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2002 Dodge RAM 2500 Pickup CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Dodge REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2002 Dodge RAM 2500 Pickup AUTOMOBILES
Air Bag System Precautions -> DaimlerChrysler -> Arming -> 1990-97 -> 1994-96 Cherokee -> 1998-2004 -> Except 1994-96 Cherokee -> Light Truck & Vans -> Passenger Cars
Vehicle: 2002 Dodge RAM 2500 Pickup 5.9 L6 DIESEL
Passenger Cars
1990-97
- Ensure no one is inside vehicle and ignition switch is in Lock position.
- Connect battery ground cable.
- Turn ignition switch to On position from passenger side of vehicle.
- The SRS warning lamp should light for six to eight seconds, then remain off for at least 45 seconds to indicate if SRS is functioning properly.
1998-2004
- Ensure no one is inside vehicle and ignition switch is in Lock position.
- Connect battery ground or remote cable or terminal.
- Turn ignition On from a safe position be...
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BRAKE SERVICE PROCEDURES FOR 2002 Dodge RAM 2500 Pickup AUTOMOBILES
Drum Brakes -> DaimlerChrysler -> Inspection -> Adjuster Mechanism -> Backing Plate -> Brake Drums -> Brake Linings & Springs -> Parking Brake Cable
Vehicle: 2002 Dodge RAM 2500 Pickup 8.0 V10 GAS
Brake Drums
Any time the brake drums are removed for brake service, the braking surface diameter should be inspected with a suitable brake drum micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If the braking surface diameter exceeds specifications, the drum must be replaced. If the braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. Minor sc...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Dodge RAM 2500 Pickup AUTOMOBILES
DaimlerChrysler Corp./Jeep Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> B Series Vans, Dakota, Durango, D & W Series, Ramcharger, Ram Truck 1500-3500 & Ram Van 1500-3500 w/Fuel Injection -> Less Fuel Pressure Test Port -> Multipoint Fuel Injection -> Throttle Body Fuel Injection -> With Fuel Pressure Test Port
Vehicle: 2002 Dodge RAM 2500 Pickup 8.0 V10 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the vehicle relearns its adaptive st...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 Dodge RAM 2500 Pickup AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> U-Joint with Injected Rings -> U-Joint with Snap Rings
Vehicle: 2002 Dodge RAM 2500 Pickup 5.9 L6 DIESEL
This procedure describes a propeller shaft equipped with a cardan joint in the tube yoke. For propeller shafts equipped with a companion/slip yoke, repeat the steps to remove the remaining cardan joint.
U-Joint with Snap Rings
Disassemble
- Tap outside of bearing cap with a drift to loosen snap ring.
- Remove snap rings from both sides of yoke.
- Position yoke with grease fitting if equipped, pointing up.
- Position a socket with a inside diameter large enough to receive bearing cap, beneath yoke on a press.
- Place another socket with an outside diameter smaller than bearing cap on ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 Dodge RAM 2500 Pickup AUTOMOBILES
Alternator, Replace
Vehicle: 2002 Dodge RAM 2500 Pickup 5.9 L6 DIESEL
- Remove battery ground cable.
- Remove alternator drive belt.
- Remove alternator pivot bolt and mounting bolts and nuts.
- Remove battery positive terminal retaining nuts.
- Remove ground terminal and field terminal retaining nuts.
- Remove upper alternator mounting bolt, ...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2002 Dodge RAM 2500 Pickup AUTOMOBILES
Chrysler LLC Trucks -> Anti-Lock Brake System Warning Lamp -> Chrysler, Dodge & Plymouth
Vehicle: 2002 Dodge RAM 2500 Pickup 5.9 L6 DIESEL
The amber lamp monitors anti-lock brake system condition. The lamp should be on during engine starting, but should go off when the self-diagnostic system determines proper system operation. If the lamp remains On, a fault in the anti-lock brake system is indicated. After diagnosis and re...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Dodge RAM 2500 Pickup AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2002 Dodge RAM 2500 Pickup 5.9 L6 DIESEL
Inlet
- Drain cooling system into a suitable container.
- Reposition heater core inlet hose clamp at engine.
- Remove hose from engine.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- D...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 Dodge RAM 2500 Pickup AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 Dodge RAM 2500 Pickup 8.0 V10 GAS
- Attach a wrench to pulley mounting bolt of automatic tensioner. Threads on this bolt are lefthand.
- Release tension from belt by rotating tensioner counterclockwise. When all belt tension has been released remove belt from tensioner first, then oth...
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COMPONENT LOCATION DIAGRAMS FOR 2002 Dodge RAM 2500 Pickup AUTOMOBILES
Component location diagrams for most 2002 Dodge RAM 2500 Pickup cars and light trucks sold in the U.S. from 1990+.
Powertrain Control Module Diagram for 2002 Dodge RAM 2500 Pickup 8.0 V10 GAS Components on diagram: |
Module Locations Diagram for 2002 Dodge RAM 2500 Pickup 8.0 V10 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2002 Dodge RAM 2500 Pickup AUTOMOBILES
OEM drawn wiring diagrams for most 2002 Dodge RAM 2500 Pickup cars and light trucks sold in the U.S.
2002 Dodge RAM 2500 Pickup 8.0 V10 GAS Wiring Diagram Components on diagram: |
2002 Dodge RAM 2500 Pickup 5.9 L6 DIESEL Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 Dodge RAM 2500 Pickup AUTOMOBILES
OEM TSB listings for most 2002 Dodge RAM 2500 Pickup cars and light trucks sold in the U.S. from 1985+.
Document: RECALL - VISIBILITY:WINDSHIELD WIPER/WASHER Vehicle: 2002 Dodge RAM 2500 Pickup 5.9 V8 GAS |
Document: AUTOMATIC TRANSMISSION DIAGNOSTIC TEARDOWN PROCEDURE - REVISED Vehicle: 2002 Dodge RAM 2500 Pickup 5.9 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 Dodge RAM 2500 Pickup AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 Dodge RAM 2500 Pickup cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2002 Dodge RAM 2500 Pickup cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2002 Dodge RAM 2500 Pickup cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2002 Dodge RAM 2500 Pickup cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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