2002 DODGE RAM dimensions

FRAME FASTENERS
Bolts, nuts and rivets can be used to repair frames
or to install a reinforcement section on the frame.
Bolts can be used in place of rivets. When replacing
rivets with bolts, install the next larger size diameter
bolt to assure proper fit. If necessary, ream the hole
out just enough to sufficiently receive the bolt.
Conical-type washers are preferred over the split-
ring type lock washers. Normally, grade-5 bolts are
adequate for frame repair.Grade-3 bolts or softer
should not be used.Tightening bolts/nuts with thecorrect torque, refer to the Introduction Group at the
front of this manual for tightening information.
SPECIFICATIONS
FRAME DIMENSION
Frame dimensions are listed in Millimeters (mm)
scale. All dimensions are from center to center of
Principal Locating Point (PLP), or from center to cen-
ter of PLP and fastener location (Fig. 10) .
DIMENSIONS FOR DIFFERING WHEELBASES*
WHEELBASE LENGTH
ALENGTH
BLENGTH
C
118 2118.0 3663.6 4185.4
134 2118.0 3994.5 4693.4
138 2626.0 4096.1 4693.4
154 2626.0 4502.5 5201.4
162 2118.0 4705.0 5042.5
*Measurements are in Millimeters (mm).
13 - 8 FRAME & BUMPERSBR/BE
FRAME (Continued)

Fig. 10 Frame Dimensions
BR/BEFRAME & BUMPERS 13 - 9
FRAME (Continued)

SPECIFICATIONS
TRANSMISSION
GENERAL
Component Metric Inch
Planetary end play 0.150-1.22
mm0.006-0.048
in.
Input shaft end play 0.86-2.13
mm0.034-0.084
in.
Clutch pack clearance/
Front.1.78-3.28
mm0.070-0.129
in.
Clutch pack clearance/
Rear.0.635-0.914
mm0.025-0.036
in.
Front clutch 3 discs
Rear clutch 4 discs
Overdrive clutch 4 discs
Component Metric Inch
Direct clutch 8 discs
Band adjustment from
72 in. lbs.
Front band Back off 2 7/8 turns
Rear band Back off 2 turns
Recommended fluid MoparTATF Plus 4, type
9602
GEAR RATIOS
1ST GEAR 2.45:1
2ND GEAR 1.45:1
3RD GEAR 1.0:1
4TH GEAR 0.69:1
REVERSE 2.21:1
THRUST WASHER/SPACER/SNAP-RING DIMENSIONS
Component Metric Inch
Front clutch thrust washer (reaction shaft support hub) 1.55 mm 0.061 in.
2.15 mm 0.084 in.
2.59 mm 0.102 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Intermediate shaft thrust plate (shaft hub pilot) 1.5-1.6 mm 0.060-0.063 in.
Output shaft thrust washer (rear clutch hub) 1.3-1.4 mm 0.052-0.054 in.
1.75-1.8 mm 0.068-0.070 in.
2.1-2.2 mm 0.083-0.085 in.
Rear clutch pack snap-ring 1.5-1.6 mm 0.060-0.062 in.
1.9-1.95 mm 0.074-0.076 in.
Planetary geartrain snap-ring (at front of output shaft) 1.4-1.5 mm 0.055-0.059 in.
1.6-1.7 mm 0.062-0.066 in.
Overdrive piston thrust plate Thrust plate and
spacer are select fit.
Refer to size charts
and selection
procedures in
Overdrive Unit D&A
procedures Intermediate shaft spacer
21 - 144 AUTOMATIC TRANSMISSION - 46REBR/BE
AUTOMATIC TRANSMISSION - 46RE (Continued)

SPECIFICATIONS
TRANSMISSION
GENERAL
Component Metric Inch
Planetary end play 0.150-1.22
mm0.006-0.048
in.
Input shaft end play 0.86-2.13
mm0.034-0.084
in.
Clutch pack clearance/
Front.1.78-3.28
mm0.070-0.129
in.
Clutch pack clearance/
Rear.0.635-0.914
mm0.025-0.036
in.
Front clutch 4 discs
Rear clutch 4 discs
Overdrive clutch 5 discs
Component Metric Inch
Direct clutch 10 discs
Band adjustment from
72 in. lbs.
Front band Back off 1 7/8 turns
Rear band Back off 3 turns
Recommended fluid MoparTATF +4, type 9602
GEAR RATIOS
1ST GEAR 2.45:1
2ND GEAR 1.45:1
3RD GEAR 1.0:1
4TH GEAR 0.69:1
REVERSE 2.21:1
THRUST WASHER/SPACER/SNAP-RING DIMENSIONS
Component Metric Inch
Front clutch thrust washer (reaction shaft support hub) 1.55 mm 0.061 in.
