🏷️ Basic Information

Make:

Dodge

Model:

Ram 1500 Series

Model Years Covered:

2002, 2003, 2004

Platform:

Third Generation Dodge Ram (DR/DH/D1)

Chassis Code:

DR

👋 Introduction

Market Position:

The Dodge Ram 1500 (third generation) represented a significant redesign in 2002, focusing on improved aerodynamics, ride comfort, and interior refinement, while maintaining its reputation for robust capability. It competed directly with the Ford F-150 and Chevrolet Silverado 1500.

Competitive Analysis:

This generation of Ram trucks offered a distinct style and ride quality compared to its competitors. The available HEMI V8 engine was a major draw, providing class-leading power. The manual covers the unique engineering and service points of this specific Dodge platform.

Key Features:

Distinctive 'crosshair' grille design, independent front suspension (on most models), available 5.7L HEMI V8 engine, updated interior ergonomics, increased towing and payload capacities over the previous generation.

📋 Manual Details

Coverage Areas:

All aspects of service, repair, maintenance, diagnostics, and troubleshooting for Dodge Ram 1500 Series trucks from 2002-2004.

Page Count:

Estimated 1500-2000+ pages (typical for comprehensive service manuals of this era).

Manual Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Systems Covered:

Engine, Transmission (Automatic & Manual), Drivetrain (4x2 & 4x4), Suspension, Steering, Brakes (ABS included), HVAC, Electrical System (including Wiring Diagrams), Body & Frame, Interior, Fuel System, Exhaust System, Cooling System, Ignition System, Emissions Control.

Systems Covered Expanded:

Detailed coverage of the Electronic Control Modules (ECM/PCM), Body Control Module (BCM), diagnostic trouble codes (DTCs) and their interpretation, sensor inputs and outputs (e.g., O2 sensors, MAF sensor, CKP/CMP sensors), and actuator testing (e.g., injectors, ignition coils).

Systems Covered Electrical:

Comprehensive electrical diagnostics including power distribution, grounding points, starter and charging system, lighting systems (headlights, taillights, interior), instrument cluster, ignition switch, relays, fuses, and power windows/locks. Detailed wiring diagrams are a key feature.

Procedures Included:

Routine Maintenance, Scheduled Maintenance, Component Removal & Installation, Disassembly & Assembly, Diagnostic Procedures, Troubleshooting Guides, Wiring Diagram Interpretation, Repair Specifications, Torque Specifications, Component Testing, System Adjustments.

Procedures Included Expanded:

Head gasket replacement, piston ring installation, cylinder head repair, crankshaft and connecting rod bearing replacement, timing chain/belt (or gear drive) service, clutch replacement (for manual transmission), brake rotor and pad replacement, caliper service, power steering pump and rack replacement, alternator and starter motor diagnostics and replacement.

Technical Depth:

Comprehensive, covering everything from basic fluid changes and filter replacements to complex engine overhauls, transmission rebuilding, electrical system diagnostics, and body panel repairs. Includes detailed diagnostic flowcharts and procedures.

📊 Manual Specifications

File Format:

PDF (Searchable text, printable pages).

File Format Details:

High-quality PDF allowing for zooming into intricate diagrams and text. Often includes bookmark functionality for easy navigation between sections.

Print Quality:

High resolution, ensuring clarity of diagrams, illustrations, and text.

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine:

4.7L Magnum V8 (P-Code)

4.7L Engine Details:

SOHC, 16-valve, cast-iron block, aluminum heads. Power output typically around 235-240 hp and 295-300 lb-ft torque.

4.7L Engine Code:

EVC, EVG, EVE, EVF (various emissions and power configurations).

Optional Engine 1:

3.7L Magnum V6 (P-Code)

3.7L Engine Details:

SOHC, 12-valve. Power output typically around 215 hp and 235 lb-ft torque. Primarily offered on 2WD models.

3.7L Engine Code:

EPL, EPX (various emissions configurations).

Optional Engine 2:

5.7L HEMI V8 (M-Code)

5.7L Engine Details:

OHV, 16-valve, HEMI head design, Pushrod. Introduced in 2003. Power output typically around 345-345 hp and 375-375 lb-ft torque. Features Multiple Displacement System (MDS) on later models within this range.

5.7L Engine Code:

EPE, EPJ (HEMI).

Performance Notes:

The 5.7L HEMI provided a significant performance advantage, making it a highly sought-after option. The manual will detail specific performance tuning and diagnostic procedures for each engine variant.

