🏷️ Basic Information

Make:

Dodge

Model:

Ram 3500 Series

Model Years Covered:

2002, 2003, 2004

Chassis Code:

DR/DH (Third Generation Ram Trucks)

👋 Introduction

Market Position:

The Dodge Ram 3500 Series of this era was a flagship heavy-duty pickup truck, positioned to compete in the demanding commercial and towing markets. Known for its robust build quality and powerful engine options.

Primary Competitors:

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

Key Features:

Renowned for its strong chassis, powerful engine options (especially the Cummins turbodiesel), and substantial towing and hauling capabilities. This generation introduced significant styling updates and interior refinements.

Manual Value Proposition:

This comprehensive PDF manual provides DIY mechanics and professional technicians with the authoritative information needed to maintain, diagnose, and repair their 2002-2004 Dodge Ram 3500 Series. Its digital format ensures portability and easy accessibility.

📋 Manual Details

Systems Covered:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Bodywork, Emissions, Diagnostics, Maintenance, Lubrication

Estimated Page Count:

1500-2000 (typical for comprehensive service manuals of this era)

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Powertrain:

Detailed coverage of Gasoline and Diesel engines, including specific variants and their components; Manual and Automatic transmissions; Transfer case; Drive axles (front and rear).

Chassis And Body:

Frame construction, suspension components (front and rear leaf springs, coil springs depending on configuration), steering gear, chassis lubrication, body panel removal and installation, interior trim, glass, and seals.

Electrical System:

Detailed wiring diagrams for all circuits, fuse and relay identification, battery and charging system, starter motor, lighting circuits, instrument cluster, power windows/locks, and trailer wiring harnesses.

Maintenance Procedures:

Scheduled maintenance, fluid changes, filter replacements, lubrication, inspection points.

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, diagnostic trouble code (DTC) interpretation and resolution, wiring diagrams, component testing.

Repair Procedures:

Step-by-step instructions for disassembly, inspection, repair, and reassembly of all major vehicle systems, including engine overhaul, transmission rebuild, brake system service, suspension component replacement, and electrical component repair.

Wheel Alignment:

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

Brake System Service:

Front and rear brake system service, including disc brake pad replacement, rotor resurfacing/replacement, caliper servicing, brake fluid flush, parking brake adjustment, and hydraulic system bleeding.

Technical Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls. Includes detailed torque specifications, clearance measurements, and special tool requirements.

Engine Management Systems:

Covers Engine Control Modules (ECM) or Powertrain Control Modules (PCM), fuel injection control, ignition timing, emissions control systems, and sensor diagnostics for both gasoline and diesel engines.

Torque Specifications:

Extensive list of torque specifications for virtually every fastener on the vehicle, critical for proper assembly and safety.

📊 Manual Specifications

File Format:

Portable Document Format (PDF)

Print Quality:

High-resolution, allowing for clear reproduction of diagrams, schematics, and text. Designed for easy printing.

Binding Type:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

Searchability:

Fully text-searchable, allowing users to quickly find specific information.

Illustrations:

Includes numerous diagrams, schematics, exploded views, and line drawings to aid in understanding procedures and component identification.

⚙️ Engine Specifications

Engine Option 1:

8.0L Magnum V10 (360ci)

Engine Option 1 Horsepower:

305 hp @ 4500 rpm

Engine Option 1 Torque:

450 lb-ft @ 2800 rpm

Engine Option 2:

5.9L Cummins Turbo Diesel I6 (360ci)

Engine Option 2 Horsepower:

305 hp @ 2800 rpm (later models may offer higher output variants, check specific VIN)

Engine Option 2 Torque:

555-600 lb-ft @ 1600 rpm (depending on model year and configuration)

Fuel System Diesel:

Common Rail Direct Injection (CRDI) for 5.9L Cummins.

Fuel System Gasoline:

Multi-port Fuel Injection (MPI) for 8.0L V10.

Ignition System:

Electronic ignition with distributor (V10); Compression ignition (Cummins Diesel).

Cooling System Capacity Diesel:

Approx. 28 quarts (26.5 Liters) with heater.

Cooling System Capacity Gasoline:

Approx. 27.5 quarts (26 Liters) with heater.

🔧 Transmission

Standard Transmission:

6-speed manual transmission (NV5600 for Cummins, often optional or replaced by automatic for V10). Details on gear ratios for specific models and configurations are within the manual.

Optional Transmission 1:

4-speed automatic transmission (47RE for earlier models, 48RE introduced later in the generation, especially for higher torque applications like the Cummins).

Optional Transmission 2:

5-speed automatic transmission (from Mercedes-Benz sourced for some models, check VIN).

Transfer Case:

Electronic Shift-on-the-Fly (ESOF) 4WD system, or manual transfer case options. Detailed operation and service procedures are covered.

Automatic Transmission Fluid:

ATF+4 (Mopar spec) is generally required for automatic transmissions. Manual transmission fluid type varies by specific gearbox (e.g., NV5600 often uses specific synthetic manual transmission fluid).

