🏷️ Basic Information

Make:

Dodge

Model:

Ram Pickup 2500 / 3500

Year:

2002

Chassis Code:

DR

Platform:

Third Generation Dodge Ram (2002-2008)

👋 Introduction

Segment:

Heavy-Duty Pickup Truck

Target Audience:

Owners, fleet managers, professional mechanics, serious DIY enthusiasts.

Competitors:

Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD.

Vehicle Strength:

Renowned for its robust construction, powerful engine options, and towing/hauling capabilities.

Manual Advantage:

Provides in-depth technical data and repair procedures essential for maintaining and repairing these heavy-duty vehicles effectively.

📋 Manual Details

Regions Covered:

North America

Estimated Pages:

2000+

Type:

Workshop Service Repair Manual

Language:

English

Format:

Downloadable Digital File (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, troubleshooting, diagnostics, components (pistons, rings, bearings, camshaft, crankshaft, valves, timing, lubrication, cooling).

Engine Performance:

Fuel delivery, ignition system, emission controls, turbocharger (if applicable), engine tuning.

Transmission Manual:

Service, repair, overhaul, diagnostics, clutch, synchronizers, gears, bearings.

Transmission Automatic:

Service, repair, overhaul, diagnostics, torque converter, valve body, internal components, fluid services.

Drivetrain:

Driveshafts, U-joints, differentials (front and rear), axle shafts, hubs, transfer case (NV241/NV271/NV273).

Suspension:

Front and rear suspension components, steering system, wheel alignment, shocks, springs, control arms, ball joints.

Brakes:

Hydraulic system, ABS, brake lines, calipers, rotors, pads, parking brake, bleeding procedures.

Steering:

Power steering system, steering column, steering gear/rack, tie rods, power steering pump.

Electrical System:

Battery, charging system, starting system, lighting, wipers, horn, power windows, power locks, instrument cluster.

Electronics Control:

PCM (Powertrain Control Module), TCM (Transmission Control Module), BCM (Body Control Module), CAN bus communication.

HVAC:

Heating, ventilation, air conditioning system components, refrigerant, operation, troubleshooting.

Body Interior:

Body panels, doors, latches, hinges, interior trim, seats, SRS (Supplemental Restraint System).

Body Exterior:

Bumpers, fenders, hood, tailgate, glass, mirrors, exterior trim.

Chassis Frame:

Frame inspection, repair, mounting points.

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting, common problems and solutions.

Repair:

Step-by-step repair procedures for all major systems, component replacement, adjustments.

Diagnostics:

OBD-II diagnostics, diagnostic trouble codes (DTCs), scan tool usage, sensor testing.

Installation:

Procedures for replacing key components and systems.

Specifications:

Torque specifications for fasteners, clearances, tolerances, electrical values.

Wiring Diagrams:

Comprehensive electrical schematics for all systems.

Depth:

Expert-level, suitable for professional technicians and advanced DIYers. Covers everything from routine maintenance to complete engine and transmission rebuilds.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for on-site workshop use.

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Options:

8.0L V10 Triton (2002-2003), 5.9L Cummins Turbo Diesel (ISB), 4.7L Magnum V8

Engine Code 8.0L V10:

370 cu in (SOHC)

Engine Code 4.7L V8:

287 cu in (SOHC)

Engine Code 5.9L Cummins Diesel:

359 cu in (OHV, Turbocharged)

8.0L V10 Horsepower:

305-310 hp @ 4,000 rpm

8.0L V10 Torque:

450-455 lb-ft @ 3,200 rpm

4.7L V8 Horsepower:

235-245 hp @ 4,800 rpm

4.7L V8 Torque:

300-325 lb-ft @ 3,200 rpm

5.9L Cummins Diesel Horsepower:

235-250 hp @ 2,900 rpm

5.9L Cummins Diesel Torque:

460-475 lb-ft @ 1,400 rpm

8.0L V10 Fuel System:

Multi-Point Fuel Injection (MPI)

4.7L V8 Fuel System:

Multi-Point Fuel Injection (MPI)

5.9L Cummins Diesel Fuel System:

Rotary Injection Pump (VP44) with direct injection

🔧 Transmission

Standard Transmission:

6-Speed Manual (NV5600 - Diesel), 5-Speed Manual (NV3500/NV4500 - Gas/Diesel)

Optional Transmission:

4-Speed Automatic (48RE - Diesel), 4-Speed Automatic (46RE - Gas)

48Re Features:

Heavy-duty, electronically controlled overdrive with lock-up torque converter.

Nv5600 Features:

Robust design for high torque applications, dual-mass flywheel.

