Dodge Ram Truck 2002-2004 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Truck Generation: Third Generation (DR/DH/D) - Ram Pickup Product Type: Workshop Repair Service Manual 👋 Introduction Market Position Vehicle Segment: Full-size pickup...

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类型: Truck

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标签: 2002 2003 2004 Cars Dodge Misc Ram Truck

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Ram Truck

Generation:

Third Generation (DR/DH/D) - Ram Pickup

Product Type:

Workshop Repair Service Manual

👋 Introduction

Market Position

Vehicle Segment:

Full-size pickup truck, highly popular in the North American market

Manual Target Audience:

Dodge Ram owners, independent repair shops, automotive technicians, fleet maintenance personnel

Competitive Analysis

Key Competitors During Era:

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

Key Features

Vehicle Strengths:

Robust chassis, powerful engine options, towing and payload capability, distinctive styling

Manual Value Proposition:

Provides in-depth technical knowledge to maintain, diagnose, and repair the vehicle, saving time and money on repairs.

📋 Manual Details

Coverage Areas

Model Years Covered:

2002, 2003, 2004

Trim Levels Covered:

All Models (e.g., SLT, Laramie, ST, Sport, TRX)

Body Styles Covered:

All body styles (e.g., Standard Cab, Club Cab, Quad Cab)

Page Count

Estimated Page Count:

Extensive (typically 2000+ pages for full workshop manuals covering all models/engines)

Manual Type

Manual Type:

Comprehensive Workshop Repair and Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emission control systems

Transmission:

Automatic and Manual Transmission diagnostics, repair, and overhaul; Transfer Case operation and repair

Drivetrain:

Driveshafts, U-joints, axles, differentials (rear and front for 4x4)

Suspension:

Front and rear suspension components, steering linkage, shocks, springs, leveling systems

Brakes:

Hydraulic brake systems (front disc, rear disc/drum), ABS, parking brake

Electrical:

Battery, charging system, starting system, lighting, instrumentation, power accessories, body control modules, fuses, relays, wiring diagrams

HVAC:

Heating, Ventilation, and Air Conditioning system diagnosis and repair

Body:

Body panels, doors, windows, seats, interior trim, exterior trim, bumpers, glass replacement

Chassis:

Frame, structural components, alignment specifications

Diagnostics:

OBD-II system, diagnostic trouble codes (DTCs), troubleshooting charts, diagnostic procedures

Procedures Included

Maintenance:

Routine maintenance procedures, fluid changes, filter replacements, lubrication points

Troubleshooting:

Systematic troubleshooting guides for common and complex issues

Repair:

Step-by-step repair instructions for major and minor components

Overhaul:

Complete engine and transmission overhaul procedures

Adjustment:

Adjustment procedures for brakes, clutch, steering, etc.

Diagnostics:

Diagnostic procedures for electrical and mechanical faults

Replacement:

Component replacement guidelines (e.g., water pump, alternator, starter, sensors)

Technical Depth

Depth Of Information:

Professional-level technical detail, suitable for dealership technicians and experienced DIY mechanics

Diagnostic Capabilities:

Includes diagnostic flowcharts, wiring schematics, and specification tables for accurate fault diagnosis

Special Tools:

Lists required special tools for specific repair and diagnostic procedures

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Likely contains searchable text for quick information retrieval

Printability:

Printable pages for on-site workshop use

Print Quality

Image Resolution:

High resolution for clear diagrams and illustrations (expected for professional manuals)

Binding Type

Binding Type Digital:

N/A (Digital Download)

Paper Type

Paper Type Digital:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Options:

3.7L Magnum V6, 4.7L Magnum V8, 5.9L Magnum V8 (OHV/OHC variants), 5.9L Cummins Turbo Diesel I6

Performance

3.7L Magnum V6 Horsepower:

Approx. 205 hp @ 5200 rpm

3.7L Magnum V6 Torque:

Approx. 235 lb-ft @ 4000 rpm

4.7L Magnum V8 Horsepower:

Approx. 235-245 hp @ 4800-5000 rpm (depending on year/variant)

4.7L Magnum V8 Torque:

Approx. 295-300 lb-ft @ 3200-3600 rpm (depending on year/variant)

5.9L Magnum V8 Horsepower:

Approx. 245-245 hp @ 4200-4800 rpm

5.9L Magnum V8 Torque:

Approx. 335-335 lb-ft @ 3200-3600 rpm

5.9L Cummins Turbo Diesel Horsepower:

Approx. 235-250 hp @ 2900-3000 rpm

5.9L Cummins Turbo Diesel Torque:

Approx. 460-475 lb-ft @ 1400-1600 rpm

Fuel System

Fuel Delivery Gasoline:

Multi-port Fuel Injection (MPI)

Fuel Type Gasoline:

Unleaded gasoline (Octane rating as per owner's manual)

Fuel System Diesel:

High-pressure common rail injection system

Fuel Type Diesel:

Diesel fuel (refer to manual for specific grades/standards)

Cooling System

Cooling System Type:

Pressurized liquid cooling system

🔧 Transmission

Standard

Standard Transmission:

4-speed automatic (e.g., 45RFE, 48RE) and 5-speed manual (NV3500/NV4500) depending on engine and configuration

Optional

Optional Transmission:

4-speed automatic (e.g., 42RE for lower output engines), 4-speed automatic heavy-duty (e.g., 47RE/48RE for higher output engines)

Features

Transfer Case:

Part-time 4WD (NV241DHD), Full-time 4WD (NV244 transfer case with electronic range selection - select models)

Fluid Specifications

Automatic Transmission Fluid Type:

ATF+4 (Chrysler Mopar)

Manual Transmission Fluid Type:

API GL-5, SAE 75W-90 (or as specified by Chrysler)

Transfer Case Fluid Type:

ATF+4 for NV244, Mopar Gear Oil 75W-90 for NV241DHD (verify with manual)

📐 Dimensions

Exterior

Wheelbase Options:

134.2 inches (Standard Bed), 140.5 inches (Long Bed - 2WD), 153.7 inches (Mega Cab - if applicable)

Overall Length Options:

222.2 inches (Standard Bed), 230.5 inches (Long Bed)

Width Excluding Mirrors:

Approx. 79.1 inches

Height:

Approx. 74.6 inches (varies with trim and 4WD)

Ground Clearance:

Varies by configuration, typically 8-10 inches

Cargo

Bed Length Options:

6.3 feet (Standard Box), 8.0 feet (Long Box)

Weights

Curb Weight Range:

Approx. 4,500 - 6,500 lbs (depending on configuration and engine)

Max Gvw Range:

Approx. 6,000 - 8,800 lbs (depending on model/payload package)

Towing Capacity Max:

Up to 8,700 lbs (for properly equipped 2500 models with 5.9L Cummins Diesel)

Payload Capacity Max:

Up to 3,300 lbs (for properly equipped models)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

4-star (2002-2004 models, varies slightly by year)

NHTSA Frontal Impact Passenger:

4-star (2002-2004 models, varies slightly by year)

IIHS Frontal Offset:

Good (for models tested)

Active Features

Standard on most models, 4-wheel disc brakes available on some configurations

Traction Control:

Available on some models

Stability Control:

Not commonly available on this generation

Passive Features

Airbags:

Driver and passenger front airbags; available side curtain airbags on later models/configurations

Seatbelts:

Three-point front seat belts with pretensioners; rear seat belts

💡 Technology Features

Infotainment

Audio Systems:

AM/FM stereo with CD player, cassette player (early models), optional premium audio systems, SiriusXM Satellite Radio availability.

Navigation:

Optional factory navigation system on higher trim levels.

Driver Assistance

Cruise Control:

Standard on most trims.

Parking Sensors:

Optional rear parking assist sensors on some models.

Connectivity

Power Outlets:

12V accessory power outlets.

Trailer Brake Controller:

Factory-integrated trailer brake controller option available on higher trims, especially with diesel engines.

🔧 Maintenance

Service Intervals

Oil Change Interval Gasoline:

Typically 3,000 miles (severe duty) or 6,000 miles (normal duty) with synthetic blend or full synthetic oil, depending on usage and oil type.

Oil Change Interval Diesel:

Typically 5,000 - 7,500 miles, depending on operating conditions.

Transmission Fluid Service Automatic:

Recommended every 30,000 - 60,000 miles, depending on towing and driving conditions.

Transfer Case Fluid Service:

Recommended every 30,000 - 60,000 miles.

Coolant Flush Interval:

Typically every 30,000 - 50,000 miles or 2-5 years.

Fluid Specifications

Engine Oil Gasoline Viscosity:

5W-30 (preferred for most conditions), 10W-30 (for higher ambient temperatures)

Engine Oil Diesel Viscosity:

15W-40 (API CI-4 or higher)

Coolant Type:

Ethylene glycol-based antifreeze (Chrysler HOAT - Hybrid Organic Additive Technology) in a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3

Known Issues

Common Issues Gasoline Engines:

Cracked exhaust manifolds (especially on 4.7L V8), distributorless ignition system failures, intake manifold gasket leaks, oil cooler line leaks (4.7L).

Common Issues Diesel Engines:

Lift pump failures, injector issues, coolant leaks (often at intake manifold or oil cooler), turbocharger wear (especially with high mileage).

Common Issues Transmission:

Overdrive planetary gear failures (45RFE/48RE), torque converter shudder, solenoid pack issues.

Common Issues Suspension Steering:

Worn ball joints, tie rod ends, and steering box; front end shimmy or death wobble (especially on 4WD models with wear).

Common Issues Electrical:

Instrument cluster failures, power window/lock motor failures, TIPM (Totally Integrated Power Module) issues on later models of this generation.

📚 Vehicle History

Brand Heritage

Dodge Truck Legacy:

Dodge has a long history of producing robust and capable trucks dating back to the 1930s.

Model Evolution

Ram Pickup Third Gen Introduction:

The third generation Ram (2002-2008) marked a significant redesign with a bolder, more muscular styling and improved aerodynamics, introducing the 'Mega Cab' configuration and updated powertrains.

Generation Design Emphasis:

This generation was designed to compete directly with Ford and Chevrolet on styling, capability, and technology.

Production

Manufacturing Locations:

Primarily Warren Truck Assembly Plant (Michigan, USA) and St. Louis Assembly (Missouri, USA) during this period.

Sales Performance:

The Ram Truck consistently ranked among the top-selling pickup trucks in North America.

🏆 Awards & Recognition

Recognitions

Motor Trend Truck Of The Year:

The Dodge Ram Truck (Third Generation) was named MotorTrend Truck of the Year for 2003.

Consumer Guide Best Buy:

Often recognized as a Best Buy in its class by automotive publications for its capability and value.