🏷️ Basic Information

Make:

Dodge

Model:

Ram 2500 / 3500

Year:

2002

👋 Introduction

Market Segment:

Heavy-duty pickup truck, serving commercial, fleet, and demanding personal use customers requiring significant towing and hauling capabilities.

Competitors:

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

Vehicle Strengths:

Renowned for robust chassis, powerful Cummins turbodiesel engine option, excellent towing and payload capacities, and generally strong build quality for its class.

Value For Buyers:

Essential for owners performing their own maintenance and repairs, or for independent repair shops. Provides factory-level accuracy, saving time and money by avoiding incorrect procedures or unnecessary part replacements.

📋 Manual Details

Coverage:

Complete service, maintenance, and repair for all systems of the 2002 Dodge Ram 2500 and 3500.

Page Count:

Estimated 2000+ pages (typical for full service manuals of this era and vehicle type)

Type:

Full Service & Repair Manual

Language:

English

Format:

Digital (likely PDF, potentially CD-ROM for older distributions)

📖 Manual Coverage

Engine:

Detailed diagnostics, repair, overhaul procedures for all gasoline and diesel engine variants including: 5.9L Magnum V8, 5.7L HEMI V8 (less common for 2500/3500 in 2002, but possible), 5.9L Cummins Turbo Diesel I6.

Transmission:

Coverage for NV4500 5-speed manual, NV5600 6-speed manual, and 48RE 4-speed automatic transmissions, including torque converters, clutch service, hydraulic systems, and electronic controls.

Drivetrain:

Front and rear axle service (Dana 44, Dana 50/60, Spicer), transfer case operation and repair (NV241DHD, NV273DHD), driveshaft maintenance, U-joints, CV joints.

Brakes:

Front disc brake overhaul, rear drum/disc brake service, ABS system diagnostics and repair, hydraulic system bleeding, parking brake adjustments.

Suspension:

Front and rear suspension component replacement (leaf springs, coil springs, shock absorbers, control arms, ball joints, sway bars), alignment specifications.

Steering:

Power steering system diagnosis and repair, steering gear service, steering column components, tie rods, drag links.

Electrical System:

Comprehensive wiring diagrams, fuse box locations, battery and charging system service, starter motor and alternator repair, lighting system troubleshooting, power accessories, instrument cluster diagnostics.

Body And Interior:

Body panel removal and installation, door hardware, interior trim, seat mechanisms, HVAC system service, body control module (BCM) information, glass replacement.

Fuel System:

Fuel pump replacement, fuel filter service, fuel injector cleaning and testing, evaporative emissions (EVAP) system diagnosis.

Cooling System:

Radiator and fan service, water pump replacement, thermostat operation, coolant types and capacities, pressure testing.

Exhaust System:

Exhaust manifold repair, catalytic converter replacement, muffler and pipe service, oxygen sensor testing.

Maintenance:

Detailed scheduled maintenance intervals (oil changes, fluid flushes, filter replacements), lubrication points, tire rotation, inspection checklists.

Troubleshooting:

Systematic diagnostic procedures, common fault codes (OBD-II), symptom-based troubleshooting guides.

Repair:

Step-by-step repair instructions for all major components and systems, including torque specifications, special tool requirements, and assembly sequences.

Diagnostics:

Engine performance diagnostics, ABS diagnostics, transmission fault tracing, electrical system troubleshooting using wiring diagrams and test procedures.

Depth:

Comprehensive; covers everything from basic fluid level checks and filter replacements to complete engine and transmission overhauls, electrical system diagnostics, and body repairs.

📊 Manual Specifications

File Format Details:

Likely a high-resolution PDF with searchable text, vector-based diagrams for clarity, and bookmark functionality for easy navigation. Print quality will depend on the source printing or PDF rendering.

Print Quality Notes:

Assuming a professionally produced digital reproduction, expect sharp text and clear, legible diagrams. Original manuals were printed on durable paper suitable for workshop environments.

Binding Type Notes:

Original manuals were typically perfect-bound or spiral-bound for lay-flat usability in a workshop. Digital versions offer navigation through bookmarks and hyperlinks.

Paper Type Notes:

Original manuals used heavy-duty, often coated paper to withstand grease and workshop conditions. Digital format bypasses this requirement.

⚙️ Engine Specifications

Engine Options:

5.9L OHV V8 Magnum (gasoline), 5.9L OHV I6 Cummins Turbo Diesel (12-valve and 24-valve variants common for this year).

5.9L Magnum V8:

Approx. 245-250 hp and 345-350 lb-ft torque (specifications vary slightly by application and year updates).

5.9L Cummins Turbo Diesel:

Approx. 235-250 hp and 460-500 lb-ft torque (depending on 12-valve or 24-valve, and specific model configuration).

Gasoline:

Multi-point Fuel Injection (MPI).

Diesel:

Rotary injection pump (VE for earlier 12V), P7100 for later 12V, and Bosch VP44 injection pump for 24-valve engines.

Gasoline:

Distributorless Ignition System (DIS) or Distributor Ignition (DI) depending on exact configuration.

Capacity Diesel:

Approx. 21 quarts (19.9 liters).

Capacity Gasoline:

Approx. 17 quarts (16.1 liters).

