2002 Dodge Ram 2500 Service and Repair Manual

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Factory-Grade Data

2002 Dodge Ram 2500 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Extended Cab Pickup 2-Door
  • Base Standard Cab Pickup 2-Door
  • Base Extended Cab Pickup 4-Door
  • Custom Standard Cab Pickup 2-Door
  • Base Cab & Chassis 2-Door
  • SLT Standard Cab Pickup 2-Door

Engines covered

  • 5.9L 360Cu. In. V8 GAS OHV Naturally Aspirated
  • 8.0L 7990CC 488Cu. In. V10 GAS OHV Naturally Aspirated
  • 5.9L 359Cu. In. l6 DIESEL OHV Turbocharged
  • 5.9L 360Cu. In. V8 GAS SOHC Naturally Aspirated
  • 4.7L 287Cu. In. V8 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2002 Dodge Ram 2500 Recalls & Complaints

NHTSA #06E02400015/03/2006Component: ENGINE AND ENGINE COOLING

CERTAIN REPLACEMENT K&N FUEL PERFORMANCE KITS, P/NOS. 57-1509, 57-1511, 57-1511-1, 57-1517, 57-1517-1, 57-1527, AND 57-1530. ALSO, A SMALL PERCENTAGE OF THESE KITS WERE SOLD UNDER THE MOPAR PERFORMAN

Consequence

A JAMMED OPEN THROTTLE COULD CAUSE UNINTENDED ACCELERATION OF THE VEHICLE, POSSIBLY RESULTING IN A C

Remedy

K&N WILL PROVIDE OWNERS WITH A FREE REPAIR KIT ALONG WITH REPAIR INSTRUCTIONS. THE RECALL BEGAN ON

TSB #11010205

Plate - Planetary

TSB #10229256

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicl

TSB #10221686

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicl

TSB #10191455

Cummins Equipped Vehicles ONLY - The replacement oil pan gasket can be a four piece gasket rather than a single piece gasket. This applies to Cummins 5.9L and 6.7L engines only.

TSB #10191460

Valve Body. These may cause over drive cycling.

TSB #10175735

Charging System, Battery Diagnostic Tools and Warranty This information only bulletin discusses using the correct test equipment for testing batteries and charging systems, and also warranty reimbursement when battery replacements are neces

TSB #10175743

Disinfectant Solution Recommended for COVID-19

TSB #10224768

Connecting to the DRB III Emulator for Cummins Engines

Showing the 8 most recent of 27 technical service bulletins on file with NHTSA.

20050304Component: SERVICE BRAKES, HYDRAULICCrash reported1 injured

VEHICLE WAS TRAVELING AT 20 MPH WHEN ALL OF A SUDDEN THE DRIVER NOTICED THAT HE LOST THE STEERING AND BRAKES. *AK THE POWER STEERING AND THE BRAKES FAILED WHEN THE CONSUMER WAS HOOKING THE VEHICLE

20020925Component: AIR BAGS:FRONTALCrash reported1 injured

CONSUMER STATES WHILE DRIVING AT 35MPH IN A FRONTAL COLLISON NONE OF THE AIRBAGS DEPLOYED ON IMPACT. PASSENGER WAS SERIOUS INJURED. VEHICLE WAS BADLY DAMAGED. NLM

20180205Component: AIR BAGSCrash reported

THE PLASTIC DASHBOARD AND RELATED UNDERPINNINGS AND SUPORT STRUCTURE FOR EVERYTHING FROM PASSENGER AIRBAG,RADIO, CLIMATE CONTROL AND VENTS, HEADLIGHT, MIRROR DEFROSTER, GAUGE POD, ONBOARD DIAGNOSTIC P

20180205Component: ELECTRICAL SYSTEMCrash reported

THE PLASTIC DASHBOARD AND RELATED UNDERPINNINGS AND SUPORT STRUCTURE FOR EVERYTHING FROM PASSENGER AIRBAG,RADIO, CLIMATE CONTROL AND VENTS, HEADLIGHT, MIRROR DEFROSTER, GAUGE POD, ONBOARD DIAGNOSTIC P

20180205Component: EXTERIOR LIGHTINGCrash reported

THE PLASTIC DASHBOARD AND RELATED UNDERPINNINGS AND SUPORT STRUCTURE FOR EVERYTHING FROM PASSENGER AIRBAG,RADIO, CLIMATE CONTROL AND VENTS, HEADLIGHT, MIRROR DEFROSTER, GAUGE POD, ONBOARD DIAGNOSTIC P

Showing the 5 most serious of 210 complaints filed with NHTSA.

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