🏷️ Basic Information

Make:

Dodge

Model:

Ram

Model Code:

DR/DH/D2 (Third Generation)

Year:

2002

Trim Levels Covered:

1500, 2500, 3500 (and variations like SLT, ST, Laramie)

Chassis Code:

DR (Light Duty), DH (Heavy Duty - 2500), D2 (Heavy Duty - 3500)

👋 Introduction

Segment:

Full-size Pickup Truck

Target Audience:

DIY mechanics, professional technicians, fleet managers, owners seeking in-depth maintenance and repair knowledge

Competitors:

Ford F-Series, Chevrolet Silverado/GMC Sierra, Toyota Tundra

Platform:

Third generation Dodge Ram (2002-2008), known for its robust construction and distinctive 'Big Rig' styling

Value Proposition:

Provides factory-level repair and maintenance data, enabling comprehensive self-service and accurate diagnostics, saving on labor costs

📋 Manual Details

Primary Focus:

Service and Repair

Scope:

Body, Chassis, Electrical Systems, Engine, Transmission, Drivetrain, Suspension, Brakes, HVAC, Steering, Fuel System, Emissions, Diagnostic Procedures

Estimated Pages:

Extensive (typical service manuals for this era are 1000+ pages)

Type:

Comprehensive Service Manual

Language:

English

File Format:

PDF

Compatibility:

Windows XP, Vista, 7, 8, Linux, Mac

Searchability:

Fully Searchable

Navigation:

Fully Bookmarked

PDF Quality:

High Resolution, Clear Text, Printable

Print Readability:

Optimized for digital viewing and printing

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, internal components, cylinder head, valve train, crankshaft, pistons, connecting rods, oil pump, timing system, cooling system, lubrication system

Engine Electrical:

Ignition system, starter motor, alternator, battery, charging system, engine control module (ECM) operation and diagnosis, fuel injection system

Fuel System:

Fuel pump, fuel injectors, fuel lines, fuel filter, evaporative emission control (EVAP) system

Transmission Manual:

NV3500, NV4500 manual transmissions: overhaul, clutch system, gear shifter mechanism

Transmission Automatic:

48RE, 47RE, 45RFE automatic transmissions: hydraulic system, valve body, torque converter, electronic controls, overhaul, torque converter clutch (TCC)

Drivetrain:

Front and rear axle assemblies, differentials, driveshafts, U-joints, transfer case (manual and electronic shift)

Suspension:

Front suspension (independent on 1500, solid axle on 2500/3500), rear suspension (leaf springs), shock absorbers, control arms, ball joints, steering knuckles, sway bars

Steering:

Power steering system, steering gear, tie rods, steering column, intermediate shaft

Brakes:

Front and rear disc brakes (and rear drums on some 3500), Anti-lock Braking System (ABS), brake calipers, rotors, pads, master cylinder, brake lines, parking brake

Electrical Body:

Lighting system (headlights, taillights, interior lights), power windows, power locks, power mirrors, wipers, horns, security system, keyless entry, remote start

Electrical Chassis:

Instrument cluster, gauges, warning lights, interior electronics, exterior sensors

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, A/C compressor, evaporator, condenser, blower motor, climate controls, refrigerant system

Body:

Body panel removal and installation, doors, hood, tailgate, bumpers, interior trim, seats, glass replacement

Emissions:

Catalytic converter, oxygen sensors, EGR system (if applicable), evaporative emission control (EVAP)

Diagnostics:

Diagnostic Trouble Codes (DTCs), OBD-II functionality, diagnostic connector pinout, using scan tools

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, lubrication points

Repair:

Component removal and installation, component overhaul, sub-assembly repairs, part replacement procedures

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides, common problem diagnosis

Wiring:

Complete Electrical Schematics, Wiring Harness Diagrams, Connector Views, Component Location Charts for all electrical systems

Specifications:

Torque specifications for fasteners, alignment specifications, fluid capacities, electrical specifications

Engine Timing:

Detailed procedures for setting ignition timing (if applicable on specific engines) and mechanical timing (e.g., timing chain/belt for gas, camshaft timing for diesel)

Wheel Alignment:

Specifications and procedures for front and rear wheel alignment, camber, caster, toe adjustments.

Depth:

Comprehensive, from basic fluid checks to complete engine and transmission rebuilds, detailed diagnostics

Diagnostic Tools Required:

OBD-II Scan Tool, Multimeter, Test Light, Pressure Gauges (fuel, oil, coolant, AC), Vacuum Gauge, Injector Test Kit (diesel)

⚙️ Engine Specifications

Engine Option 1:

4.7L Magnum V8 (SOHC)

Displacement 4.7L:

4.7 Liters (287 cu in)

Horsepower 4.7L:

Approx. 235-240 hp @ 4500 rpm (varies slightly by model year/tune)

Torque 4.7L:

Approx. 300-305 lb-ft @ 3200 rpm (varies slightly)

Fuel System 4.7L:

Sequential Multi-Port Fuel Injection (MPI)

Engine Option 2:

5.9L Cummins Turbo Diesel I6 (ISB)

Displacement 5.9L:

5.9 Liters (359 cu in)

Horsepower 5.9L:

Approx. 235-250 hp @ 2500 rpm

Torque 5.9L:

Approx. 460-475 lb-ft @ 1400 rpm

Fuel System 5.9L:

High-pressure Common Rail (HPCR) fuel injection (starting with 5.9L common rail in 2003, but manual covers diagnostic aspects potentially for earlier non-HPCR versions if they existed for export or specific configurations for 2002, though 2002 was transition to common rail)

Engine Variants:

Manual covers both gasoline (4.7L Magnum V8) and the highly regarded 5.9L Cummins Turbo Diesel. Some 2002 models may still have the older 24-valve 5.9L VE pump or early common rail depending on production date.

