Market Segment:
Heavy-Duty Pickup Truck
Competitors:
Ford F-250 Super Duty, Chevrolet Silverado 2500HD, GMC Sierra 2500HD
Vehicle Strengths:
Robust chassis, powerful engine options, high towing and payload capacity, versatile for work and recreation
Target Audience:
DIY mechanics, independent repair shops, fleet maintenance personnel
Engine Mechanical:
Complete engine overhaul, rebuild procedures, component testing, diagnostics
Engine Performance:
Fuel system, ignition system, emission controls, turbocharger diagnostics (if applicable)
Transmission:
Automatic and Manual transmission service, rebuilds, fluid changes, diagnostic procedures
Drivetrain:
Front and Rear Axles, Driveshafts, CV joints, differentials, 4WD system
Suspension:
Front and Rear suspension components, steering system, alignment specifications
Brakes:
Brake system diagnosis, repair, ABS system, rotor and pad replacement, bleeding procedures
Electrical System:
Wiring diagrams, component testing, fuse and relay locations, charging system, starting system
Body And Frame:
Body panel repair, interior trim removal, door and latch mechanisms, chassis repair
HVAC:
Heating, Ventilation, and Air Conditioning system diagnosis and repair
Restraints:
Airbag system diagnosis and repair, seatbelt mechanisms
Maintenance:
Scheduled maintenance intervals, fluid checks and changes, filter replacements
Troubleshooting:
Diagnostic flowcharts, common problems and solutions, symptom-based diagnosis
Repair:
Step-by-step repair procedures for all major components and systems
Diagnostics:
Detailed diagnostic steps for electrical and mechanical systems, including DTC (Diagnostic Trouble Code) interpretation
Rebuilds:
Complete engine and transmission rebuild procedures with torque specifications and clearances
Depth:
Comprehensive, from basic maintenance to complete engine and transmission overhauls
Engine Options:
8.0L V10 Magnum (370 hp @ 4600 rpm, 460 lb-ft @ 3200 rpm), 5.9L Cummins Turbo Diesel I6 (250 hp - 305 hp, 460 lb-ft - 555 lb-ft torque depending on application)
Horsepower Range:
250 - 370 hp
Torque Range:
460 - 555 lb-ft
Fuel Delivery:
Multi-point Fuel Injection (V10), Bosch High-Pressure Common Rail Injection (Cummins)
Cummins Diesel Codes:
ISB, QSL (depending on specific configuration, 24-valve common rail)
Transmission Options:
NV4500 5-speed manual (diesel), NV5600 6-speed manual (diesel), 47RE 4-speed automatic (V10 & diesel), 48RE 4-speed automatic (late 2003+ diesel)
Optional Transmissions:
See standard transmission options
Transfer Case:
2WD or 4WD with manual or electronic shift transfer case
Automatic Transmission Fluid:
ATF+4 (MS-9602)
Manual Transmission Fluid:
API GL-3 or GL-4 gear oil (specific viscosity varies)
Wheelbase Options:
134.1 inches (Regular Cab), 154.1 inches (Club Cab/Quad Cab 8ft bed), 158.1 inches (Regular Cab 8ft bed), 177.1 inches (Club Cab/Quad Cab 9.25ft bed)
Bed Length Options:
6.3 ft, 8.0 ft, 9.25 ft
Curb Weight:
Approximately 6,000 - 7,500 lbs (depending on configuration)
Gvwr:
9,200 lbs - 10,500 lbs
Max Towing Capacity:
Up to 13,200 lbs (with proper equipment and configuration)
Max Payload Capacity:
Up to 4,000 lbs (with proper configuration)
Audio System:
Factory AM/FM/CD or Cassette/CD player, optional Infinity sound system
Navigation:
Not typically factory-installed on these models, aftermarket options available
Driver Aids:
Basic - Cruise control, power windows/locks (if equipped)
Connectivity Features:
Limited to basic audio inputs, no Bluetooth or USB typically from factory
Oil Change Interval:
7,500 miles or 6 months for gasoline, 5,000-7,500 miles for diesel (depending on severe service/towing)
Transmission Fluid Change:
30,000 - 60,000 miles for automatic, consult manual for manual transmission
Engine Oil Gasoline:
API SL, SAE 5W-30 or 10W-30 (check owner's manual for specific temperature ranges)
Engine Oil Diesel:
API CI-4 or CH-4, SAE 15W-40 (Cummins recommendation)
Coolant:
HOAT (Hybrid Organic Acid Technology) Extended Life, Mopar OAT 5 Year/100,000 Mile
Common Diesel Issues:
Injector failure, VP44 injection pump failure (earlier 5.9L models), turbocharger issues, exhaust manifold cracks (less common on these specific years), camshaft wear
Common Gasoline Issues:
Spark plug issues (coil-on-plug or distributorless ignition), valve seat recession (less common on V10), occasional oil leaks
Common Chassis Issues:
Front suspension wear (ball joints, tie rods), U-joint wear, rust on body panels (especially in salt belt regions), HVAC blower motor failures
Oil Filter Diesel:
Fleetguard LF16035 or equivalent
Fuel Filter Diesel:
Fleetguard FS1022 or equivalent
Dodge Truck Legacy:
Dodge has a long history of producing rugged and capable trucks, with the Ram nameplate becoming synonymous with heavy-duty performance.
Second Gen Ram:
The 2002-2004 models represent the latter part of the second-generation Ram (BR/BE), known for its distinctive 'big rig' styling and significant mechanical upgrades over earlier models, particularly the introduction of the common-rail Cummins diesel.
Manufacturing Plant:
Saltillo Truck Plant, Mexico; Warren Truck Assembly Plant, Michigan, USA
Diesel Engine Recognition:
The 5.9L Cummins Turbo Diesel engine from this era is highly regarded for its durability, reliability, and performance, making it a sought-after powerplant.
Truck Of The Year:
While specific model years may have received awards from trucking publications, the overall second-generation Ram platform was well-received in the heavy-duty segment.
