2002-2004 Dodge Ram 1500 Series Service & Repair Manual

GROUP TAB LOCATOR Introduction 0 Lubrication & Maintenance 2 Suspension 3 Differential & Driveline 5 Brakes 6 Clutch 7 Cooling 8A Audio/Video 8B Chime/Buzzer 8E Electronic Control Modules 8F Engine Systems 8G Heated Systems 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8M Message Systems 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers/Washers 8T Navigation/Telecommunication 8W Wiring 9 Engine 11 Exhaust System 13 Frame & Bumpers 14 Fuel System 19 Steering 21 Transmission and Transfer Case 22 Tires/Wheels 23 Body 24 Heating & Air Conditioning 25 Emissions Control Component and System Index Service Manual Comment Forms (Rear of Manual)

INTRODUCTION TABLE OF CONTENTS page page VEHICLE IDENTIFICATION NUMBER DESCRIPTION .......................... 1 VEHICLE EMISSION CONTROL INFORMATION (VECI) DESCRIPTION .......................... 2 BODY CODE PLATE DESCRIPTION .......................... 3 INTERNATIONAL VEHICLE CONTROL & DISPLAY SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS ...5 FASTENER IDENTIFICATION DESCRIPTION .......................... 5 FASTENER USAGE DESCRIPTION - FASTENER USAGE ......... 8 THREADED HOLE REPAIR DESCRIPTION - THREADED HOLE REPAIR .... 8 METRIC SYSTEM DESCRIPTION .......................... 8 TORQUE REFERENCES DESCRIPTION ......................... 10 VEHICLE CERTIFICATION LABEL DESCRIPTION ......................... 11 VEHICLE IDENTIFICATION NUMBER DESCRIPTION VIN CODING/LOCATIONS The Vehicle Identification Number (VIN) plate is located on the lower windshield fence near the left a-pillar (Fig. 1). The VIN contains 17 characters that provide data concerning the vehicle. Refer to the VIN decoding chart to determine the identification of a vehicle. The VIN is also imprinted on the: • Body Code Plate. • Equipment Identification Plate. • Vehicle Safety Certification Label. • Frame rail. To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the VIN. The check digit is used by the manufacturer and govern- ment agencies to verify the authenticity of the vehicle and official documentation. The formula to use the check digit is not released to the general public. POSITION INTERPRETATION CODE = DESCRIPTION 1 Country of Origin 1 = Manufactured By DaimlerChrysler Corporation 3 = Manufactured By DaimlerChrysler De Mexico 2 Make D = Dodge 3 Vehicle Type 2 = Incomplete with Side Airbag 3 = Truck with Side Airbag 6 = Incomplete Less Side Airbag 7 = Truck Less Side Airbag Fig. 1 VIN LOCATION 1 - DASH PANEL 2 - VIN CODE PLATE DR INTRODUCTION 1

POSITION INTERPRETATION CODE = DESCRIPTION 4 Gross Vehicle Weight Rating G = 5,001-6000 lbs. H = 6,001-7,000 lbs. J = 7,001-8,000 lbs. K = 8,001-9,000 lbs. L = 9,001-10,000 lbs. M = 10,001-14,000 lbs. W = Buses/Incomplete Vehicles with Hydraulic Brakes 5 Vehicle Line A = Ram Pickup 4X2 U = Ram Pickup 4X4 N = Ram Pickup 4X2 DX Family 6 Series 1 = 1500 2 = 2500 3 = 3500 Less Dual Rear Wheels 4 = 3500 With Dual Rear Wheels 5 = 4000 DX Family 7 Body Style 6 = Conventional Cab/Cab Chassis 8 = Quad Cab Full Rear Doors 8 Engine K = 3.7L 6 cyl. MPI Gasoline N = 4.7L 8 cyl. MPI Gasoline D = 5.7L 8 cyl. SMPI Gasoline 6 = 5.9L 6 cyl. Turbo Diesel 24v C = 5.9L 6 cyl. Turbo Diesel High Output 9 Check Digit 0 through 9 or X 10 Model Year 4 = 2004 11 Plant Location S = Dodge City G = Saltillo J = St. Louis (North) 12 thru 17 Vehicle Build Sequence VEHICLE EMISSION CONTROL INFORMATION (VECI) DESCRIPTION All models have a Vehicle Emission Control Infor- mation (VECI) Label. DaimlerChrysler permanently attaches the label in the engine compartment (Fig. 2). The label cannot be removed without defacing label information and destroying label. The label contains the vehicle’s emission specifications and vacuum hose routings. All hoses must be connected and routed according to the label. The label also contains an engine vacuum schematic. There are unique labels for vehicles built for sale in the state of California and the country of Canada. Canadian labels are written in both the English and French languages. The VECI label contains the following: • Engine family and displacement • Evaporative family • Emission control system schematic • Certification application • Engine timing specifications (if adjustable) • Idle speeds (if adjustable) • Spark plug and gap Fig. 2 VEHICLE EMISSIONS CERTIFICATION INFORMATION LABEL 1 - VECI LABEL LOCATION 2 - RADIATOR SUPPORT 2 INTRODUCTION DR VEHICLE IDENTIFICATION NUMBER (Continued)

