2002 Dodge Ram Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Ram Year: 2002 Codes Chassis Code: DR Vin Prefix: 1B7 👋 Introduction Market Position Segment: Full-size pickup truck Target Audience: Heavy-duty users, tradespeople,...

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Year:

Codes

Chassis Code:

Vin Prefix:

👋 Introduction

Market Position

Segment:

Full-size pickup truck

Target Audience:

Heavy-duty users, tradespeople, families requiring robust utility and towing capacity

Competitive Analysis

Competitors:

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

Key Features

Engine Options:

Wide range of powerful gasoline and legendary diesel engines

Durability:

Renowned for its robust construction and durability

Towing Capacity:

Class-leading towing and hauling capabilities

Off Road Capability:

Available 4x4 system provides excellent off-road and all-weather traction

📋 Manual Details

Coverage Areas

Coverage Type:

Complete Factory Service Repair

Page Count

Estimated Pages:

3000+

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, but not explicitly stated, assume printable)

📖 Manual Coverage

Systems Covered

Engine:

All gasoline and diesel engines (e.g., 3.7L Magnum V6, 4.7L Magnum V8, 5.9L Magnum V8, 5.9L Cummins Turbo Diesel)

Transmission:

Manual and automatic transmissions (e.g., NV3500, NV4500, 45RFE, 48RE)

Drivetrain:

4x2 and 4x4 systems, transfer cases, axles, driveshafts, differentials

Suspension:

Front and rear suspension systems, steering components

Brakes:

Front and rear brake systems (disc/drum configurations), ABS, parking brake

Electrical:

Complete electrical system, wiring schematics, lighting, instruments, power accessories, starter, alternator

Body:

Exterior body panels, interior trim, doors, windows, seats, bumpers, chassis components

HVAC:

Heating, Ventilation, and Air Conditioning systems

Fuel System:

Fuel delivery, fuel tank, fuel pump, injectors

Cooling System:

Radiator, water pump, thermostat, cooling fans

Exhaust System:

Exhaust manifolds, pipes, mufflers, catalytic converters

Safety Systems:

Airbags, seat belts

Procedures Included

Maintenance:

Routine maintenance checks, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement

Diagnostics:

Troubleshooting guides for common issues, symptom-based diagnostics, diagnostic trouble codes (DTCs)

Repair:

Step-by-step repair procedures for all major components and systems

Overhaul:

Complete engine and transmission overhaul procedures

Replacement:

Component replacement procedures (e.g., alternator, starter, water pump, brake pads, fuel pump)

Adjustment:

Component adjustments (e.g., valve lash, clutch, parking brake)

Installation:

Procedures for installing or replacing parts

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine rebuilds and complex electrical diagnostics

Detail Level:

Detailed illustrations, diagrams, exploded views, and specifications

Wiring Schematics:

Included, covering all electrical systems

📊 Manual Specifications

File Format

Digital Format:

Likely PDF, optimized for digital viewing and printing

Print Quality

Illustrations:

High-quality, detailed illustrations and diagrams

Text Legibility:

Clear, legible text for easy reading and referencing

Binding Type

Physical Binding:

N/A (assuming digital format, if printed, would typically be comb-bound or perfect bound)

Paper Type

Physical Paper:

N/A (assuming digital format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

3.7L (3701cc)

Engine 1 Configuration:

Magnum V6 (2 valves per cylinder)

Engine 1 Bore X Stroke:

3.78 in x 3.37 in (96 mm x 85.5 mm)

Engine 1 Horsepower:

Approx. 215 hp @ 5200 rpm

Engine 1 Torque:

Approx. 235 lb-ft @ 4000 rpm

Engine 2 Displacement:

4.7L (4701cc)

Engine 2 Configuration:

Magnum V8 (2 valves per cylinder)

Engine 2 Bore X Stroke:

3.70 in x 3.41 in (94 mm x 86.6 mm)

Engine 2 Horsepower:

Approx. 235 hp @ 4800 rpm

Engine 2 Torque:

Approx. 295 lb-ft @ 3200 rpm

Engine 3 Displacement:

5.9L (5899cc)

Engine 3 Configuration:

Magnum V8 (2 valves per cylinder)

Engine 3 Bore X Stroke:

4.01 in x 3.58 in (101.6 mm x 90.9 mm)

Engine 3 Horsepower:

Approx. 245 hp @ 4000 rpm

Engine 3 Torque:

Approx. 345 lb-ft @ 1600 rpm

Engine 4 Displacement:

5.9L (359 cu in)

Engine 4 Configuration:

Cummins ISB Turbo Diesel (4 valves per cylinder)

Engine 4 Horsepower:

Approx. 235 hp @ 2600 rpm

Engine 4 Torque:

