🏷️ Basic Information

Make:

Dodge

Model:

Ram Truck 3500 Series

Year:

2002

Vehicle Platform:

BR/BE (Third Generation Ram Pickup)

👋 Introduction

Target Audience:

Dodge Ram Truck 3500 Series (2002) owners, DIY mechanics, and professional repair shops.

Segment:

Heavy-Duty Pickup Truck segment, designed for towing, hauling, and commercial use.

Authenticity:

Actual Genuine Repair Service Factory Manuals, not third-party.

Accessibility:

Downloadable PDF format, accessible on PC (Windows) and Mac. No specialized computer skills required. Immediate availability post-payment.

📋 Manual Details

Coverage Scope:

Complete official factory service repair manual covering all styles of the 2002 Dodge Ram Truck 3500 Series.

Estimated Pages:

Hundreds of pages (specific count not provided, but implies comprehensive nature).

Type:

Factory Service Repair Manual

Language:

English

File Format:

PDF (Downloadable)

📖 Manual Coverage

Powertrain:

Engine Service/Repair, Transmission Service/Repair, Differential/Drive, Axle, Cooling System, Fuel Injection/Fuel System, Emission System, Engine Control System.

Chassis And Suspension:

Brake System, Suspension, Steering, Chassis/Body, Periodic Lubrication.

Electrical And Electronics:

Wiring Diagram, Electrical System, Restraint System.

Comfort And Convenience:

Heater/Air Conditioning, Interior.

Other Systems:

Includes: Ignition System, Exhaust System, Power Steering System, Transfer Case (if 4WD equipped), Driveshafts, Body Electrical, Lighting System, Wiper System, Horn System, Instrument Cluster, and more.

Cooling System Details:

Includes radiator, coolant reservoir, thermostat, water pump, cooling fan, and temperature sensors. Also covers pressure testing and leak detection.

Braking System Details:

Covers front and rear disc/drum brakes, hydraulic system, ABS components, parking brake, and brake fluid specifications. Includes procedures for pad/shoe replacement, rotor/drum service, and caliper/wheel cylinder repair.

Suspension Details:

Front and rear suspension components including coil springs (front), leaf springs (rear), shock absorbers, ball joints, control arms, sway bars, and steering linkage.

Maintenance:

General Maintenance, Periodic Lubrication.

Diagnostics:

Troubleshooting, Advanced Troubleshooting Guide.

Repair And Rebuild:

Step-by-step repair procedures for all covered systems, including engine rebuild, transmission overhaul, brake system repair, electrical diagnostics, etc.

Specific Procedures:

Detailed procedures for cylinder head removal/installation, piston replacement, crankshaft bearing service, fuel pump replacement, brake caliper rebuild, suspension component replacement (ball joints, tie rods, shocks), steering gear service, AC system evacuation/recharge, and complete electrical troubleshooting with wiring diagrams.

Engine Diagnostics:

On-Board Diagnostics (OBD-II) code retrieval, interpretation, and component testing based on fault codes. Includes procedures for spark plug replacement, ignition coil testing, and exhaust system diagnostics.

Depth:

Comprehensive factory-level detail, covering everything a professional technician would use. Includes detailed illustrations, diagrams, photos, substeps, notes, cautions, and warnings.

Diagnostic Tools:

Procedures often require specific diagnostic tools like a scan tool for accessing engine control module (ECM) data, ABS codes, and transmission codes.

📊 Manual Specifications

File Type:

PDF

Searchability:

The PDF format allows for full text searching, enabling users to quickly find specific information or procedures.

Printability:

Printable without restriction (entire manual or specific pages).

Binding:

N/A (Digital Download - User prints and binds as needed).

Paper:

N/A (Digital Download - User selects paper type for printing).

⚙️ Engine Specifications

Engine Options:

This manual covers the 2002 Dodge Ram 3500 Series, which was typically offered with the following engines (specific engine variants depend on model configuration): 5.9L Magnum V8 (360 cu in), 8.0L Magnum V10 (488 cu in), and the 5.9L Cummins Turbo Diesel I6.

Engine Code Examples:

Examples: 5.9L Diesel - ISB (Interim Specific Build), 8.0L V10 - VIP.

Hp Torque General:

Performance figures vary significantly by engine. For example, the 5.9L Cummins Turbo Diesel typically produced around 235 hp and 540 lb-ft of torque in this era, while the V8 and V10 gasoline engines offered different power and torque curves.

Torque Curve Diesel:

The 5.9L Cummins is known for its strong low-end torque, crucial for towing heavy loads. The manual provides torque specifications for engine components.

Fuel Delivery:

The manual covers fuel injection systems for all gasoline and diesel engines, including fuel pump operation, injectors, fuel pressure regulation, and diagnostics.

Diesel Fuel System:

Comprehensive coverage of the Bosch VP44 injection pump and associated fuel lines, filters, and lift pump for the 5.9L Cummins.

