🏷️ Basic Information

Make:

Dodge

Model:

Ram Truck

Model Line:

Third Generation Ram Truck (DR/DH/D1)

Model Designation:

DR Series (2WD), DH Series (4WD), D1 Series (Heavy Duty)

Chassis Codes:

DR, DH, D1

👋 Introduction

Market Position:

The 2002-2004 Dodge Ram Truck represented a significant redesign, solidifying its position as a strong contender in the full-size pickup truck market, known for its bold styling and robust capabilities.

Competitive Analysis:

Competed directly with the Ford F-Series, Chevrolet Silverado/GMC Sierra, and Toyota Tundra. The Ram was often praised for its distinctive styling and powerful engine options.

Key Features:

Distinctive 'crosshair' grille design, coil spring rear suspension (on some models for improved ride), available HEMI V8 engine, and a wide range of body styles and configurations.

Engine Availability Expansion:

The 2003 model year saw the highly anticipated introduction of the 5.7L HEMI V8, significantly boosting the Ram's performance credentials in the half-ton segment.

Model Segment:

Full-size pickup truck.

📋 Manual Details

Covered Years:

2002, 2003, 2004

Page Count:

2627

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Fuel System, Cooling System, Exhaust System, Body & Frame, Interior Trim, Emissions, Diagnostic Procedures, Wiring Diagrams

Chassis And Suspension Details:

Covers front independent front suspension (IFS) with torsion bars or coil springs (depending on configuration), solid rear axle with leaf springs. Includes steering system (rack and pinion or recirculating ball) and brake system (disc front/rear or disc front/drum rear).

Electrical System Details:

Extensive coverage of the vehicle's electrical system, including battery, charging system, starting system, lighting, instrument cluster, body control modules (BCM), power accessories, and comprehensive wiring diagrams.

Body And Interior Coverage:

Detailed instructions for interior trim removal/installation, door panel repair, dashboard service, seat removal, and body panel adjustments.

Procedures Included:

Routine Maintenance, Troubleshooting, Diagnostic Checks, Component Removal and Installation, Overhaul Procedures, Repair Techniques, Electrical System Diagnosis, Body Repair, Suspension and Steering Alignment, Brake Service, Engine Tuning, Transmission Repair

Engine Rebuild Procedures:

Detailed procedures for engine disassembly, inspection, component replacement (pistons, rings, bearings, valves, camshaft), cylinder head reconditioning, and engine reassembly with torque specifications.

Transmission Overhaul Procedures:

Step-by-step instructions for the overhaul of the 42RE, 44RE, 48RE, and 545RFE automatic transmissions, including valve body diagnosis, clutch pack replacement, seal replacement, and torque converter procedures.

Emission System Diagnosis:

Covers diagnosis and repair of emission control systems, including EVAP, EGR, and catalytic converter systems, with specifications for testing and component replacement.

Technical Depth:

Comprehensive from basic maintenance to advanced diagnostics and complete rebuilds, including detailed specifications, procedures, and diagnostic flowcharts.

Diagnostic Troubleshooting Charts:

Includes detailed diagnostic flowcharts and symptom-based troubleshooting guides for common issues across all major vehicle systems.

Wiring Diagram Comprehensiveness:

Extremely detailed wiring diagrams, color-coded by circuit, component, and location, facilitating electrical diagnostics.

📊 Manual Specifications

File Format:

PDF

Searchability:

Searchable PDF, allowing users to quickly find specific topics or keywords.

Print Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine Options:

4.7L Magnum V8 (235 hp, 295 lb-ft torque), 5.9L Magnum V8 (245 hp, 335 lb-ft torque), 5.7L HEMI V8 (345 hp, 375 lb-ft torque - introduced for 2003 model year, primarily on 1500 series).

Engine Code Magnum 4.7L:

ECL

Engine Code Magnum 5.9L:

44R

Engine Code Hemi 5.7L:

EZH

Engine Performance Highlights:

The introduction of the 5.7L HEMI engine was a major performance boost, offering class-leading horsepower and torque for its time.

Engine Torque Curve Characteristics:

Magnum V8s provide strong low-end torque, while the HEMI offers a broader and more powerful torque curve across the rev range, suitable for towing and hauling.

Fuel System Type:

Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI) for Magnum engines, Multi-Point Injection (MPI) for HEMI.

🔧 Transmission

Standard Transmission Options:

4-speed automatic transmission (42RE, 44RE, 48RE depending on engine and model), 5-speed manual transmission (NV3500 for lighter duty applications).

Optional Transmission Options:

4-speed automatic transmission with Electronic Range Select (ERS) on some models. 5-speed automatic (545RFE) became more prevalent, especially with the HEMI.

Manual Transmission Option Heavy Duty:

NV4500 (5-speed manual for 2500/3500 models with specific diesel or higher torque gas engines).

Transmission Features:

TorqueFlite automatic transmissions known for durability. The 48RE was a heavy-duty automatic used in some higher-GVM applications. The 545RFE featured an electronically controlled overdrive.