48Re Fluid Type:

ATF+4 (Chrysler Specification MS-9602)

Nv5600 Fluid Type:

API GL-5, SAE 75W-90 Synthetic Gear Lubricant

📐 Dimensions

Wheelbase Options:

134.1 in (Regular Cab 8' Bed), 147.5 in (Club Cab 8' Bed), 167.5 in (Club Cab 8' Bed DRW), 162.1 in (Quad Cab 6'4" Bed)

Overall Length Approx:

236 - 261 inches (depending on configuration)

Overall Width Approx:

79.9 inches

Overall Height Approx:

77.4 - 78.5 inches (depending on configuration)

Gvwr Range:

8,830 lbs (2500) to 10,700 lbs (3500 DRW)

Curb Weight Approx:

5,500 - 7,000 lbs (depending on configuration)

Towing Capacity Max:

Up to 13,000 lbs (3500 DRW with proper configuration)

Payload Capacity Max:

Up to 5,000 lbs (depending on configuration)

🛡️ Safety Features

NHTSA Frontal Impact Driver:

Not rated or N/A for this specific model year's testing parameters for heavy trucks.

NHTSA Frontal Impact Passenger:

Not rated or N/A for this specific model year's testing parameters for heavy trucks.

IIHS Ratings:

Generally considered 'Acceptable' to 'Good' in frontal impacts based on contemporary reviews for similar heavy-duty trucks.

ABS:

Standard Anti-lock Braking System (4-wheel).

Trailer Brake Controller Prep:

Available pre-wiring for aftermarket or factory trailer brake controllers.

Airbags:

Driver and Passenger front airbags.

Seatbelts:

Three-point front seatbelts with pretensioners; rear seatbelts as applicable.

Srs:

Supplemental Restraint System for front airbags.

💡 Technology Features

Audio System:

Base AM/FM cassette and/or CD player. Optional premium Infinity sound system.

Display:

Basic instrument cluster with analog gauges. No central infotainment screen in base models.

Cruise Control:

Standard or available electronic cruise control.

Parking Assist:

Rear parking assist sensors were an option on some higher trims.

Phone Integration:

No factory integrated Bluetooth or smartphone connectivity. Aftermarket solutions available.

OBD Ii Port:

Standard OBD-II diagnostic port for emissions and engine diagnostics.

🔧 Maintenance

Oil Change Gas Engine:

Every 3,000-5,000 miles or 3-6 months (severe vs. normal use), or per manual. Typically uses SAE 5W-30 or 10W-30.

Oil Change Diesel Engine:

Every 7,500-10,000 miles or 6-12 months with diesel-specific oil. Manual recommendation is key.

Transmission Fluid Change Auto:

Every 30,000-60,000 miles for ATF+4 (heavy duty use may require more frequent changes).

Transmission Fluid Change Manual:

Inspect every 30,000 miles, typically recommended for replacement around 100,000 miles or if contaminated.

Coolant Flush:

Every 30,000-60,000 miles or 2-4 years with appropriate coolant (e.g., Mopar OAT).

Engine Oil Gas:

API Service SJ or SL, SAE 10W-30 or 5W-30 (check owner's manual for specific viscosity).

Engine Oil Diesel:

API Service CH-4 or CI-4 rated, SAE 15W-40 (check owner's manual for specific viscosity).

Coolant Type:

Mopar OAT (Organic Additive Technology) or equivalent HOAT (Hybrid OAT) for diesel, consult manual for exact type.

Brake Fluid:

DOT 3.

Diesel Injection Pump:

VP44 injection pump on the 5.9L Cummins can be prone to failure due to fuel pressure issues or heat. Upgraded lift pumps are often recommended.

Front Suspension Wear:

Ball joints, tie rod ends, and track bar can experience premature wear due to the weight and duty cycle of the truck.

Automatic Transmission Slipping:

The 48RE transmission can sometimes develop slipping issues, often related to torque converter clutch wear or valve body solenoid issues. Overheating is also a concern.

Cracked Exhaust Manifolds:

Cast iron exhaust manifolds on the V10 and Cummins engines can develop cracks due to thermal cycling.

Rear Main Seal Leaks:

Rear main crankshaft seal leaks can occur on both gas and diesel engines.

📚 Vehicle History

Dodge Truck Legacy:

Dodge has a long-standing reputation for building durable and capable trucks, dating back to the 1930s.

Third Generation Ram:

Introduced for the 2002 model year, this generation featured a complete redesign with a bolder, more muscular exterior styling and an improved interior. It marked a significant departure from the previous generation.

Powertrain Changes:

The 2002 model year saw the introduction of the updated 5.9L Cummins Turbo Diesel and the robust NV5600 6-speed manual transmission, solidifying the Ram's position as a top contender in the diesel truck market.

Production Locations:

Warren Truck Assembly Plant, Warren, Michigan, USA.

🏆 Awards & Recognition

Truck Of The Year:

While specific awards vary, the Dodge Ram line consistently received praise for its styling and capability in this era.

Customer Satisfaction:

Generally strong for its segment, particularly the Cummins diesel models, which have a dedicated following.

Emissions Standards:

Compliant with all applicable EPA emissions standards for the model year.