2.15 mm 0.084 in.
2.59 mm 0.102 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Intermediate shaft thrust plate (shaft hub pilot) 1.5-1.6 mm 0.060-0.063 in.
Output shaft thrust washer (rear clutch hub) 1.3-1.4 mm 0.052-0.054 in.
1.75-1.8 mm 0.068-0.070 in.
2.1-2.2 mm 0.083-0.085 in.
Rear clutch pack snap-ring 1.5-1.6 mm 0.060-0.062 in.
1.9-1.95 mm 0.074-0.076 in.
Planetary geartrain snap-ring (at front of output shaft) 1.4-1.5 mm 0.055-0.059 in.
1.6-1.7 mm 0.062-0.066 in.
Overdrive piston thrust plate Thrust plate and
spacer are select fit.
Refer to size charts
and selection
procedures in
Overdrive Unit D&A
procedures Intermediate shaft spacer
21 - 314 AUTOMATIC TRANSMISSION - 47REBR/BE
AUTOMATIC TRANSMISSION - 47RE (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS . . . 1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - WATER LEAKS . 2
DIAGNOSIS AND TESTING - WIND NOISE . . . 3
SPECIFICATIONS
WELD LOCATIONS.....................4
STRUCTURAL ADHESIVE LOCATIONS.....44
BODY SEALER LOCATIONS.............47
BODY GAP AND FLUSH MEASUREMENTS . . 56
BODY OPENING DIMENSIONS...........60TORQUE SPECIFICATIONS.............61
DECKLID/HATCH/LIFTGATE/TAILGATE.......63
DOOR - FRONT.........................68
DOOR - CARGO.........................77
EXTERIOR.............................86
HOOD................................100
INSTRUMENT PANEL SYSTEM............105
INTERIOR.............................118
PAINT................................129
SEATS...............................131
STATIONARY GLASS....................145
WEATHERSTRIP/SEALS..................151
BODY
WARNING
SAFETY PRECAUTIONS AND WARNINGS
WARNING: USE AN OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
²AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL ± BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
²DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
²Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
²Always have a fire extinguisher ready for use
when welding.
²Disconnect the negative (-) cable clamp from
the battery when servicing electrical components
that are live when the ignition is OFF. Damage to
electrical system can result.
²Do not use abrasive chemicals or compounds
on painted surfaces. Damage to finish can result.
²Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
²Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
BR/BEBODY 23 - 1

BODY OPENING DIMENSIONS
WINDSHIELD OPENING
DOOR OPENING - REGULAR CAB
BACKLITE OPENING
DOOR OPENING - QUAD CAB
23 - 60 BODYBR/BE
BODY (Continued)

NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, try the original shims first. When install-
ing a new clutch onto a compressor that previously
did not have a clutch, use 1.0, 0.50, and 0.13 milli-
meter (0.040, 0.020, and 0.005 inch) shims from the
clutch hardware package that is provided with the
new clutch.
(12) On models with the diesel engine option,
install the compressor on the engine. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - INSTALLATION)
(13) Connect the battery negative cable.
A/C COMPRESSOR CLUTCH
RELAY
DESCRIPTION
The a/c compressor clutch relay is a International
Standards Organization (ISO) micro-relay. The termi-
nal designations and functions are the same as a con-
ventional ISO relay. However, the micro-relay
terminal orientation (footprint) is different, the cur-
rent capacity is lower, and the relay case dimensions
are smaller than those of the conventional ISO relay.
OPERATION
The compressor clutch relay is a electromechanical
device that switches battery current to the compres-
sor clutch coil when the Powertrain Control Module
(PCM) grounds the coil side of the relay. The PCM
responds to inputs from the a/c heater control, the a/closs of charge switch, the a/c pressure transducer and
the evaporator fin probe.
The compressor clutch relay is located in the Power
Distribution Center (PDC) in the engine compart-
ment. Refer to the PDC label for relay identification
and location.
The compressor clutch relay cannot be repaired
and, if faulty or damaged, it must be replaced.
DIAGNOSIS AND TESTING - A/C COMPRESSOR
CLUTCH RELAY
RELAY TEST
The compressor clutch relay (Fig. 16) is located in
the Power Distribution Center (PDC). Refer to the
PDC label for relay identification and location.
Remove the relay from the PDC to perform the fol-
lowing tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.
(3) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, see the Relay Circuit Test below. If not
OK, replace the faulty relay.
RELAY CIRCUIT TEST
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information).