📐 Dimensions

Wheelbase Options:

Multiple wheelbase options available, typically ranging from 130.5 inches (Standard Cab) to 160.5 inches (Long Bed Crew Cab/Quad Cab). Specific dimensions for various configurations are detailed.

Curb Weight Range:

Approximately 6,000 - 7,500 lbs (2721 - 3402 kg), depending on configuration (engine, cab, drivetrain).

Gross Vehicle Weight Rating Gvw:

Exceeds 10,000 lbs (typically 11,000 - 14,000+ lbs), defining it as a Class 3 truck. Specific GVWRs vary by model and configuration.

Max Towing Capacity:

Up to 12,000+ lbs (5,443+ kg), depending on axle ratio, engine, cab configuration, and fifth-wheel/gooseneck hitch installation. The manual details towing limits for each configuration.

Bed Length Options:

8-foot (96 inches) is standard for most 3500 models. Some configurations might offer shorter beds, but 8-foot is predominant.

🛡️ Safety Features

NHTSA Crash Test Ratings:

Specific ratings vary by test year and configuration. Generally, heavy-duty trucks of this era focused on occupant protection and structural integrity for towing. Manual may reference specific test results or safety feature explanations.

Active Safety Features:

Anti-lock Braking System (ABS) is standard. Available trailer brake controller integration. Traction control may have been available on specific trims.

Passive Safety Features:

Driver and passenger airbags, three-point seat belts, high-strength steel frame and body construction.

Lighting Systems:

Halogen headlamps, front and rear turn signals, brake lights, reverse lights. Manual covers bulb types and replacement procedures.

💡 Technology Features

Infotainment Systems:

Base models featured AM/FM radio with cassette and CD player. Higher trims offered upgraded Infinity sound systems, and optional CD changers. Manual may detail radio removal/installation and speaker wiring.

Driver Assistance Features:

Features were more basic compared to modern vehicles. Cruise control was standard on most trims. Parking assist sensors were not common on this generation.

Connectivity Options:

Limited to basic audio input (cassette/CD). No Bluetooth or USB connectivity from the factory. Manual will cover wiring for these systems if aftermarket upgrades are considered.

OBD Ii Support:

Equipped with OBD-II (On-Board Diagnostics II) port for emissions and engine diagnostics. Manual provides pinouts and DTC information.

🔧 Maintenance

Oil Change Interval Gasoline:

Typically every 3,000-7,500 miles (4,800-12,000 km) or 6 months, depending on driving conditions. Manual will specify exact intervals and oil types.

Oil Change Interval Diesel:

Typically every 7,500-15,000 miles (12,000-24,000 km) or 12 months for the 5.9L Cummins, using appropriate diesel-grade oil. Manual provides precise intervals.

Transmission Fluid Change Interval:

Automatic: Typically every 30,000-100,000 miles (48,000-160,000 km) based on load and driving conditions. Manual specifies intervals for severe vs. normal service.

Engine Oil Gasoline:

API Certified SAE 5W-30 or 10W-30. Verify exact specification and viscosity for specific engine and ambient temperatures in the manual.

Engine Oil Diesel:

API CJ-4 or CI-4 rated synthetic or conventional heavy-duty diesel engine oil, typically 15W-40 or 5W-40 (for cold weather). Manual provides precise specifications and capacities.

Coolant:

Mopar OAT (Orange) or HOAT (Hybrid Orange) Antifreeze/Coolant, 50/50 mix with distilled water. Manual specifies approved types and capacities.

Brake Fluid:

DOT 3 brake fluid.

Power Steering Fluid:

Power Steering Fluid (Mopar specific or equivalent).

Common Issues Diesel:

Potential issues include cracked cylinder heads (early versions), injection pump failures, and turbocharger wear. The manual provides diagnostic and repair procedures for these.

Common Issues Gasoline:

V10 can experience ignition system issues (spark plugs, coils), and potential exhaust manifold leaks. Manual covers these diagnostics.

Common Issues General:

Rust on body panels, especially around wheel wells and rocker panels; u-joint wear; potential for HVAC system component failures; rear axle seal leaks.

📚 Vehicle History

Brand Heritage:

Dodge has a long history of producing rugged and capable trucks, with the 'Ram' nameplate becoming synonymous with heavy-duty performance and workhorse capability.

Third Generation Ram:

This period covers the third generation of the Dodge Ram (2002-2008), codenamed DR/DH. This generation featured a significant redesign with a bolder, more aggressive exterior styling and a more modern interior compared to its predecessor.

Production Plants:

Primarily manufactured at the Saltillo Truck Plant in Mexico and Warren Truck Assembly Plant in Michigan.

Sales Performance:

The Ram series consistently ranked among the top sellers in the heavy-duty pickup truck segment during these years, appealing to a broad customer base for work and recreation.

🏆 Awards & Recognition

Diesel Engine Recognition:

The 5.9L Cummins Turbo Diesel engine consistently received praise for its durability, power, and longevity, often considered one of the best diesel powertrains available in a pickup truck during its production run.

Truck Of The Year Awards:

While specific year-by-year awards might vary, the Ram series frequently appeared on 'Best' lists for towing, hauling, and overall value in the heavy-duty segment from automotive publications.