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Dodge Ram Truck 2500 3500 2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck 2500/3500 Year: 2002 Generation Generation Designation: Third Generation (DR/DH/D2) Codes Platform: DR platform 👋 Introduction Market Position Vehicle Segment: Heavy-duty pickup...
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Dodge Ram Truck 2500 3500 2002 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Ram Truck 2500/3500
Year:
2002
Generation
Generation Designation:
Third Generation (DR/DH/D2)
Codes
Platform:
DR platform
👋 Introduction
Market Position
Vehicle Segment:
Heavy-duty pickup truck
Target Audience:
Commercial users, fleet operators, individuals requiring heavy-duty towing and hauling capabilities
Competitive Analysis
Primary Competitors:
Ford Super Duty F-250/F-350, Chevrolet Silverado 2500HD/3500HD, GMC Sierra 2500HD/3500HD
Key Features
Vehicle Purpose:
Heavy-duty work, towing, hauling, off-road capability
Manual Value Proposition:
Comprehensive, detailed repair and maintenance guidance for DIY mechanics and professional technicians, saving on dealership service costs.
📋 Manual Details
Coverage Areas
Model Variants Covered:
Dodge Ram 2500, Dodge Ram 3500
Page Count
Total Pages:
2255
Manual Type
Manual Classification:
Workshop Service Repair Manual
Language
Primary Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder heads, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system
Engine Performance:
Fuel injection, ignition system, emission control systems, turbocharger (if applicable)
Transmission Drivetrain:
Manual and automatic transmission overhaul, transfer case, drive shafts, differentials, axle assemblies
Brakes:
Front and rear brake systems (disc/drum), ABS, parking brake
Steering:
Power steering system, steering gear, steering linkage
Suspension:
Front and rear suspension components, shock absorbers, springs, bushings
Electrical System:
Battery, charging system, starting system, lighting, instrument cluster, body control modules, sensors, wiring diagrams
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair
Body And Interior:
Body panels, doors, windows, seats, trim, bumpers, glass replacement
Chassis And Frame:
Frame construction, diagnosis, and repair
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication
Repair Procedures:
Detailed step-by-step repair instructions for all major vehicle systems
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnosis, fault code interpretation
Overhaul Procedures:
Complete disassembly, inspection, and reassembly of major components like engines and transmissions
Installation Procedures:
Guidance for component replacement and installation
Technical Depth
Diagnostic Capability:
Advanced diagnostics, including detailed wiring diagrams and component testing procedures
Repair Complexity:
Covers basic maintenance to complete engine and transmission rebuilds
Information Detail:
Includes torque specifications, clearances, tolerances, and OEM procedures
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable PDF
Print Quality
Printability:
Printable pages for easy workshop use
Binding Type
Digital Binding:
N/A (Digital Download)
Paper Type
Digital Paper Emulation:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options:
5.7L V8 Magnum, 8.0L V10 Magnum, 5.9L Cummins I6 Turbo Diesel
Performance
5.7L Magnum Horsepower:
Approx. 325 hp
5.7L Magnum Torque:
Approx. 370 lb-ft
8.0L Magnum Horsepower:
Approx. 305 hp
8.0L Magnum Torque:
Approx. 450 lb-ft
5.9L Cummins Horsepower:
Approx. 235-250 hp (depending on configuration)
5.9L Cummins Torque:
Approx. 460-475 lb-ft (depending on configuration)
Fuel System
Gasoline Fuel System:
Multi-point fuel injection (MPI)
Diesel Fuel System:
High-pressure common rail injection system (Cummins)
🔧 Transmission
Standard
Standard Transmission:
5-speed manual (NV4500 for some models/engines)
Optional
Optional Transmission Gas:
4-speed automatic (46RE/48RE)
Optional Transmission Diesel:
5-speed automatic (48RE)
Features
Transfer Case Options:
Part-time 4WD (NV271 or NV273 manual shift, or NP241DHD electric shift)
📐 Dimensions
Exterior
Wheelbase Options:
134.1 inches (Regular Cab 8' Box), 144.1 inches (Crew Cab 6'4" Box), 162.1 inches (Regular Cab 8' Box Long Bed), 164.1 inches (Crew Cab 8' Box)
Bed Length Options:
6 feet 4 inches, 8 feet
Weights
Gvwr Range:
8,800 lbs to 13,500 lbs (depending on configuration and model)
Curb Weight Range:
Approx. 6,000 - 7,500 lbs
Towing Capacity Max:
Up to 14,000+ lbs (depending on axle ratio, engine, and configuration)
Payload Capacity Max:
Up to 6,000+ lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
Not explicitly rated by NHTSA for this year and model in comprehensive data sets, typically focused on occupant protection for heavy-duty vehicles.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels
Passive Features
Airbags:
Driver and passenger front airbags
Seatbelts:
Three-point seatbelts with pretensioners
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio with CD player, cassette player (optional); available upgraded audio systems
Driver Assistance
Cruise Control:
Standard cruise control
Connectivity
Trailer Tow Prep:
Available trailer tow packages with integrated trailer brake controller wiring and heavy-duty cooling
🔧 Maintenance
Service Intervals
Oil Change Interval Gas:
Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specifics)
Oil Change Interval Diesel:
Every 5,000-7,500 miles or 6 months (refer to manual for specifics)
Transmission Fluid Change:
Every 30,000-60,000 miles (refer to manual for specifics)
Fluid Specifications
Engine Oil Gas Recommendation:
API SG or SH rated, SAE 5W-30 or 10W-30 (refer to manual for specific viscosity based on temperature)
Engine Oil Diesel Recommendation:
API CG-4 or CH-4 rated, SAE 15W-40 (refer to manual for specific viscosity)
Coolant Type:
Ethylene glycol based antifreeze (Mopar OAT or equivalent)
Transmission Fluid Automatic:
ATF+4 (Mopar)
Transmission Fluid Manual:
API GL-5 gear oil, SAE 75W-90 or 80W-90 (refer to manual)
Differential Fluid:
API GL-5 gear oil (viscosity varies by application)
Known Issues
Common Wear Items:
Ball joints, tie rod ends, track bar bushings, U-joints, water pump, fuel injectors (diesel)
Diesel Specific Concerns:
VP44 injection pump failures (early models), injector line issues, exhaust manifold cracks (high mileage)
📚 Vehicle History
Brand Heritage
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, dating back to the 1930s.
Model Evolution
Third Generation Intro:
The third generation Ram trucks were introduced for the 2002 model year, marking a significant redesign with a more aggressive 'big rig' styling.
Production
Manufacturing Locations:
Saltillo, Mexico; St. Louis, Missouri, USA
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
While specific awards for the 2002 model year are less publicized, Dodge Ram trucks consistently received praise for their towing and hauling capabilities and distinctive styling within the heavy-duty segment.
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