Fig. 15 CHECK CLUTCH AIR GAP
1 - FEELER GAUGE
Fig. 16 COMPRESSOR CLUTCH RELAY
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
BR/BECONTROLS 24 - 17
A/C COMPRESSOR CLUTCH (Continued)

BLOCK - DIAGNOSIS AND TESTING,
JUNCTION........................8W-97-7
BLOCK - INSPECTION, ENGINE.......9-27,9-85
BLOCK HEATER - 5.9L - DESCRIPTION,
ENGINE.............................7-44
BLOCK HEATER - 5.9L - INSTALLATION,
ENGINE.............................7-44
BLOCK HEATER - 5.9L - OPERATION,
ENGINE.............................7-44
BLOCK HEATER - 5.9L - REMOVAL,
ENGINE.............................7-44
BLOCK HEATER - 5.9L DIESEL -
DESCRIPTION, ENGINE.................7-46
BLOCK HEATER - 5.9L DIESEL -
INSTALLATION, ENGINE................7-46
BLOCK HEATER - 5.9L DIESEL -
OPERATION, ENGINE...................7-46
BLOCK HEATER - 5.9L DIESEL -
REMOVAL, ENGINE....................7-46
BLOCK HEATER - 8.0L - DESCRIPTION,
ENGINE.............................7-45
BLOCK HEATER - 8.0L - INSTALLATION,
ENGINE.............................7-45
BLOCK HEATER - 8.0L - OPERATION,
ENGINE.............................7-45
BLOCK HEATER - 8.0L - REMOVAL,
ENGINE.............................7-45
BLOCK REFACING - STANDARD
PROCEDURE, CYLINDER...............9-148
BLOWER MOTOR - DESCRIPTION.......24-31
BLOWER MOTOR - DIAGNOSIS AND
TESTING...........................24-32
BLOWER MOTOR - INSTALLATION........24-32
BLOWER MOTOR - OPERATION.........24-31
BLOWER MOTOR - REMOVAL...........24-32
BLOWER MOTOR RELAY - DESCRIPTION . . 24-22
BLOWER MOTOR RELAY - DIAGNOSIS
AND TESTING.......................24-22
BLOWER MOTOR RELAY -
INSTALLATION.......................24-23
BLOWER MOTOR RELAY - OPERATION . . . 24-22
BLOWER MOTOR RELAY - REMOVAL.....24-23
BLOWER MOTOR RESISTOR BLOCK -
DESCRIPTION.......................24-23
BLOWER MOTOR RESISTOR BLOCK -
DIAGNOSIS AND TESTING.............24-23
BLOWER MOTOR RESISTOR BLOCK -
INSTALLATION.......................24-24
BLOWER MOTOR RESISTOR BLOCK -
OPERATION.........................24-23
BLOWER MOTOR RESISTOR BLOCK -
REMOVAL..........................24-24
BLOWER MOTOR SWITCH -
DESCRIPTION.......................24-24
BLOWER MOTOR SWITCH - DIAGNOSIS
AND TESTING.......................24-25
BLOWER MOTOR SWITCH - OPERATION . . 24-24
BLOWER MOTOR SWITCH - REMOVAL . . . 24-25
BODY - ADJUSTMENTS, VALVE . . 21-257,21-428
BODY - ASSEMBLY, VALVE......21-248,21-420
BODY & CABLE - DESCRIPTION,
ANTENNA...........................8A-4
BODY & CABLE - INSTALLATION,
ANTENNA...........................8A-6
BODY & CABLE - OPERATION, ANTENNA . . . 8A-4
BODY & CABLE - REMOVAL, ANTENNA....8A-6
BODY - CLEANING, VALVE......21-244,21-418
BODY - DESCRIPTION, THROTTLE.......14-47
BODY - DESCRIPTION, VALVE....21-218,21-391
BODY - DISASSEMBLY, VALVE . . . 21-237,21-409
BODY - INSPECTION, VALVE.....21-244,21-419
BODY - INSTALLATION, VALVE . . . 21-256,21-428
BODY - OPERATION, THROTTLE.........14-47
BODY - OPERATION, VALVE.....21-223,21-394
BODY - REMOVAL, VALVE.......21-236,21-407
BODY CODE PLATE - DESCRIPTION.....Intro.-4
BODY GAP AND FLUSH
MEASUREMENTS, SPECIFICATIONS......23-56
BODY OPENING DIMENSIONS,
SPECIFICATIONS.....................23-60
BODY SEALER LOCATIONS,
SPECIFICATIONS
.....................23-47
BODY SIDE MOLDINGS - INSTALLATION
. . 23-87
BODY SIDE MOLDINGS - REMOVAL
