Segment:
Heavy-duty pickup truck
Target Audience:
Owners of 2002 Dodge Ram 2500/3500, independent repair shops, fleet maintenance
Competitors:
Ford Super Duty F-250/F-350, Chevrolet Silverado 2500HD/3500HD, GMC Sierra 2500HD/3500HD
Vehicle Strengths:
Robust chassis, powerful engine options, towing and hauling capability
Manual Value Proposition:
Provides essential factory data for maintaining and repairing a capable heavy-duty truck
Overall Coverage:
Comprehensive service, maintenance, and troubleshooting
Specific Models Covered:
Dodge Ram 2500, Dodge Ram 3500
Engine Coverage:
All Engines (specific engine types TBD by internal documentation)
Transmission Coverage:
All Transmissions (specific transmission types TBD by internal documentation)
Body Style Coverage:
All Body Styles (TBD by internal documentation)
Estimated Page Count:
Likely 1000+ pages (typical for comprehensive factory service manuals)
Type:
Workshop Repair Service Manual
Engine:
Detailed diagnostics, repair, overhaul for gasoline and diesel engines
Transmission:
Service and repair for manual and automatic transmissions
Drivetrain:
Front axle, rear axle, driveshafts, transfer case (4WD models)
Suspension:
Front and rear suspension components, steering system
Brakes:
Hydraulic system, ABS, parking brake, component replacement
Electrical:
Wiring diagrams, lighting, ignition, charging system, starting system, body electrical, instrumentation
Fuel System:
Fuel delivery, injection systems (gasoline), fuel injection (diesel), fuel tank and lines
Cooling System:
Radiator, water pump, thermostat, fan, heater system
Exhaust System:
Catalytic converter, mufflers, pipes, emission controls
HVAC:
Heating, Ventilation, and Air Conditioning system components and service
Body:
Body panels, doors, glass, trim, structural components
Chassis:
Frame, engine mounting, suspension mounting points
Routine Maintenance:
Oil changes, filter replacements, fluid checks, tire rotation
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting guides
Repair Procedures:
Step-by-step instructions for component replacement and repair
Diagnostics:
On-board diagnostics (OBD-II) information, diagnostic trouble codes (DTCs)
Rebuilding:
Engine and transmission rebuilding specifications and procedures
Specifications:
Torque specifications, clearances, alignments, electrical specifications
Depth:
Factory-level detail, suitable for professional technicians and experienced DIYers
Scope:
Covers all aspects from basic maintenance to major overhauls and diagnostics
Common Gas Engine:
8.0L V10 Magnum (450 cu in) - Estimated 305-310 hp / 450-455 lb-ft torque
Common Diesel Engine:
5.9L Cummins I6 Turbo Diesel (359 cu in) - Estimated 235-250 hp / 460-470 lb-ft torque
Power Delivery:
Emphasis on low-end torque for towing and hauling
Gasoline Injection:
Multi-point fuel injection (MPI)
Diesel Injection:
High-pressure common rail (HPCR) for Cummins engines
V10 Gas:
V10 (specific engine ID depends on exact configuration)
Cummins Diesel:
5.9L ISB Cummins (specific engine ID depends on exact configuration)
Standard Transmission Type:
5-speed manual (NV4500 for some applications)
Optional Automatic Transmission:
4-speed automatic (47RE / 48RE for gasoline and diesel)
4Wd System:
Part-time 4WD with manual transfer case lever or electronic shift on the fly (ESOF)
Wheelbase Options:
Varies by cab and bed configuration (e.g., 130.5", 140.5", 154.5" for 2500)
Bed Length Options:
Standard Bed (approx. 6.3 ft), Long Bed (approx. 8 ft)
Gvwr Range:
Starts around 8,800 lbs for 2500, up to 11,500+ lbs for 3500
Curb Weight Range:
Varies significantly by configuration, typically 6,000-7,500 lbs
Max Conventional Towing:
Up to ~10,000 - 12,000 lbs (depending on configuration and axle ratio)
Max Gooseneck Towing:
Up to ~13,000 - 16,000 lbs (depending on configuration and axle ratio, typically 3500 DRW)
NHTSA Front Crash:
NHTSA frontal crash ratings are generally good for trucks of this era, specific score varies by configuration.
ABS:
Anti-lock Braking System (ABS) standard on all wheels
Trailer Brake Controller Provision:
Provision for factory or aftermarket trailer brake controller
Airbags:
Driver and passenger front airbags
Seatbelts:
Three-point front seat belts with pretensioners, rear seat belts
Audio System:
Base AM/FM radio with cassette player and optional CD player. Higher trims may offer premium audio.
Display:
Minimal central display for basic information, no integrated touchscreens typical for this era.
Cruise Control:
Standard on most trims
Tow Haul Mode:
Available on automatic transmissions to optimize shifting for towing.
Auxiliary Inputs:
No factory auxiliary audio input or USB ports typically.
Oil Change Interval:
Typically 3,000-5,000 miles or 6 months for gasoline, 5,000-7,500 miles or 6 months for diesel, depending on severe/normal service.
Transmission Fluid Change:
Automatic: 30,000-50,000 miles. Manual: Inspect at 30,000 miles, fluid change typically 60,000-100,000 miles.
Engine Oil Gasoline:
API Certified SAE 10W-30 or 10W-40 (check manual for specific viscosity recommendations and API classifications like CI-4/SL)
Engine Oil Diesel:
API CI-4 rated SAE 15W-40 diesel engine oil (Cummins recommendation)
Transmission Fluid Auto:
ATF+3 or ATF+4 (Chrysler spec)
Transmission Fluid Manual:
API GL-3 or GL-4 SAE 75W-90 gear oil (for NV4500)
Coolant:
Mopar Antifreeze/Coolant (HOAT - Hybrid Organic Acid Technology), typically a 50/50 mix with distilled water
Common Diesel Issue:
VP44 injection pump failures (especially on earlier models with insufficient lift pump pressure), injector issues, front axle U-joint wear.
Common Gas Issue:
Spark plug fouling on V10, exhaust manifold leaks, some transmission hard shifting issues.
Common Chassis Issue:
Frame rust (especially in areas with road salt), ball joint wear, rear axle seal leaks.
Oil Filter Gasoline:
Mopar MO-090 or equivalent (e.g., Wix 51515, Purolator L20093)
Oil Filter Diesel:
Mopar MO-899 or equivalent (e.g., Wix 57108, Fleetguard LF9009)
Dodge Truck Legacy:
Dodge has a long history of producing rugged and capable trucks for work and utility.
Second Generation Ram:
The 2002 model falls into the second generation (1994-2001) with a facelift for 2002-2003, featuring updated styling (grille, headlights) and interior refinements.
Manufacturing Plant:
Saltillo Truck Plant, Mexico; St. Louis Assembly Plant, Missouri (pre-2004)
Truck Of The Year Competitors:
While not specific to the 2002 model, the Dodge Ram lineup has historically received accolades for its design and capability.
Consumer Reports Reliability:
Reliability ratings for 2002 models can be mixed, often depending on the specific engine and drivetrain. Cummins diesel generally rated higher for durability.