Torque Curve Notes:

The HEMI's significant torque availability across a broad RPM range made it ideal for towing and hauling, a characteristic that the manual implicitly supports through its detailed powertrain servicing guidelines.

Fuel System:

Sequential Multi-Port Fuel Injection (MPI).

🔧 Transmission

Standard Transmission:

4-Speed Automatic (42RE, 44RE, 45RFE/48RE depending on engine).

Optional Transmission:

5-Speed Manual (NV3500 for V6, NV4500 for V8 applications on some models).

Transmission Details 45Rfe:

The 45RFE and its evolution, the 48RE (used with the HEMI), are electronically controlled 4-speed automatics known for their robustness. The manual will cover their internal components, solenoid operation, and diagnostic troubleshooting.

Drivetrain:

Available in 4x2 (Rear Wheel Drive) and 4x4 (Four Wheel Drive) configurations. 4x4 systems are typically part-time with electronic engagement (NV244, NV242 transfer cases).

Transmission Fluid:

ATF+4 (Mopar material number 05013457AA or equivalent).

Transmission Details 42Re:

A robust 4-speed automatic primarily used with the 4.7L Magnum V8. The manual will cover adjustments, band tension, valve body service, and troubleshooting for this common transmission.

Transmission Details 44Re:

Similar to the 42RE but with different torque converter and gear ratios, often paired with the 5.2L and 5.9L Magnum V8s in earlier generations, but the manual will detail its presence if applicable to specific 2002-2004 configurations or its evolution into the 45RFE.

Transmission Fluid Capacity:

Approximately 11-13 quarts (3.0-3.4 gallons) for automatic transmissions, but the manual provides exact capacities for dry fill and refill after service.

📐 Dimensions

Exterior Dimensions:

Varies by cab style (Regular Cab, Extended Cab/Quad Cab) and bed length (6', 8'). Wheelbase typically ranges from 120.5 inches to 140.5 inches. Overall length can exceed 240 inches.

Wheelbase Regular Cab:

134.0 inches

Wheelbase Quad Cab:

140.5 inches

Interior Dimensions:

Significant cabin space, especially in Quad Cab models, offering comfortable seating for up to six passengers. The manual details interior component removal and installation.

Cargo Dimensions:

Bed lengths typically 78.0 inches (6.5 ft) or 98.3 inches (8 ft). Payload capacity varies from approximately 1,300 lbs to over 2,000 lbs depending on configuration.

Weights:

Curb weight ranges from approximately 4,500 lbs to 5,500 lbs. Gross Vehicle Weight Rating (GVWR) typically ranges from 6,050 lbs to 6,700 lbs.

Towing Capacity:

Can range from 4,000 lbs to over 8,000 lbs depending on engine, drivetrain, axle ratio, and factory tow package. The manual details how to determine and maximize towing capacity.

Axle Ratio Options:

Common axle ratios included 3.55, 3.92, and 4.10, typically paired with specific engines and transmission configurations. The manual will guide on identifying the correct ratio for optimal performance and fuel economy.

🛡️ Safety Features

Safety Ratings:

IIHS (Insurance Institute for Highway Safety) and NHTSA (National Highway Traffic Safety Administration) ratings should be referenced for specific model year and configuration. The manual provides details on safety system components.

Active Features:

Anti-lock Braking System (ABS), available Traction Control System (TCS).

Active Safety System Details:

The manual provides detailed diagnostic flowcharts for ABS and TCS faults, including sensor testing (wheel speed sensors), hydraulic modulator checks, and ABS control module troubleshooting.

Passive Features:

Front airbags, optional side curtain airbags (availability varies by trim and year), seatbelt pre-tensioners, crumple zones designed into the frame and body structure.

Brake Specs:

Front: Vented discs with caliper. Rear: Drums or discs depending on GVWR and configuration. ABS system is integral to braking performance. Manual details pad and rotor specifications, fluid flush procedures, and bleeding sequences.

💡 Technology Features

Infotainment:

Base models featured AM/FM radio and CD players. Higher trims offered premium audio systems, CD changers, and optional SiriusXM satellite radio. Navigation systems were not commonly integrated during these years.

Infotainment Upgrades:

Aftermarket head units are commonly installed to upgrade connectivity features like Bluetooth, Apple CarPlay, and Android Auto. The manual will detail the factory wiring harnesses for these integrations.

