🏷️ Basic Information

Make:

Dodge

Model:

Ram 2500

Model Years Covered:

2002, 2003, 2004

Chassis Code:

DR (Third Generation Ram)

👋 Introduction

Vehicle Segment:

Heavy-Duty Pickup Truck

Target Audience:

Commercial users, fleet operators, and owners requiring towing and hauling capabilities.

Key Competitors:

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

Vehicle Purpose:

Designed for robust towing, heavy hauling, and off-road capability.

Chassis Design:

Body-on-frame construction for durability and payload capacity.

📋 Manual Details

Coverage Type:

Workshop Service Repair Manual

Page Count:

2627

Manual Type:

Comprehensive Service and Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECM/PCM).

Transmission:

Manual transmission (NV4500, NV5600) and automatic transmission (48RE, NV246 transfer case) overhaul, diagnostics, and service.

Drivetrain:

Front and rear axle assemblies, propeller shafts, U-joints, differentials, 4WD system operation and repair.

Braking System:

Front and rear brake systems (disc/drum), hydraulic system, ABS operation, service, and troubleshooting.

Suspension:

Front and rear suspension components (leaf springs, shocks, ball joints, steering linkage), alignment procedures, troubleshooting.

Steering:

Power steering system, steering gear, tie rods, steering column, troubleshooting.

Electrical System:

Battery, charging system, starting system, lighting, instrumentation, power accessories, body control modules (BCM), wiring diagrams.

HVAC System:

Heating, ventilation, and air conditioning system diagnosis and repair, component replacement.

Body And Frame:

Body panels, doors, interior trim, glass, frame repair, payload and towing information.

Diagnostics And Troubleshooting:

Fault code interpretation (OBD-II), diagnostic procedures for various systems, symptom-based troubleshooting guides.

Maintenance Procedures:

Routine maintenance tasks such as oil changes, filter replacements, fluid checks, tire rotations, and brake inspections.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for all major vehicle systems.

Overhaul Procedures:

Detailed guides for the complete disassembly, inspection, and reassembly of engines, transmissions, and differentials.

Diagnostic Procedures:

Systematic approaches to identifying and resolving mechanical and electrical issues, including wiring harness testing and sensor diagnostics.

Specifications And Tolerances:

Precise measurements, torque specifications, clearances, and other critical parameters for proper assembly and adjustment.

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle circuits, facilitating troubleshooting and repair of electrical components.

Depth Level:

In-depth technical information suitable for professional mechanics and experienced DIY enthusiasts.

Diagnostic Capabilities:

Advanced diagnostic strategies, including interpretation of diagnostic trouble codes (DTCs) and use of scan tools.

Rebuild Instructions:

Detailed instructions for complete engine, transmission, and axle rebuilds, including component specifications and procedures.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, clear text and diagrams suitable for printing.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Options:

5.7L Magnum V8 (360 ci), 8.0L V10 Triton (488 ci), 5.9L Cummins Turbo Diesel I6.

5.7L Magnum V8:

Approx. 245-250 hp, 330-335 lb-ft torque (specific output varied slightly by year/trim).

8.0L V10 Triton:

Approx. 305-310 hp, 450-455 lb-ft torque.

5.9L Cummins Turbo Diesel:

Approx. 235-250 hp, 460-505 lb-ft torque (HP increased in 2003/2004 models).

Fuel System Type:

Multi-port fuel injection (MPI) for V8 and V10; Direct injection (common rail for 2003+ Cummins) for diesel.

360 Magnum:

EGA

488 V10:

TBA (Engine specific code often associated with trim/package)

5.9L Cummins:

ISB (Engine family), specific variant codes apply based on HP/torque.

🔧 Transmission

Transmission Options:

Available with manual or automatic transmissions.

Manual Transmissions:

5-speed Getrag NV4500, 6-speed New Venture Gear NV5600 (diesel models).

Automatic Transmissions:

4-speed 48RE automatic transmission (heavy-duty version of the 727).

Transfer Case:

Part-time 4WD with electronic shift (NV246 or similar) or manual transfer case lever options.

📐 Dimensions

Body Styles:

Regular Cab, Club Cab (Quad Cab), Mega Cab (introduced later in the generation, check specific year).

Bed Lengths:

Short Bed (approx. 6.3 ft), Long Bed (approx. 8 ft).

Curb Weight:

Varies significantly by configuration (e.g., approx. 5,500 - 7,500+ lbs).

Gross Vehicle Weight Rating Gvwr:

Exceeds 8,500 lbs, often in the 8,800 lbs to 9,500+ lbs range depending on configuration.

🛡️ Safety Features

NHTSA Frontal Crash Rating:

4-star driver, 4-star passenger (for comparable models of this era, specific ratings should be verified for exact year/configuration).

Braking System:

Four-wheel disc brakes (front vented, rear solid) or front disc/rear drum configurations depending on GVWR and year; ABS available.

Airbags:

Driver and passenger front airbags.

💡 Technology Features

Infotainment System:

Base models feature a basic AM/FM radio with cassette and CD player. Higher trims may offer premium audio systems and auxiliary input jacks. Navigation was not standard.

Anti Lock Braking System:

ABS was available and standard on some configurations, particularly those with higher GVWRs.

Connectivity Features:

Limited connectivity compared to modern vehicles; features like Bluetooth or USB ports were not standard or widely available in this model year range.

🔧 Maintenance

Oil Change Interval:

Typically 3,000-5,000 miles for gasoline engines, 5,000-7,500 miles for Cummins diesel (refer to manual for exact specifications).

Transmission Fluid Change:

Refer to manual for specific intervals, generally around 30,000-60,000 miles depending on usage (towing).

Engine Oil Gasoline:

SAE 5W-30 or 10W-30 (check manual for specific engine and temperature range, API classification SN or earlier).

Engine Oil Diesel Cummins:

CJ-4 or CK-4 rated diesel engine oil, viscosity typically 15W-40 or 5W-40 for cold weather (consult manual and oil manufacturer).

Transmission Fluid 48Re:

ATF+4 (Mopar Part Number: 68083383AA or equivalent).

Manual Transmission Fluid:

NV4500: GL-3 or GL-4 rated manual transmission fluid (e.g., Castrol Syntrans, Mopar Manual Transmission Lubricant).

Coolant:

Mopar Antifreeze/Coolant (HOAT) or equivalent HOAT coolant, typically a 50/50 mix with distilled water.

Cummins Injectors:

Early 5.9L Common Rail (2003+) injectors can be prone to failure due to water contamination or wear; the manual will guide on diagnostics and replacement.

Transmission Issues:

NV4500 5th gear nut issues (requiring updated retainer), 48RE 'clunk' or delayed engagement can occur. Manual provides troubleshooting.

Front Suspension/Steering:

Ball joints and steering linkage components can wear prematurely due to the heavy nature of the truck; regular inspection is recommended.

Electrical Gremlins:

Like many vehicles of this era, intermittent electrical issues can arise; the comprehensive wiring diagrams in the manual are crucial for diagnosis.

📚 Vehicle History

Dodge Truck Legacy:

Dodge has a long history of producing robust and capable trucks, with the Ram line dating back to 1981.

Third Generation Ram:

The 2002-2008 generation (DR) marked a significant redesign from the previous generation, featuring a more aerodynamic design and increased interior space. This generation introduced the Mega Cab option and significant powertrain updates, particularly for the Cummins diesel.

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, reliability, and strong aftermarket support, often considered a benchmark in its class.

Towing Capacity:

Excellent towing and payload capacities, a primary selling point for the Ram 2500, capable of towing over 10,000 lbs depending on configuration.