🏷️ Basic Information

Make:

Dodge

Model:

Ram Truck

Sub Model:

1500, 2500, 3500

Year:

2002

Platform:

DR/DH/D1

👋 Introduction

Segment:

Full-size pickup truck, popular for heavy-duty work, towing, and hauling. Competes with Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra.

Key Advantages 2002 Ram:

Distinctive styling, powerful engine options (especially the Cummins diesel), robust build quality, capable towing and payload capacities.

Manual Benefits:

Empowers DIY mechanics and professional technicians with comprehensive information for accurate diagnosis and repair, reducing labor costs and downtime. Covers all major systems for a complete service solution.

Vehicle Appeal:

Renowned for its distinctive 'crosshair' grille design, robust chassis, and the availability of the highly regarded Cummins turbodiesel engine, making it a workhorse and a favorite among truck enthusiasts.

📋 Manual Details

Coverage:

Comprehensive repair, service, maintenance, diagnostics, and troubleshooting for all Dodge Ram Trucks 1500, 2500, and 3500 models equipped with applicable engines for the 2002 model year.

Page Count:

3246

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

3.7L Magnum V6, 4.7L Magnum V8, 5.9L Magnum V8 (Gas), 5.9L Cummins Turbo Diesel I6

Transmission:

45RFE/545RFE (4-speed automatic), NV3500 (5-speed manual), NV4500 (5-speed manual), NV5600 (6-speed manual)

Drivetrain:

Front axle, rear axle, transfer case (2WD/4WD), propeller shafts, CV joints.

Suspension:

Front suspension (independent torsion bar/coil spring options), rear suspension (leaf springs), steering system (power steering, steering linkage).

Brakes:

Front disc brakes, rear drum brakes, anti-lock braking system (ABS), parking brake system.

Electrical:

Battery, charging system, starting system, ignition system, lighting, gauges, instrument cluster, power accessories, body control module (BCM), Powertrain Control Module (PCM), fuse and relay identification.

Body:

Exterior panels, doors, hood, tailgate, bumpers, interior trim, seats, glass, seals, HVAC system (air conditioning, heating, ventilation).

Diagnostics:

OBD-II diagnostics, trouble code (DTC) interpretation, scan tool procedures, component testing, circuit diagrams, wiring schematics.

Engine Repair:

Engine assembly/disassembly, cylinder head service, piston/ring installation, crankshaft/bearing service, valve train repair, timing belt/chain service (where applicable), cooling system service, lubrication system service.

Transmission Service:

Transmission fluid change, filter replacement, torque converter service, clutch replacement (manual), transmission overhaul procedures (automatic and manual).

Brake Service:

Brake pad/shoe replacement, rotor/drum replacement, caliper/wheel cylinder service, brake fluid flush and bleed, ABS component diagnosis and replacement.

Suspension Steering Repair:

Shock absorber/strut replacement, ball joint/tie rod end replacement, wheel bearing replacement, power steering pump/rack and pinion service.

Electrical Diagnostics:

Charging system testing, starting system troubleshooting, ignition system repair, lighting system diagnosis, body electrical component testing, wiring harness repair.

Body Work:

Door panel removal, glass replacement, seal replacement, minor body panel repair procedures, interior trim component removal/installation.

HVAC Service:

Refrigerant recharge, component replacement (compressor, condenser, evaporator), blower motor replacement, ducting inspection.

Depth:

Detailed diagnostic procedures, component-level repair, complete overhaul instructions, torque specifications, wiring diagrams, special tool recommendations, and exploded views for assembly/disassembly.

📊 Manual Specifications

File Type:

PDF

Quality:

High-resolution digital scans, optimized for clarity and readability on screen and for printing individual pages.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine 1500 1:

3.7L (226 ci) Magnum V6

Engine 1500 2:

4.7L (285 ci) Magnum V8

Engine 2500 3500 1:

5.9L (360 ci) Magnum V8 (Gas)

Engine 2500 3500 2:

5.9L (359 ci) 24-valve Cummins Turbo Diesel I6

3.7L V6 Hp:

215 hp @ 4600 rpm

3.7L V6 Torque:

235 lb-ft @ 3200 rpm

4.7L V8 Hp:

235 hp @ 4800 rpm

4.7L V8 Torque:

305 lb-ft @ 3200 rpm

5.9L V8 Hp:

235 hp @ 4400 rpm

5.9L V8 Torque:

330 lb-ft @ 3200 rpm

5.9L Cummins Hp:

235 hp @ 2400 rpm (standard output)

5.9L Cummins Torque:

460 lb-ft @ 1400 rpm (standard output)

Gas Engines:

Multi-point Fuel Injection (MPI)

Diesel Engine:

High-pressure common rail (HPCR) fuel injection

🔧 Transmission

Manual Standard:

NV3500 5-speed manual (1500 models, 2WD)

Automatic Optional:

45RFE/545RFE 4-speed automatic (1500 models)

Heavy Duty Manual Optional:

NV4500 5-speed manual (2500/3500 models)

Heavy Duty Manual Optional 2:

NV5600 6-speed manual (2500/3500 models with Cummins)

Heavy Duty Automatic Optional:

47RE 4-speed automatic (2500/3500 models with 5.9L Magnum V8)

Heavy Duty Automatic Optional 2:

48RE 4-speed automatic (2500/3500 models with 5.9L Cummins Diesel - some late 2002 models, primarily 2003 MY intro)

Transfer Case Options:

Part-time 4WD (NV241DLD, NV241DHD), Full-time 4WD (NV244 - optional on some models).

📐 Dimensions

Wheelbase Regular Cab Standard Bed:

131.3 inches

Wheelbase Extended Cab Standard Bed:

147.3 inches

Wheelbase Crew Cab Standard Bed:

160.3 inches

Bed Lengths:

6.3 feet (standard), 8.0 feet (long bed)

Curb Weight Range:

Approx. 4,500 - 7,500 lbs (Varies significantly by configuration, engine, and drivetrain)

Towing Capacity Max:

Up to 13,000+ lbs (with 3500, Cummins, appropriate configurations)

Payload Capacity Max:

Up to 6,000+ lbs (with 3500, appropriate configurations)

🛡️ Safety Features

NHTSA Frontal Driver 1500:

4 stars (some configurations)

NHTSA Frontal Passenger 1500:

4 stars (some configurations)

ABS:

Standard on most models, optional on some earlier configurations.

Airbags:

Driver and passenger front airbags. Side curtain airbags were not commonly available for this model year.

Seat Belts:

Three-point seat belts with pretensioners.

💡 Technology Features

Audio Systems:

Factory AM/FM/Cassette/CD player options. Sirius Satellite Radio available on some trims.

Cruise Control:

Standard on most models.

Trailer Tow Prep:

Optional trailer brake controller provisions, trailer wiring harnesses.

🔧 Maintenance

Oil Change Gas:

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

Oil Change Diesel:

Every 7,500-15,000 miles or 6-12 months (Cummins engines).

Transmission Fluid Change:

Every 30,000-60,000 miles for automatic transmissions, depending on service classification.

Engine Oil Gas Recommendation:

API SJ or SL rated, SAE 5W-30 (most engines), SAE 10W-30 for certain conditions.

Engine Oil Diesel Recommendation:

API CH-4 or CI-4 rated, SAE 15W-40 (Cummins engines).

Transmission Fluid Automatic:

ATF+4 (MS-9602 compliant) for 45RFE/545RFE and 47RE/48RE transmissions.

Manual Transmission Fluid:

GL-5 rated manual transmission fluid (specific viscosity varies by transmission model, consult manual).

Coolant:

Mopar OAT (Orange) Antifreeze/Coolant or equivalent (50/50 mix).

Common Problems General:

Interior trim wear, HVAC blend door actuator failure, exhaust manifold leaks (especially on V8s), automatic transmission issues (particularly on early 47RE/48RE units under heavy use).

Common Problems Cummins:

Injector line failures, VP44 injection pump issues (earlier models), potential for cracking exhaust manifolds, turbocharger issues (high mileage).

📚 Vehicle History

Dodge Truck Legacy:

Dodge has a long history of producing durable and capable trucks, evolving from early 'Power Wagon' models to modern Ram trucks.

Third Generation Ram:

The 2002 model year represents the continuation of the third generation (2002-2008), characterized by a significant redesign with a more powerful stance and improved interior.

Manufacturing Locations:

Saltillo Truck Assembly, Mexico; Warren Truck Assembly Plant, Michigan, USA.

🏆 Awards & Recognition

Cummins Engine Reputation:

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