🔧 Transmission

Transmission Option 1:

45RFE 4-Speed Automatic

Transmission Option 2:

NV3500 5-Speed Manual

Transmission Option 3:

47RE 4-Speed Automatic (with Diesel engines, sometimes 48RE on heavier duty)

Transmission Option 4:

NV4500 5-Speed Manual (with Diesel engines, typically 2500/3500)

Overdrive:

All automatic transmissions feature overdrive (OD) gears for improved fuel economy at highway speeds

Transfer Case:

Part-time 4WD systems with manual or electronic shift-on-the-fly transfer cases (NV241DLD, NV241DHD, NV244G, NV271D, NV273D)

📐 Dimensions

Wheelbase 1500:

Standard Cab: 131.1 inches; Quad Cab: 148.1 inches

Wheelbase 2500/3500:

Standard Cab: 131.1 inches; Quad Cab: 148.1 inches; 3500 DRW (Dual Rear Wheel): 131.1 inches (SC), 148.1 inches (QC)

Bed Length Options:

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

Curb Weight 1500:

Approx. 4,800 - 5,500 lbs

Gvwr 1500:

Approx. 6,000 - 6,500 lbs

Gvwr 2500:

Approx. 7,000 - 8,000 lbs

Gvwr 3500:

Approx. 9,000 - 11,500 lbs (including DRW)

🛡️ Safety Features

NHTSA Driver Front:

Good (for 2002 model year testing, but generally strong for its class)

NHTSA Passenger Front:

Good

ABS:

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

Brake Assist:

Available

Airbags:

Standard front driver and passenger airbags

Seatbelts:

Three-point height-adjustable front seat belts, pretensioners

💡 Technology Features

Audio System:

Factory AM/FM stereo, CD player, cassette player. Optional premium Infinity sound system available. Sirius Satellite Radio availability.

Navigation:

Optional factory navigation system available on some higher trims.

Cruise Control:

Standard cruise control

Towing Features:

Factory trailer brake controller pre-wiring, integrated trailer wiring harnesses

Keyless Entry:

Optional remote keyless entry system

🔧 Maintenance

Oil Change Gas:

Every 3,000-6,000 miles or 6 months (depending on oil type and driving conditions, consult manual for specifics)

Oil Change Diesel:

Every 7,500-15,000 miles or 12 months (with appropriate diesel-rated oil and filter)

Tire Rotation:

Every 7,500 miles

Transmission Fluid Change Auto:

Every 30,000-60,000 miles (check manual for specific intervals and fluid type)

Transmission Fluid Change Manual:

Every 50,000-100,000 miles (check manual)

Engine Oil Gas 4.7L:

SAE 5W-30 (API Certified)

Engine Oil Diesel 5.9L:

SAE 15W-40 (CJ-4 or CK-4 rated diesel oil recommended for Cummins)

Coolant:

Chrysler HOAT (Hybrid Organic Additive Technology) or equivalent long-life coolant (typically pink or orange)

Brake Fluid:

DOT 3 or DOT 4 (check manual for specific application)

Power Steering Fluid:

ATF+4 (Automatic Transmission Fluid, Type 9602) or equivalent

Transfer Case Fluid:

NV241DLD/DHD: ATF+4; NV271D/273D: Manual Transmission Fluid (MTF)

Differential Fluid:

API GL-5 (e.g., 75W-90 for front/rear, 75W-140 for heavy duty/towing)

Gas Engine 4.7L:

Spark plug blowout (early models), intake manifold gasket leaks, oil filter housing leaks, potential head gasket issues under severe use

Diesel Engine 5.9L:

Lift pump failures (early models), injector issues (especially with incorrect fuel or additives), occasional turbocharger issues, exhaust manifold cracks (less common on 2002 models than later ones), transmission issues (47RE can have torque converter clutch or solenoid problems)

Electrical:

Instrument cluster failure (HVAC controls, gauges), body control module (BCM) issues, power window regulators, ignition switch problems

Suspension Steering:

Worn ball joints and tie rod ends on solid front axles (2500/3500), steering box looseness, front end shimmy or wander

Brakes:

Premature rotor warping on heavy-duty models, parking brake adjustment

📚 Vehicle History

Dodge Trucks:

Dodge has a long history of producing capable and rugged trucks, with the Ram nameplate evolving significantly since its introduction in 1981.

Third Generation:

The 2002 model year marks the introduction of the third generation of the Dodge Ram (2002-2008), a complete redesign featuring a more aggressive 'Big Rig' grille, improved interior, and updated chassis and powertrain options. This generation saw the introduction of the Common Rail Cummins in 2003.

Manufacturing Location:

Saltillo, Mexico; Warren, Michigan, USA

🏆 Awards & Recognition

Cummmins Diesel Reputation:

The 5.9L Cummins Turbo Diesel engine is widely celebrated for its durability, longevity, and strong performance, often considered one of the best diesel engines of its era.

Truck Of The Year:

While specific awards for the 2002 model vary, the Ram platform consistently received accolades for its towing and hauling capabilities, and styling.