Diesel Oil Capacity:

10 quarts (9.5 L) of 15W-40 API CI-4 or CH-4 diesel engine oil (check manual for exact spec).

Gasoline Oil Capacity:

6 quarts (5.7 L) of 5W-30 or 10W-30 API SN/SM/SL engine oil (check manual for exact spec).

🔧 Transmission

Manual Options:

New Process (NV) 4500 5-speed manual (common for 2500, less so for 3500), NV5600 6-speed manual (often found in higher trim 3500 models).

Automatic Option:

Chrysler 48RE 4-speed automatic transmission with overdrive.

48Re Features:

Electronic governor pressure control, torque converter lock-up clutch for improved fuel economy.

48Re Fluid Type:

ATF+4 (MS-9602 or equivalent).

Nv4500 Fluid Type:

Manual transmission fluid (MTF) meeting Chrysler specification MS-9224, typically SAE 75W-90 or 75W-85 GL-4.

📐 Dimensions

Wheelbase Options:

Various wheelbases available depending on cab configuration (e.g., 130.5" for Regular Cab SWB, 154.5" for Regular Cab LWB, 148.5" for Quad Cab SWB, 170.5" for Quad Cab LWB).

Bed Lengths:

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

Gvwr Range:

Approximately 9,750 lbs to 12,000 lbs (GVWR varies significantly by configuration).

Curb Weight Range:

Approximately 6,000 lbs to 7,500 lbs (highly dependent on engine, drivetrain, and cab configuration).

Max Towing Capacity:

Up to 14,000+ lbs (GCWR dependent, requires proper configuration and equipment).

Max Payload Capacity:

Up to 5,000+ lbs (payload capacity varies significantly by configuration).

🛡️ Safety Features

NHTSA Ratings:

Specific NHTSA ratings for 2002 models are not as standardized as modern vehicles. Generally, heavy-duty trucks prioritize structural integrity for their intended use.

ABS:

Standard Anti-lock Braking System (ABS) on all wheels, with different calibration for 2WD and 4WD models.

Airbags:

Standard front airbags for driver and passenger. Some models might offer side airbags as an option, but less common in this era for heavy-duty trucks.

Seatbelts:

Three-point front seat belts with pretensioners, three-point rear seat belts in Quad Cab models.

Frame Construction:

Heavy-duty ladder frame construction for superior rigidity and load-bearing capacity.

💡 Technology Features

Audio System:

Factory AM/FM/CD player, optional cassette player, available premium Infinity sound system with subwoofer.

Climate Control:

Manual or optional automatic climate control (HVAC) system with cabin air filter.

Cruise Control:

Standard cruise control.

Trailer Tow Prep:

Wiring harness for trailer brakes and lighting often pre-installed or available as an option.

Gauge Cluster:

Includes speedometer, tachometer (diesel models), fuel level, engine temperature, oil pressure, and voltmeter. May include auxiliary gauges for diesel models (e.g., boost pressure, EGT).

🔧 Maintenance

Oil Change Interval Gas:

Every 7,500 miles or 6 months, or at 3,000-5,000 miles under severe duty (check manual for specific conditions).

Oil Change Interval Diesel:

Every 7,500 miles or 6 months (synthetic oil recommended by some users, but follow manual's API rating).

Fuel Filter Diesel:

Replace every 15,000-30,000 miles or as recommended, critical for VP44 pump longevity.

Transmission Fluid Change:

Automatic: Every 30,000-60,000 miles. Manual: Check for leaks, fluid changes typically at higher mileage or if shifting issues arise.

Coolant Type:

Chrysler HOAT (Hybrid Organic Acid Technology) coolant, typically Mopar OAT or equivalent (e.g., Peak Final Charge).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (check manual for specific recommendation).

Power Steering Fluid:

Mopar ATF+4 or equivalent.

Vp44 Diesel Pump:

VP44 injection pump on the 5.9L 24-valve Cummins is known for potential failure due to low lift pump pressure or contaminated fuel.

Automatic Transmission Overheating:

48RE transmissions can overheat under heavy towing; auxiliary transmission coolers are a common upgrade.

Frontend Component Wear:

Ball joints, tie rods, and steering linkage components can experience wear due to the weight and use of these trucks.

Heater Core:

Heater core can be prone to leaks, requiring dashboard removal for replacement.

Body Rust:

Rust can form on fenders, rocker panels, and the undercarriage, especially in areas with road salt.

📚 Vehicle History

Dodge Truck Legacy:

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

Third Generation Ram:

The 2002 model year represents the first year of the third-generation Ram trucks (2002-2008), marking a significant redesign with a more aggressive exterior styling, updated interior, and revised powertrain options, including the introduction of the 5.7L HEMI V8 in later years of this generation.

Manufacturing Location:

Saltillo, Mexico; Warren, Michigan, USA (primary assembly plants for this generation).

Model Run:

2002-2008 (Third Generation).

🏆 Awards & Recognition

Cummins Engine Reputation:

The 5.9L Cummins Turbo Diesel engine itself is highly regarded for its durability, reliability, and performance, often considered a benchmark in the diesel truck market.

Model Sales:

The third-generation Ram trucks, including the 2500/3500, were strong sellers in their segment, contributing significantly to Chrysler's truck sales volume.