......23-86
BODY STRIPES AND DECALS -
INSTALLATION
.......................23-87
BODY STRIPES AND DECALS -
REMOVAL
..........................23-87BODY VENT - INSTALLATION..........23-126
BODY VENT - REMOVAL..............23-126
BOOST PRESSURE - DIAGNOSIS AND
TESTING...........................14-93
BOOST PRESSURE - DIAGNOSIS AND
TESTING, TURBOCHARGER.............11-13
BOOSTER - DIAGNOSIS AND TESTING,
HYDRAULIC..........................5-18
BOOSTER - DIAGNOSIS AND TESTING,
MASTER CYLINDER/POWER.............5-26
BOOSTER - INSTALLATION, POWER
BRAKE..............................5-19
BOOSTER - REMOVAL, POWER BRAKE....5-19
BOOT - INSTALLATION, 4WD FLOOR
SHIFT.............................23-122
BOOT - MANUAL TRANSMISSION -
INSTALLATION, SHIFT................23-122
BOOT - MANUAL TRANSMISSION -
REMOVAL, SHIFT....................23-122
BOOT - REMOVAL, 4WD FLOOR SHIFT . . . 23-122
BORE - DE-GLAZE - STANDARD
PROCEDURE, CYLINDER...............9-148
BORE HONING - STANDARD
PROCEDURE, CYLINDER............9-11,9-65
BORE REPAIR - STANDARD
PROCEDURE, CAM...................9-151
BORE REPAIR - STANDARD
PROCEDURE, CYLINDER...............9-149
BOX - ASSEMBLY, GLOVE.............23-111
BOX - DISASSEMBLY, GLOVE..........23-110
BOX - INSTALLATION, CARGO..........23-97
BOX - REMOVAL, CARGO..............23-97
BOX LAMP AND SWITCH -
INSTALLATION, GLOVE................8L-36
BOX LAMP AND SWITCH - REMOVAL,
GLOVE.............................8L-35
BOX LATCH STRIKER - INSTALLATION,
GLOVE............................23-112
BOX LATCH STRIKER - REMOVAL,
GLOVE............................23-111
BOX OPENING UPPER TRIM -
INSTALLATION, GLOVE...............23-112
BOX OPENING UPPER TRIM - REMOVAL,
GLOVE............................23-112
B-PILLAR DOOR SEAL - INSTALLATION . . 23-151
B-PILLAR DOOR SEAL - REMOVAL......23-151
B-PILLAR TRIM - INSTALLATION.......23-120
B-PILLAR TRIM - REMOVAL...........23-120
BRACKET - INSTALLATION, CAB
CHASSIS ADAPTER...................13-10
BRACKET - INSTALLATION, REARVIEW
MIRROR SUPPORT..................23-126
BRACKET - REMOVAL, CAB CHASSIS
ADAPTER...........................13-10
BRAKE - DESCRIPTION, CONTROLLER
ANTILOCK..........................8E-11
BRAKE - DESCRIPTION, PARKING........5-28
BRAKE - INSTALLATION, CONTROLLER
ANTILOCK..........................8E-12
BRAKE - OPERATION, CONTROLLER
ANTILOCK..........................8E-11
BRAKE - OPERATION, PARKING..........5-28
BRAKE - REMOVAL, CONTROLLER
ANTILOCK..........................8E-11
BRAKE BOOSTER - INSTALLATION,
POWER.............................5-19
BRAKE BOOSTER - REMOVAL, POWER....5-19
BRAKE CABLE - INSTALLATION, FRONT
PARKING............................5-30
BRAKE CABLE - INSTALLATION, REAR
PARK...............................5-30
BRAKE CABLE - REMOVAL, FRONT
PARKING............................5-29
BRAKE CABLE - REMOVAL, REAR PARK . . . 5-29
BRAKE CALIPERS - DESCRIPTION, DISC . . . 5-10
BRAKE CALIPERS - OPERATION, DISC.....5-10
BRAKE FLUID CONTAMINATION -
DIAGNOSIS AND TESTING..............5-15
BRAKE FLUID LEVEL - STANDARD
PROCEDURE.........................5-15
BRAKE FLUID, SPECIFICATIONS
..........5-15
BRAKE INDICATOR - DESCRIPTION,
BRAKE/PARK
........................8J-15
BRAKE INDICATOR - DIAGNOSIS AND
TESTING
...........................8J-16
BRAKE INDICATOR - OPERATION,
