Market Segment:
Heavy-Duty Pickup Truck
Primary Competitors:
Ford F-Series Super Duty, Chevrolet Silverado HD, GMC Sierra HD
Vehicle Target Audience:
Commercial use, towing, heavy hauling, fleet operations
Manual Purpose:
To provide detailed repair, maintenance, and diagnostic information for Dodge Ram 3500 models from 2002-2004.
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine electrical, automatic transmission, manual transmission, transfer case (4WD)
Chassis:
Front suspension, rear suspension, steering system, brake system (front and rear disc, ABS), wheels and tires
Body:
Exterior body panels, interior trim, doors, windows, seats, HVAC system, body electrical, lighting, safety restraints (airbags, seatbelts)
Electrical:
Wiring diagrams, electrical component locations, diagnostic procedures for electrical systems, battery, charging system, starting system, lighting, instrumentation, body control modules, infotainment systems
Diagnostic Procedures:
Troubleshooting charts, symptom-based diagnostics, OBD-II diagnostic trouble codes (DTCs) and their resolution
Maintenance Procedures:
Fluid changes (oil, coolant, transmission fluid, brake fluid), filter replacements, lubrication, inspection schedules
Repair And Overhaul:
Engine rebuilds, transmission overhaul, suspension component replacement, brake system repairs, steering system repairs, body panel repair, electrical component replacement
Special Tools And Equipment:
Identification and use of specific Chrysler/Dodge factory special tools required for certain procedures
Technical Depth:
Comprehensive, covering everything from basic maintenance and fluid checks to in-depth engine and transmission overhauls and complex electrical system diagnostics. Assumes a knowledgeable technician.
File Quality:
High-resolution scans, typically searchable text with clear diagrams and images
Print Quality Potential:
Printable, allowing for physical copies for workshop use
Binding Type For Print:
PDF format does not have a binding type; intended for digital viewing or printing and binding by user
Paper Type For Print:
N/A (digital format)
Engine Option 1:
8.3L V10 Magnum (P-Code)
Engine Option 2:
5.9L Cummins Turbo Diesel (ISB/QSL variants)
Engine Option 3:
5.7L Hemi V8 (Introduced later in the generation, less common in early 3500 models of this range, but potentially covered)
8.3L V10 Horsepower:
Approx. 500 hp (Viper-derived engine)
8.3L V10 Torque:
Approx. 500 lb-ft
5.9L Cummins Horsepower:
Ranging from 235 hp to 325 hp depending on the specific year and engine tune
5.9L Cummins Torque:
Ranging from 460 lb-ft to 610 lb-ft depending on the specific year and engine tune
8.3L V10 Fuel System:
Multi-point Fuel Injection (MPI)
5.9L Cummins Fuel System:
High-pressure Common Rail (HPCR) fuel injection system (starting from 2003 model year)
Transmission Option 1:
NV5600 6-speed manual transmission (for Cummins Diesel and V10)
Transmission Option 2:
48RE 4-speed automatic transmission (for Cummins Diesel)
Transmission Option 3:
47RE 4-speed automatic transmission (for V10 and earlier diesel models)
Transfer Case:
New Process (NP) 241 DHD (241 Heavy Duty) manual shift or electric shift 4WD transfer case
Cab Configurations:
Regular Cab, Club Cab (Extended Cab), Quad Cab (Crew Cab)
Bed Lengths:
8-foot bed, 9.25-foot bed (Mega Cab)
Gvwr Range:
Typically 9,600 lbs to 13,500 lbs (depending on configuration and axle)
Curb Weight Range:
Varies significantly by configuration, often starting around 6,000 lbs and exceeding 7,000 lbs
NHTSA Crash Test Ratings:
Generally good for its class, though specific ratings vary by year and test configuration. Frontal impact often rated well.
Active Safety Features:
Anti-lock Braking System (ABS) standard, available Integrated Trailer Brake Controller (ITBC)
Passive Safety Features:
Front airbags, three-point seat belts, optional side curtain airbags (later years)
Infotainment Options:
Factory AM/FM/CD players, optional satellite radio, cassette player. Higher trims may have upgraded speaker systems.
Driver Assistance Features:
Limited by modern standards. Primarily ABS. Parking sensors were not common on these models.
Connectivity Features:
Basic connectivity, no Bluetooth or USB ports typically from the factory. Trailer lighting harnesses were standard for towing.
Engine Oil Change Diesel:
Typically every 7,500 to 15,000 miles or 6 months, depending on usage (heavy duty towing may shorten interval)
Engine Oil Change Gas:
Typically every 5,000 to 7,500 miles or 6 months
Fuel Filter Replacement Diesel:
Recommended every 15,000 miles or annually
Transmission Fluid Change:
Automatic: 30,000 to 60,000 miles. Manual: Less frequent, check for leaks and condition.
Engine Oil Diesel:
Cummins recommends API CJ-4 or CK-4 synthetic diesel engine oil, viscosity grade 15W-40 or 5W-40 (depending on temperature). Consult specific engine manual for precise specs.
Engine Oil V10 Gas:
API SN, SAE 10W-30 or 5W-30 (check owners manual for exact viscosity and spec based on climate)
Coolant:
Mopar OAT (Organic Additive Technology) coolant or equivalent extended-life coolant, typically a 50/50 mix with distilled water.
Transmission Fluid Automatic:
Chrysler ATF+4 (or equivalent)
Transmission Fluid Manual Nv5600:
GL-4 rated gear oil, SAE 75W-90
Brake Fluid:
DOT 3 or DOT 4
Cummins 5.9L Common Issues:
Injectors (especially if using non-spec fuel), VP44 injection pump (earlier models), fuel supply issues (lift pump failures), potential turbocharger issues if maintenance is neglected.
V10 8.3L Common Issues:
Spark plug blow-out (thread repair often needed), ignition coil issues, cooling system leaks, exhaust manifold cracks (less common than other trucks).
Transmission Auto Common Issues:
Overheating, torque converter lock-up issues, solenoid pack failures, worn clutch packs (especially under heavy load).
Suspension And Steering:
Worn ball joints, tie rod ends, track bar bushings due to heavy load and torque. Steering gear play.
Dodge Truck Legacy:
Dodge has a long history of producing robust and capable trucks, with the Ram line established as a dedicated truck brand in 1994.
Third Generation Introduction:
The third generation Ram (DR/DH/D2) debuted for the 2002 model year, featuring a significantly revised exterior and interior design, and major powertrain updates, including the introduction of the powerful 8.3L V10 and the High-Pressure Common Rail 5.9L Cummins.
Production Plants:
St. Louis Assembly Plant (Missouri, USA), Saltillo Truck Assembly Plant (Mexico)
Diesel Engine Reputation:
The 5.9L Cummins turbo diesel is renowned for its durability, longevity, and strong performance, often considered one of the best diesel engines in its class.
Truck Of The Year:
While specific 'Truck of the Year' awards for these exact years might vary, the Dodge Ram line consistently received positive reviews for its styling, comfort, and capability within the heavy-duty segment.
