🏷️ Basic Information

Make:

Dodge

Model:

Ram 2500 / Ram 3500

Year:

2002

Chassis Code:

DR

Platform:

Third Generation Ram (1994-2001 with significant updates for 2002)

👋 Introduction

Segment:

Heavy Duty Pickup Truck (Class 2b and 3)

Target Audience:

Owners, professional mechanics, DIY enthusiasts specializing in heavy-duty trucks.

Key Competitors:

Ford Super Duty F-250/F-350, Chevrolet Silverado 2500HD/3500HD, GMC Sierra 2500HD/3500HD.

Vehicle Purpose:

Designed for heavy towing, hauling, and commercial use.

Manual Value Proposition:

Provides authorized, detailed repair procedures, crucial for maintaining optimal performance and longevity of a heavy-duty vehicle.

📋 Manual Details

Coverage:

Comprehensive maintenance, troubleshooting, and repair procedures for 2002 Dodge Ram 2500 and 3500 Heavy Duty pickup trucks.

Page Count:

Estimated 2000+ pages (typical for factory service manuals of this era).

Manual Type:

Factory Service Manual (FSM) / Workshop Manual

Language:

English

Format:

Electronic (PDF/digital, as implied by 'electronic version')

📖 Manual Coverage

Powertrain:

Engine mechanical (5.9L Cummins Turbo Diesel, 5.9L Magnum V8 gasoline, 8.0L V10 Magnum gasoline), fuel system, cooling system, lubrication system, exhaust system.

Transmission:

Manual transmissions (NV4500), Automatic transmissions (48RE, NV3500).

Drivetrain:

Front and rear axle assemblies, transfer cases (part-time and full-time 4WD), drive shafts, propeller shafts, U-joints.

Suspension:

Front independent suspension (for 2500), solid front axle (for 3500 4x4), rear solid axle, leaf springs, shock absorbers, steering linkage.

Brakes:

Front disc brakes (vented rotors), rear disc brakes (on some models/options) or drum brakes, Anti-lock Braking System (ABS), parking brake system.

Electrical:

Battery, charging system, starting system, lighting system, ignition system, instrument cluster, body control modules (BCM), power distribution, grounding, fuses, relays.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, refrigerant handling (R-134a).

Body:

Exterior body panels, doors, hoods, tailgates, interior trim, glass, mirrors, bumpers.

Chassis:

Frame construction, engine mounting, suspension mounting points.

Diagnostics:

On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), scan tool procedures, component testing.

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, lubrication, fluid checks and changes.

Troubleshooting:

System-specific diagnostic flowcharts, symptom-based troubleshooting guides, common problems and solutions.

Repair:

Component removal and installation, overhaul procedures, assembly and disassembly instructions.

Adjustments:

Wheel alignment specifications, parking brake adjustments, clutch adjustments.

Specifications:

Torque specifications for all fasteners, electrical specifications, fluid capacities and types, diagnostic specifications.

Wiring Diagrams:

Detailed electrical wiring diagrams for all vehicle systems.

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including advanced diagnostic strategies and wiring schematics.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable (typical for factory digital manuals).

Image Resolution:

High resolution for clear diagrams, illustrations, and text.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine 1 Type:

5.9L (359 cu in) Cummins Turbo Diesel I6

Engine 1 Hp:

235 hp @ 2800 rpm (approximate, depending on specific turbo/injection pump configuration)

Engine 1 Torque:

460 lb-ft @ 1600 rpm (approximate)

Engine 1 Fuel System:

High-pressure common rail direct injection (Bosch VP44 rotary injection pump on earlier models, Cummins ECM controlled common rail for later 5.9L configurations in 2002).

Engine 1 Induction:

Turbocharged, intercooled

Engine 2 Type:

5.9L (359 cu in) Magnum V8 Gasoline

Engine 2 Hp:

245 hp @ 4000 rpm (approximate)

Engine 2 Torque:

345 lb-ft @ 3200 rpm (approximate)

Engine 2 Fuel System:

Multi-point fuel injection (MPI)

Engine 3 Type:

8.0L (488 cu in) V10 Magnum Gasoline

Engine 3 Hp:

305 hp @ 4000 rpm (approximate)

Engine 3 Torque:

450 lb-ft @ 3200 rpm (approximate)

Engine 3 Fuel System:

Multi-point fuel injection (MPI)

🔧 Transmission

Transmission 1 Type:

Getrag NV4500 5-speed manual (common with Cummins Diesel)

Transmission 2 Type:

Chrysler 48RE 4-speed automatic (heavy-duty, common with Cummins Diesel and V10)

Transmission 3 Type:

Chrysler NV3500 5-speed manual (less common, usually with 5.9L V8 gasoline)

Transfer Case Gas 4X4:

NV241DHD (part-time 4WD) or NV243DHD (full-time 4WD)

Transfer Case Diesel 4X4:

NV241DHD (part-time 4WD) or NV243DHD (full-time 4WD)

Axle Ratio:

Typically 3.73 or 4.10, depending on engine and configuration.