BODY CODE PLATE DESCRIPTION The Body Code Plate (Fig. 4) is located on the right front hydroform fender rail just behind the headlight assembly (Fig. 3). There are seven lines of information on the body code plate. Lines 5, 6, and 7 are not used to define service information. Information reads from left to right, starting with line 4 in the center of the plate to line 1 at the bottom of the plate. The last code imprinted on a vehicle code plate will be followed by the imprinted word END. When two vehicle code plates are required, the last available spaces on the first plate will be imprinted with the letters CTD (for continued). When a second vehicle code plate is necessary, the first four spaces on each row will not be used because of the plate overlap. BODY CODE PLATE—LINE 4 DIGITS 1 THROUGH 12 Vehicle Order Number DIGITS 13, 14, AND 15 Transmission Codes • DG4 = 4–speed Automatic (45RFE) • DG8 = 4–speed Automatic (48RE) • DDC = 5–speed Manual (NV3500) • DDP = 5–speed Manual (NV4500) • DEC = 6–speed Manual (NV5600) • DEE = 6–speed Manual Tremec (T-56) DIGITS 16, 17, AND 18 Car Line Shell • DR1 = 1500 4 X 2 • DR6 = 1500 4 X 4 • DR2 = 2500 4 X 2 • DR7 = 2500 4 X 4 • DR3 = 3500 4 X 2 • DR8 = 3500 4 X 4 DIGIT 19 Price Class • L = Low • H = Highline DIGITS 20 AND 21 Body Type • 41 = Ram Truck Quad Cab, Short Box • 42 = Ram Truck Quad Cab, Long Box • 61 = Ram Truck Standard Cab, Short Box • 62 = Ram Truck Standard Cab, Long Box Fig. 3 BODY CODE PLATE LOCATION 1 - FENDER 2 - RADIATOR CROSSMEMBER 3 - HYDROFORM FENDER RAIL 4 - RIVOT (2) 5 - BODY CODE PLATE Fig. 4 BODY CODE PLATE 1 - PRIMARY PAINT 2 - SECONDARY PAINT 3 - TRANSMISSION CODE 4 - VEHICLE MODEL NUMBER 5 - ENGINE CODE 6 - INTERIOR TRIM CODE 7 - VEHICLE IDENTIFICATION NUMBER 8 - TAILGATE CODE 9 - CARGO BOX CODE 10 - TAILGATE TRIM CODE 11 - BODY-IN-WHITE SEQUENCE 12 - MARKET CODE 13 - SPECIES CODE 14 - PAINT PROCEDURE 15 - VEHICLE ORDER NUMBER DR INTRODUCTION 3