Transfer Case Options:

Available 2-speed transfer cases (NV241, NV271/273 depending on model) for 4WD models, with electronic shift-on-the-fly capabilities on some.

📐 Dimensions

Typical Wheelbase Options:

134.1 inches (Regular Cab), 140.5 inches (Quad Cab), 159.1 inches (Long Bed Regular Cab), 164.5 inches (Long Bed Quad Cab).

Typical Overall Length Options:

Varies by wheelbase and cab configuration, generally ranging from 215 to 255 inches.

Cab Configurations:

Regular Cab (2-door), Quad Cab (4-door).

Bed Size Options:

Short Bed (approx. 6.3 ft), Long Bed (approx. 8 ft).

Gross Vehicle Weight Rating Gvwr:

Ranges from approximately 6,000 lbs for light-duty models to over 10,000 lbs for heavy-duty 2500/3500 models.

Curb Weight Range:

Approximately 4,500 lbs to 6,500 lbs depending on configuration.

🛡️ Safety Features

NHTSA Crash Test Ratings:

Side impact: 5-star driver, 4-star passenger (varies by year and configuration). Frontal impact: 4-star driver, 5-star passenger (varies).

Active Safety Features:

Anti-lock Braking System (ABS) standard on all wheels, available brake assist, available traction control (on some models).

Passive Safety Features:

Front airbags, available side curtain airbags (introduced later in the generation), three-point seat belts with pretensioners, reinforced cab construction.

Seat Belt System:

Front seat belt system with adjustable shoulder belt height and pretensioners.

💡 Technology Features

Infotainment Features:

Available AM/FM radio with CD player, cassette player, premium audio systems (Infinity), steering wheel mounted audio controls on higher trims.

Navigation System:

Optional factory navigation system available on higher trim levels.

Driver Assistance Features:

Cruise control, available parking assist sensors (rear), available trailer brake controller.

ABS System Details:

Four-wheel ABS with electronic proportioning and brake assist, enhancing stopping power and control.

Connectivity Features:

Power outlets, available satellite radio (SiriusXM).

🔧 Maintenance

Recommended Oil Change Interval:

Every 3,000 to 7,500 miles (or 6 months), depending on driving conditions and oil type used (refer to manual for specific engine recommendations).

Tire Rotation Interval:

Every 5,000 to 7,500 miles.

Spark Plug Replacement Interval:

Varies by engine: Magnum V8s typically 30,000-100,000 miles (depending on plug type), HEMI V8s often around 100,000 miles with specific iridium plugs.

Engine Oil Specification:

SAE 5W-30 or 5W-20 for most gasoline engines (check manual for specific engine/year), API certified. For HEMI, often a specific Chrysler spec like MS-6395.

Transmission Fluid Specification:

ATF+4 (Type 9985) for automatic transmissions. Manual transmission fluid varies by gearbox manufacturer.

Coolant Specification:

Chrysler HOAT (Hybrid Organic Acid Technology) antifreeze/coolant, typically a 50/50 mix with distilled water. Mopar OAT (Organic Acid Technology) for some later models/applications.

Power Steering Fluid:

ATF+4 or specific Mopar power steering fluid.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Common Known Issues:

Rocker arm failure (HEMI), exhaust manifold leaks (HEMI), plenum gasket issues (older Magnum engines), water pump failures, fuel pump failures, ABS sensor failures, transmission solenoid issues.

Common Known Issues Hmi Update:

Early HEMI 5.7L engines can suffer from valve tick or misfires due to the Multi-Displacement System (MDS) engaging prematurely or valve train wear. Camshaft and lifter wear are also noted.

Common Known Issues Transmission:

Early 48RE transmissions could experience harsh shifting or slipping, often related to solenoid pack issues or torque converter clutch (TCC) failure.

📚 Vehicle History

Brand Heritage:

Dodge has a long history of producing robust and capable trucks, dating back to the 1930s. The 'Ram' nameplate was introduced in 1981, becoming a distinct identity for Dodge's truck line.

Model Evolution Overview:

The 2002 model year marked the debut of the third-generation Ram Truck, a complete redesign with a larger and more aggressive appearance. It introduced the HEMI engine option in 2003.

Third Generation Design Philosophy:

The third generation emphasized a more aggressive, muscular exterior design and a more refined interior compared to its predecessor.

Third Generation Styling Impact:

The distinctive styling of the third-generation Ram, particularly its prominent grille and sculpted fenders, made it stand out in the competitive truck market.

Production Locations:

Assembled primarily at the Sterling Heights Assembly Plant in Sterling Heights, Michigan, and the Saltillo Truck Assembly Plant in Saltillo, Coahuila, Mexico.

🏆 Awards & Recognition

Major Recognitions:

Frequently cited for powerful engine options, especially the HEMI. Often praised for styling and interior space. Competed well in J.D. Power and Associates customer satisfaction surveys for its segment.