📐 Dimensions

Wheelbase 2500 Std Cab:

134.1 inches

Wheelbase 2500 Crew Cab:

148.7 inches

Wheelbase 3500:

134.1 inches (single rear wheel), 148.7 inches (dually)

Bed Length:

6.3 ft (short bed), 8.0 ft (long bed)

Gvwr 2500:

8,800 lbs - 9,200 lbs (approximate)

Gvwr 3500:

9,750 lbs - 11,500 lbs (approximate)

Curb Weight:

Varies significantly by configuration, typically 5,500 - 7,000+ lbs.

🛡️ Safety Features

NHTSA Frontal Driver:

Not rated (typical for trucks of this era without specific data available)

NHTSA Frontal Passenger:

Not rated

Airbags:

Driver and passenger front airbags.

Seat Belts:

3-point front seat belts, 3-point rear seat belts (on applicable cab configurations).

ABS:

Standard Anti-lock Braking System (ABS) on all wheels.

💡 Technology Features

Audio System:

Factory AM/FM/CD/Cassette stereo systems, optional Infinity speaker upgrade. Basic digital display for radio information.

Cruise Control:

Standard cruise control.

Towing Features:

Provision for trailer brake controller (if equipped), trailer tow mirrors (often optional).

Power Features:

Optional power windows, power door locks, power mirrors.

🔧 Maintenance

Oil Change Gas:

Every 3,000 - 7,500 miles or 6 months, depending on usage and oil type (check manual for specifics).

Oil Change Diesel:

Every 7,500 - 15,000 miles or 12 months for the Cummins Diesel (synthetic or heavy-duty diesel oil recommended).

Transmission Fluid Change Auto:

Every 30,000 - 60,000 miles for the 48RE automatic transmission. Filter service often recommended concurrently.

Transmission Fluid Change Manual:

Every 50,000 - 100,000 miles for manual transmissions.

Engine Oil Gas:

API SJ or SL, SAE 5W-30 or 10W-30 (refer to manual for exact recommendation).

Engine Oil Diesel:

API CI-4 or CH-4, SAE 15W-40 (heavy-duty diesel engine oil).

Transmission Fluid 48Re:

Chrysler ATF+4 (MS-9602).

Transmission Fluid Nv4500:

GL-3 or GL-4 gear oil, SAE 75W-90 (specific manual recommendation is critical for longevity of the NV4500).

Coolant:

Ethylene Glycol based, 50/50 mix with distilled water. Mopar OAT (Organic Additive Technology) or HOAT (Hybrid Organic Additive Technology) coolant is recommended.

Cummins Vp44:

Injection pump (VP44) failures due to fuel starvation/heat are a known concern for earlier 5.9L Cummins engines of this era; ensure proper fuel pressure monitoring.

Automatic Transmission 48Re:

Torque converter shudder, potential for overheating under heavy load. Regular fluid and filter changes are essential.

Front End Components:

Wear on ball joints, tie rod ends, and steering components, especially in 4x4 models, due to heavy-duty use.

Rear Main Seal:

Potential for rear main seal leaks on both gasoline and diesel engines.

📚 Vehicle History

Dodge Trucks:

Dodge has a long history of producing robust and capable pickup trucks, with the Ram nameplate becoming synonymous with heavy-duty performance.

Third Gen Ram:

The 2002 model year represented a significant refresh for the Dodge Ram, often referred to as the 'third generation' or 'new body style.' This included updated styling, chassis refinements, and improved powertrains, particularly the evolution of the Cummins engine and the introduction of the heavy-duty automatic transmission.

Manufacturing Location:

Saltillo, Mexico; Warren, Michigan, USA.

🏆 Awards & Recognition

Cummins Engine Reputation:

The 5.9L Cummins Turbo Diesel engine is widely recognized for its durability, torque, and longevity, making it a highly sought-after powertrain in the used market.