Approx. 460 lb-ft @ 1400 rpm

Fuel System

Fuel Delivery Gasoline:

Multi-point fuel injection (MPI)

Fuel Delivery Diesel:

High-pressure common rail (HPCR) or VE rotary injection pump (depending on specific 5.9L variant, manual will clarify)

Fuel Type:

Unleaded gasoline (for V6/V8), Diesel fuel (for 5.9L Cummins)

🔧 Transmission

Standard

Transmission Std Manual:

5-speed manual (e.g., NV3500 for light-duty, NV4500 for heavy-duty)

Optional

Transmission Opt Auto:

4-speed automatic (e.g., 45RFE, 48RE)

Features

Transfer Case:

Part-time 4WD with electronic or manual shift transfer case available

Gear Ratios:

Detailed gear ratios for all transmissions are provided in the manual

📐 Dimensions

Exterior

Wheelbase Short:

134.0 inches (3404 mm)

Wheelbase Long:

154.5 inches (3924 mm)

Overall Length:

Varies by configuration (e.g., 229.7 inches for standard cab, 249.7 inches for long bed)

Overall Width:

Approx. 79.1 inches (2009 mm)

Overall Height:

Approx. 75.2 inches (1910 mm)

Weights

Curb Weight:

Varies significantly by configuration and engine, typically 4,500 - 6,000 lbs (2041 - 2722 kg)

Gvw Range:

6,000 - 9,500 lbs (2722 - 4309 kg)

Cargo

Bed Length:

6.3 ft (1.9 m) or 8.0 ft (2.4 m)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4/5 stars (2WD), 3/5 stars (4WD) - *Note: Ratings can vary slightly based on specific configuration and test year. Manual would provide specific data for the model year.*

Active Features

Standard Anti-lock Braking System (ABS)

Passive Features

Airbags:

Driver and front passenger airbags

Seat Belts:

Front seat belts with pretensioners, rear seat belts

💡 Technology Features

Infotainment

Audio System:

Base AM/FM radio, optional CD player, upgraded Infinity sound system available

Display:

Basic analog gauges and digital odometer

Driver Assistance

Cruise Control:

Available

Tow Haul Mode:

Available on some automatic transmissions for improved towing performance

Connectivity

Trailer Wiring:

Factory-equipped trailer brake controller connector and wiring often available

🔧 Maintenance

Service Intervals

Oil Change Interval Gas:

Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (manual will specify)

Oil Change Interval Diesel:

Every 3,000-5,000 miles or 6 months, depending on oil type and driving conditions (manual will specify)

Air Filter Replacement:

Every 15,000-30,000 miles or as needed based on conditions

Spark Plug Replacement V8:

Approx. 100,000 miles (for V8 engines with platinum plugs, manual will confirm)

Transmission Fluid Change Auto:

Every 30,000-60,000 miles, or as per severe service schedule

Transfer Case Fluid Change:

Every 30,000-50,000 miles

Fluid Specifications

Engine Oil V6 V8:

SAE 5W-30 or SAE 10W-30, API certified (manual will confirm viscosity based on temperature)

Engine Oil Diesel:

Cummins CES 20071, CES 20076, or CES 20077 specification, typically 15W-40

Transmission Fluid Auto:

ATF+4 (MS-9602)

Transmission Fluid Manual:

GL-4 or GL-5 gear oil, specific viscosity as per manual

Coolant:

Mopar OAT (Organic Additive Technology) or HOAT coolant, typically a 50/50 mix with distilled water

Brake Fluid:

DOT 3

Known Issues

Common Problems 1:

Crankshaft position sensor failures

Common Problems 2:

Intake manifold gasket leaks (especially on 4.7L V8)

Common Problems 3:

Powertrain control module (PCM) issues

Common Problems 4:

Rust issues on rocker panels and rear wheel arches

Common Problems 5:

Heat from the exhaust manifold can sometimes damage starter motor insulation

📚 Vehicle History

Brand Heritage

Brand Legacy:

Dodge has a long history of producing robust trucks and commercial vehicles.

Model Evolution

Generation:

Third generation Dodge Ram (1994-2001), this 2002 model represents the first year of the significantly redesigned fourth generation (2002-2008).

Design Changes 2002:

Marked a major redesign with a larger, more aerodynamic exterior, updated interior, new engine options (3.7L V6), and improved chassis dynamics.

Production

Manufacturing Plant:

Saltillo Truck Assembly Plant, Mexico; Warren Truck Assembly Plant, Michigan, USA

🏆 Awards & Recognition

Recognitions

Truck Of The Year Diesel:

5.9L Cummins equipped Rams often received accolades for their diesel engines, though specific 'Truck of the Year' awards vary by publication and year.