,500 miles or 6 months for gasoline engines, and 5,000-10,000 miles or 12 months for the Cummins diesel, depending on usage and oil type specified in the manual.

Fluid Specifications Engine Oil:

Gasoline engines: API SN, SAE 5W-30 or 5W-40. Cummins Diesel: API CJ-4, SAE 15W-40 (or synthetic equivalent).

Fluid Specifications Transmission:

Automatic Transmissions: ATF+4 (MS-9602). Manual Transmissions: GL-4 or GL-5 gear oil depending on specific unit.

Fluid Specifications Coolant:

Mopar OAT (Organic Additive Technology) Antifreeze/Coolant, typically a 50/50 mix with distilled water.

Known Issues Diesel Injector:

Potential for injector failure or issues with the injection pump, particularly with older fuel or contamination. Manual covers diagnostic procedures.

Known Issues Suspension:

Wear in ball joints, tie rod ends, and steering linkages due to heavy-duty use. Front end alignment checks are crucial.

Known Issues Transmission Auto:

The 48RE automatic transmission, while robust, can experience wear in torque converters and solenoids with high mileage or heavy towing. Manual details overhaul procedures.

Known Issues Electrical:

Corrosion on wiring connectors, particularly in salt-belt regions, can lead to intermittent issues. The 'Wiring' section is invaluable.

Filter Part Numbers:

Manual provides specific part numbers or references for oil filters, fuel filters (especially critical for diesel), air filters, and cabin air filters for all engine options.

Tune Up Procedures:

Covers spark plug replacement, ignition system checks, fuel filter replacement, and air filter replacement for gasoline engines. Diesel specific maintenance like fuel filter changes and injector checks are also detailed.

📚 Vehicle History

Brand Heritage:

Dodge has a long history in the truck market, with the Ram nameplate becoming synonymous with capability and toughness since its introduction.

Model Evolution:

The 2002 model year marked the beginning of the third generation (2002-2008) for the Dodge Ram pickup, which featured a significant redesign with a larger, more aggressive styling, an improved interior, and the introduction of the HEMI V8 in subsequent years.

Production Location:

Primary manufacturing plants included Warren Truck Assembly Plant in Warren, Michigan, and Saltillo Truck Assembly Plant in Saltillo, Mexico.

Model Designations:

Ram 2500 indicates a capacity rating for heavier loads than a 1500, and the Ram 3500 signifies even greater payload and towing capability, often featuring dual rear wheels (DRW) in some configurations.