BODY CODE PLATE—LINE 3 DIGITS 1,2, AND 3 Paint Procedure • APA = Monotone • AP9 = Special • APD = Two-tone (Lower break) DIGIT 4 Open Space DIGITS 5 THROUGH 8 Primary Paint (Refer to 23 - BODY/PAINT - SPECIFICATIONS) for color codes. DIGIT 9 Open Space DIGITS 10 THROUGH 13 Secondary Paint DIGIT 14 Open Space DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20, 21, AND 22 Engine Code • EKG = 3.7 L 6 cyl. MPI Gasoline • EVA = 4.7 L 8 cyl. MPI Gasoline • EZA = 5.7 L 8 cyl. SMPI Gasoline • ETC = 5.9 L 6 cyl. Cummins Turbo Diesel • ETH = 5.9 L 6 cyl. Cummins Turbo Diesel High Output BODY CODE PLATE—LINE 2 DIGIT 1 Open Space DIGITS 2 AND 3 Species Code. (Used for Manufacturing) DIGIT 4 Open Space DIGIT 5 Market Code • B = International • C = Canada • M = Mexico • U = United States DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number (VIN) (Refer to VEHICLE DATA/VEHICLE INFORMA- TION/VEHICLE IDENTIFICATION NUMBER - DESCRIPTION) for proper breakdown of VIN code. BODY CODE PLATE—LINE 1 DIGITS 1 THROUGH 6 Body-in-white assembly sequence. DIGIT 7 Open Space DIGIT 8 Tailgate trim code. DIGIT 9 Open Space DIGITS 10 THROUGH 12 Cargo box code DIGIT 13 Open Space DIGITS 14 THROUGH 16 Tailgate code 4 INTRODUCTION DR BODY CODE PLATE (Continued)

INTERNATIONAL VEHICLE CONTROL & DISPLAY SYMBOLS DESCRIPTION - INTERNATIONAL SYMBOLS The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify various instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel. FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater the bolt strength. Identification is determined by the line marks on the top of each bolt head. The actual bolt strength grade corresponds to the number of line marks plus 2. The most commonly used metric bolt strength classes are 9.8 and 10.9. The metric strength class identification number is imprinted on the head of the bolt. The higher the class number, the greater the bolt strength. Some metric nuts are imprinted with a single-digit strength class on the nut face. Refer to the Fastener Identification and Fastener Strength Charts (Fig. 5) and (Fig. 6). INTERNATIONAL SYMBOLS 1 High Beam 13 Rear Window Washer 2 Fog Lamps 14 Fuel 3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature 4 Turn Warning 16 Battery Charging Condition 5 Hazard Warning 17 Engine Oil 6 Windshield Washer 18 Seat Belt 7 Windshield Wiper 19 Brake Failure 8 Windshield Wiper and Washer 20 Parking Brake 9 Windscreen Demisting and Defrosting 21 Front Hood 10 Ventilating Fan 22 Rear hood (Decklid) 11 Rear Window Defogger 23 Horn 12 Rear Window Wiper 24 Lighter DR INTRODUCTION 5

Fig. 5 FASTENER IDENTIFICATION 6 INTRODUCTION DR FASTENER IDENTIFICATION (Continued)

Fig. 6 FASTENER STRENGTH DR INTRODUCTION 7 FASTENER IDENTIFICATION (Continued)

FASTENER USAGE DESCRIPTION - FASTENER USAGE WARNING: USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY. Fasteners and torque specifications references in this Service Manual are identified in metric and SAE format. During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used. THREADED HOLE REPAIR DESCRIPTION - THREADED HOLE REPAIR Most stripped threaded holes can be repaired using a Helicoilt. Follow the vehicle or Helicoilt recommen- dations for application and repair procedures. METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million. The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa. CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY BY TO GET MULTIPLY BY TO GET in-lbs x 0.11298 = Newton Meters (N·m) N·m x 8.851 = in-lbs ft-lbs x 1.3558 = Newton Meters (N·m) N·m x 0.7376 = ft-lbs Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi Inches x 25.4 = Millimeters (mm) mm x 0.03937 = Inches Feet x 0.3048 = Meters (M) M x 3.281 = Feet Yards x 0.9144 = Meters M x 1.0936 = Yards mph x 1.6093 = Kilometers/Hr. (Km/h) Km/h x 0.6214 = mph Feet/Sec x 0.3048 = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec mph x 0.4470 = Meters/Sec (M/S) M/S x 2.237 = mph Kilometers/Hr. (Km/h) x 0.27778 = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr. (Km/h) COMMON METRIC EQUIVALENTS 1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters 1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter 1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter 1 Mile = 1.6 Kilometers Refer to the Metric Conversion Chart to convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between millimeters (mm) and inches (in.) (Fig. 7). 8 INTRODUCTION DR

Fig. 7 METRIC CONVERSION CHART DR INTRODUCTION 9 METRIC SYSTEM (Continued)

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2002-2004 Dodge Ram 1500 Series Service & Repair Manual

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