Driver Assistance:

Limited by modern standards. Features primarily included ABS and Traction Control. Cruise control was standard on most trims.

Connectivity:

No Bluetooth or USB connectivity in base models. Some higher trims might have offered auxiliary audio inputs for external devices.

🔧 Maintenance

Service Intervals:

Standard intervals include oil changes every 3,000-5,000 miles or 6 months (depending on oil type and driving conditions), filter changes, tire rotations every 5,000-7,500 miles. Detailed schedules for spark plugs, transmission service, coolant, and other components are provided in the manual.

Spark Plug Replacement Interval:

Typically every 30,000-60,000 miles depending on spark plug type (e.g., copper vs. platinum/iridium). The 5.7L HEMI often uses a different interval or plug type. The manual specifies exact types and intervals.

Fluid Specifications:

Engine Oil: SAE 5W-20 or 5W-30 (per engine and climate, check manual for specific OE recommendation, typically 5 quarts for V6/4.7L V8, 7 quarts for 5.7L HEMI). Coolant: Mopar Antifreeze/Coolant (HOAT - Hybrid Organic Acid Technology), typically a 50/50 mix with distilled water. Brake Fluid: DOT 3. Power Steering Fluid: ATF+4 or specified Mopar fluid. Gear Oil: SAE 75W-90 GL-5 for differentials.

Coolant Capacity:

Approximately 13-15 quarts (3.25-3.75 gallons) for the 4.7L V8, and 15-17 quarts (3.75-4.25 gallons) for the 5.7L HEMI, when using a 50/50 mix. Manual confirms exact capacities.

Engine Oil Capacity 47L:

5 Quarts (4.7 Liters) when using SAE 5W-20 or SAE 5W-30. Manual specifies Mopar or equivalent API certified oil.

Engine Oil Capacity 57L Hemi:

7 Quarts (6.6 Liters) when using SAE 5W-20 or SAE 5W-30. Manual specifies Mopar or equivalent API certified oil with advanced additive package for HEMI.

Filter Part Numbers:

Oil Filter (e.g., for 4.7L V8, Mopar Part # MO-090 or equivalent from brands like Wix, Fram, Bosch). Air Filter (e.g., Mopar Part # 53005601 or equivalent). Fuel Filter (location and part number vary by engine and fuel system type, often integrated within the fuel pump module on later models). Cabin Air Filter (if equipped, varies by trim).

Known Issues:

Common issues can include: 'Death Wobble' (steering/suspension play, particularly affecting front-end components), rear axle seal leaks, intake manifold gasket leaks (especially on 4.7L), PCM (Powertrain Control Module) failures, occasional transmission solenoid issues (45RFE/48RE), and rust formation on certain body panels. The manual provides diagnostic procedures for these and other common problems.

Known Issues 47L Intake:

Intake manifold gaskets on the 4.7L Magnum V8 are prone to cracking or degradation, leading to vacuum leaks and performance issues. The manual provides the correct procedure and torque sequence for replacement.

📚 Vehicle History

Brand Heritage:

Dodge has a long history of producing robust and capable trucks under the Ram nameplate, known for their distinctive styling and strong performance, particularly with their V8 engine offerings.

Model Evolution:

The 2002 model year marked the debut of the third generation Ram, a complete redesign from the second generation. Key changes included a revised chassis, updated styling with a more integrated grille and bumper, improved aerodynamics, and the introduction of the HEMI engine in 2003.

Model Evolution Key Advancements:

Introduction of the independent front suspension on most models (a significant departure from the solid front axle of previous generations), which improved on-road handling and ride comfort considerably. The aggressive styling cues were also a major differentiator.

Model Evolution Hemitrack:

The successful introduction of the 5.7L HEMI in 2003 significantly boosted the Ram's performance credentials and market appeal, setting a new benchmark for power in the half-ton segment. The manual's thoroughness on HEMI-specific components is a testament to its importance.

Production Location:

Saltillo, Mexico and Warren, Michigan, USA.

🏆 Awards & Recognition

Recognitions:

The third-generation Ram trucks, particularly those equipped with the HEMI V8, received critical acclaim for their performance and styling. While specific awards vary, the HEMI engine itself was a significant technological achievement widely recognized for its power and versatility.

Ratings:

Consumer satisfaction ratings and professional reviews from automotive publications of the era often highlighted the HEMI's performance, the truck's comfortable ride, and its towing capabilities. The manual is essential for maintaining these capabilities.