🔧 Transmission

Transmission Types:

The 2002 Ram 3500 Series was available with various transmissions, including manual and automatic options. Common transmissions include the NV4500 (5-speed manual), and 48RE (4-speed automatic) for diesel models, and 46RE/47RE (4-speed automatic) for gasoline models.

Transmission Options:

Details for both manual and automatic transmission service, repair, and overhaul procedures are included.

Transmission Features:

The manual provides information on clutch service, torque converter operation, valve body diagnostics, transmission fluid specifications, and shift control systems.

Transmission Fluid Type:

Automatic transmissions typically require ATF+4 (or equivalent). Manual transmissions require specific gear oil. Correct specifications and capacities are crucial and found in the manual.

📐 Dimensions

Body Styles:

Covers all styles, likely including Regular Cab, Club Cab (Quad Cab), and various bed lengths (e.g., 8-foot bed).

Wheelbase Options:

Wheelbase options would vary based on cab and bed configuration, typically ranging from around 130 inches to over 160 inches.

Gross Vehicle Weight Rating:

Gross Vehicle Weight Ratings (GVWR) for the 3500 series typically ranged from approximately 10,000 lbs to over 13,000 lbs, depending on configuration. Specific GVWR for various configurations would be detailed in the manual.

Curb Weight:

Curb weight varied significantly based on engine, drivetrain (2WD/4WD), cab configuration, and bed length, generally ranging from 5,500 lbs to over 7,000 lbs.

🛡️ Safety Features

Passive Safety Systems:

The manual covers the Restraint System, which includes airbags, seatbelts, and related control modules.

Active Safety Features:

Limited active safety features by modern standards. Focus on reliable mechanical systems and driver control.

💡 Technology Features

Audio Systems:

While basic compared to modern vehicles, the 2002 Ram 3500 offered AM/FM radio, cassette, and CD player options. The manual may cover basic diagnostics for these systems.

Diagnostics Availability:

The manual will contain procedures for diagnosing audio system faults, speaker issues, and antenna problems.

ABS:

Anti-lock Braking System (ABS) was available. The manual details ABS component testing and diagnostics.

Remote Keyless Entry:

Available on some trims. The manual can assist with troubleshooting related to the keyless entry system and its components.

🔧 Maintenance

Oil Change Interval:

For gasoline engines, typically every 3,000-7,500 miles depending on oil type and driving conditions. For the 5.9L Cummins, oil changes were often recommended every 5,000-10,000 miles or 6 months, with fuel filter and oil filter changes at similar intervals. Precise intervals are detailed in the manual.

Transmission Fluid Interval:

Automatic transmission fluid changes typically recommended every 30,000-100,000 miles depending on service and manufacturer recommendations. Manual transmission fluid changes are less frequent, often at 60,000-100,000 miles.

Air Filter Interval:

Engine air filter replacement is typically recommended every 15,000-30,000 miles or sooner in dusty conditions. Diesel engines have more robust air filtration systems.

Engine Oil Spec:

Gasoline engines typically used SAE 5W-30 or 10W-30 API SJ certified oil. The 5.9L Cummins Turbo Diesel typically required SAE 15W-40 API CG-4 or CH-4 certified heavy-duty diesel engine oil. Specific grades and capacities are in the manual.

Coolant Spec:

Typically a 50/50 mix of ethylene glycol antifreeze and distilled water. Specific Mopar coolant type is recommended. Capacity varies by engine, but around 20-25 quarts.

Brake Fluid Spec:

DOT 3 brake fluid is standard. Fluid level checks and bleeds are routine maintenance items.

Common Problems:

Potential common issues for this generation of Ram 3500 include: fuel injector issues in early Cummins engines, radiator leaks, HVAC blower motor resistor failure, and minor electrical gremlins. The manual provides diagnostic procedures for these and many more.

Suspension Wear:

Ball joints, tie rod ends, and steering linkage components can experience wear, especially in vehicles used for heavy hauling or off-road driving.

Electrical Connections:

Corrosion or looseness in electrical connectors, particularly in the engine bay and under the chassis, can lead to intermittent issues.

📚 Vehicle History

Generation Details:

The 2002 model year falls within the third generation of the Dodge Ram Pickup (BR/BE platform, 1994-2001 for first two generations, extended to 2002 for heavy duty models). This generation saw significant updates and refinements, particularly in powertrains and chassis design.

Manufacturing Location:

Dodge Ram trucks were primarily manufactured at Chrysler's Saltillo Truck Assembly Plant in Mexico and Warren Truck Assembly Plant in Michigan, USA.

Dodge Truck Legacy:

Dodge's heritage in heavy-duty trucks is long-standing, with the Ram line evolving significantly since its introduction, emphasizing power, towing, and work capability.

🏆 Awards & Recognition

Truck Of The Year:

While specific awards for the 2002 model year may vary, Dodge Ram trucks have historically received numerous 'Truck of the Year' awards from various automotive publications.