Market Segment:
Heavy-duty pickup truck segment, known for towing, hauling, and rugged capability.
Key Competitors:
Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD.
Vehicle Strengths:
Robust construction, powerful engine options, excellent towing capacity, traditional truck design.
Systems Covered:
Comprehensive coverage of all major vehicle systems including engine, transmission, chassis, brakes, steering, suspension, electrical, HVAC, fuel, exhaust, emissions, body, and interior.
Estimated Page Count:
1500-2000+ (typical for comprehensive factory service manuals of this era)
Manual Type:
Factory Service Manual / Repair Manual
Format:
Print (typical, or potentially digital PDF if specified)
Engine Systems:
Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emission control systems for all gasoline and diesel variants.
Drivetrain Systems:
Transmission (manual and automatic), transfer case, driveline, differentials (front and rear), axles.
Chassis Systems:
Suspension (front and rear), steering, brakes (hydraulic, ABS), wheels, tires.
Electrical Systems:
Battery, starting system, charging system, ignition system, instrument panel, lighting, horn, speed control, turn signals, hazard warning, wipers, washers, audio systems, power distribution, power locks, theft/security, power seats, power windows, power mirrors, chimes/buzzers, overhead console.
Body And Comfort Systems:
Body construction, frame, bumpers, interior trim, heating, ventilation, air conditioning (HVAC), passive restraint systems (airbags), electrically heated systems.
Maintenance Procedures:
Lubrication schedules, fluid changes, filter replacements, tire rotations, battery checks, general inspections.
Diagnostic Procedures:
Troubleshooting charts, symptom analysis, diagnostic trouble codes (DTCs) interpretation, electrical system diagnostics.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, repair, assembly, and installation for all major systems.
Rebuilding Procedures:
Detailed instructions for engine, transmission, and differential rebuilds, including specifications and tolerances.
Wiring Diagrams:
Complete, detailed wiring diagrams for all electrical systems, including component locations and wire routing.
Depth Of Information:
Comprehensive; covers basic maintenance to complete engine and transmission overhauls, including component-level diagnostics and repair.
Digital Format:
Likely PDF if digital, optimized for printing and searching.
Print Quality:
High-resolution for clear diagrams, charts, and text (if print version).
Binding:
Likely perfect bound or saddle-stitched for print versions, designed for durability in a workshop environment.
Paper Quality:
Durable, heavy-stock paper suitable for workshop use, resistant to grease and oil stains (typical for factory manuals).
Gasoline Engine Options:
8.0L V10 Magnum (10-cylinder), 5.9L V8 Magnum (8-cylinder).
Diesel Engine Options:
5.9L Cummins Turbo Diesel (6-cylinder ISB).
Gasoline V8 Performance:
Approx. 245-250 hp, 330-345 lb-ft torque (Varying by specific tune).
Gasoline V10 Performance:
Approx. 305-310 hp, 450-455 lb-ft torque.
Diesel Cummins Performance:
Approx. 235 hp, 460-505 lb-ft torque (Varying by specific tune and turbocharger).
Gasoline Fuel System:
Multi-port Fuel Injection (MPFI).
Diesel Fuel System:
Rotary injection pump (VE pump) or high-pressure common rail (HPCR) depending on specific 5.9L Cummins configuration (likely rotary for this year's heavy duty application).
Wheelbase Options:
Various wheelbases available depending on cab and bed configuration (e.g., 134.2", 154.7", 177.2").
Bed Length Options:
8ft or 6ft bed configurations.
Gross Vehicle Weight Rating:
GVWR typically ranges from 8,800 lbs to over 11,500 lbs depending on configuration and axle ratings for 2500/3500 models.
Curb Weight:
Varies significantly by configuration, but typically starts around 6,000-7,000 lbs.
NHTSA Front Impact Rating:
Not explicitly rated by NHTSA for this year/configuration, but generally designed for robustness.
ABS:
Standard Anti-lock Braking System (ABS) on rear wheels, optional 4-wheel ABS.
Airbags:
Driver and passenger front airbags.
Seatbelts:
Front and rear seat belts with pretensioners.
Audio Systems:
Factory AM/FM/CD players, optional premium audio systems, cassette players.
ABS:
Anti-lock Braking System (ABS) available.
Power Features:
Available power windows, power door locks, power mirrors, power seats.
Oil Change Interval:
Typically every 3,000-7,500 miles or 3-6 months, depending on engine type (gas/diesel) and driving conditions (severe vs. normal).
Transmission Fluid Change:
Every 30,000-100,000 miles for automatics, depending on usage and fluid type. Manuals less frequent.
Engine Oil Gasoline:
API Certified SAE 10W-30 or 5W-30 (check owner's manual for specific viscosity and API service category, e.g., API SJ or SL).
Engine Oil Diesel Cummins:
API Certified SAE 15W-40, CJ-4 or CK-4 rated (check owner's manual for specific viscosity and API service category).
Coolant:
HOAT (Hybrid Organic Acid Technology) Extended Life Antifreeze/Coolant, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Transfer Case Fluid:
MS-947-HD (for manual transfer cases) or ATF+4 (for some automatic transfer cases, consult manual).
Differential Fluid:
API GL-5, SAE 75W-90 (or 80W-90 for rear diff, potentially limited slip additive required for LSDs).
Common Gasoline Engine Issues:
Spark plug electrode wear, intake manifold gasket leaks, occasional distributor issues.
Common Diesel Engine Issues:
VP44 injection pump failures (on earlier models before common rail, though this year might still use it), injector line leaks, grid heater element failure, exhaust manifold gasket leaks.
Common Transmission Issues:
Torque converter shudder (automatic), clutch wear (manual), bearing noise in transfer case.
Common Suspension Issues:
Ball joint wear, tie rod end wear, leaf spring fatigue.
Common Brake Issues:
Brake pad and rotor wear, seized caliper pistons, front hub bearing wear.
Common Electrical Issues:
Alternator failure, starter motor issues, gauge cluster malfunctions, power window regulator failures.
Dodge Truck Legacy:
Dodge has a long-standing history in the pickup truck market, dating back to the 1930s, building a reputation for toughness and utility.
Third Generation Ram:
The 2002 model year falls within the third generation of the Dodge Ram pickup (introduced for the 2002 model year for 1500, and 2003 for 2500/3500), marking a significant redesign with a larger, more aggressive styling and improved chassis.
Manufacturing Location:
St. Louis Assembly, St. Louis, Missouri, USA.