BRAKE/PARK
........................8J-15
BRAKE LAMP SWITCH - DESCRIPTION
....8L-4BRAKE LAMP SWITCH - DIAGNOSIS
AND TESTING........................8L-5
BRAKE LAMP SWITCH - INSTALLATION....8L-6
BRAKE LAMP SWITCH - OPERATION......8L-4
BRAKE LAMP SWITCH - REMOVAL.......8L-5
BRAKE ROTOR, DIAGNOSIS AND
TESTING - DISC......................5-20
BRAKE SHOES - ADJUSTMENT, PARKING . . 5-33
BRAKE, SPECIFICATIONS - BASE..........5-2
BRAKE SYSTEM - DIAGNOSIS AND
TESTING, BASE........................5-5
BRAKE SYSTEM - STANDARD
PROCEDURE, BLEEDING ABS............5-36
BRAKE/PARK BRAKE INDICATOR -
DESCRIPTION.......................8J-15
BRAKE/PARK BRAKE INDICATOR -
OPERATION.........................8J-15
BRAKES - ABS - DESCRIPTION...........5-35
BRAKES - ABS - OPERATION............5-36
BRAKES - DIAGNOSIS AND TESTING,
ANTILOCK...........................5-36
BRAKES, SPECIAL TOOLS - BASE.........5-4
BR/BE PAINT COLOR CODES,
SPECIFICATIONS - 2002..............23-129
BREAKER - DESCRIPTION, CIRCUIT....8W-97-4
BREAKER - DIAGNOSIS AND TESTING,
CIRCUIT.........................8W-97-4
BREAK-IN - STANDARD PROCEDURE,
A/C COMPRESSOR CLUTCH............24-13
BREATHER VAPOR CANISTER -
INSTALLATION, CRANKCASE.............9-126
BREATHER VAPOR CANISTER -
REMOVAL, CRANKCASE...............9-125
BUCKLE - INSTALLATION, FRONT SEAT
BELT ..............................8O-20
BUCKLE - INSTALLATION, REAR SEAT
BELT ..............................8O-27
BUCKLE - REMOVAL, FRONT SEAT BELT . . 8O-20
BUCKLE - REMOVAL, REAR SEAT BELT . . . 8O-27
BUMPER - INSTALLATION, FRONT........13-4
BUMPER - INSTALLATION, REAR.........13-6
BUMPER - INSTALLATION, SLAM........23-67
BUMPER - REMOVAL, FRONT............13-4
BUMPER - REMOVAL, REAR.............13-6
BUMPER - REMOVAL, SLAM...........23-67
BUMPER - SPORT - INSTALLATION,
FRONT..............................13-5
BUMPER - SPORT - REMOVAL, FRONT....13-5
BUMPERS - DESCRIPTION..............13-1
BURNT FLUID - DIAGNOSIS AND
TESTING, CAUSES OF..........21-157,21-327
BUS - DESCRIPTION, CCD DATA..........8E-6
BUS - DIAGNOSIS AND TESTING, CCD
DATA ..............................8E-11
BUS - OPERATION, CCD DATA...........8E-7
BUSHING - INSTALLATION,
DISTRIBUTOR........................9-35
BUSHING - INSTALLATION, EXTENSION
HOUSING....................21-156,21-326
BUSHING - REMOVAL, DISTRIBUTOR......9-35
BUSHING - REMOVAL, EXTENSION
HOUSING....................21-156,21-326
BUSHING AND SEAL - INSTALLATION,
EXTENSION HOUSING..........21-460,21-497
BUSHING AND SEAL - REMOVAL,
EXTENSION HOUSING..........21-460,21-497
BUSHINGS - INSTALLATION.............2-27
BUSHINGS - REMOVAL.................2-27
BYPASS HOSE WITH AIR CONDITIONING
- INSTALLATION, WATER PUMP..........7-76
BYPASS HOSE WITH AIR CONDITIONING
- REMOVAL, WATER PUMP..............7-73
BYPASS HOSE WITHOUT AIR
CONDITIONING - INSTALLATION,
WATER PUMP........................7-77
BYPASS HOSE WITHOUT AIR
CONDITIONING - REMOVAL, WATER
PUMP..............................7-76
CAB - INSTALLATION, CLUB/QUAD.......8O-20
CAB - INSTALLATION, STANDARD.......8O-19
CAB - REMOVAL, CLUB/QUAD
..........8O-19
CAB - REMOVAL, STANDARD
...........8O-18
CAB CHASSIS ADAPTER BRACKET -
INSTALLATION
.......................13-10
CAB CHASSIS ADAPTER BRACKET -
REMOVAL
..........................13-10
CAB SIDE PANEL SPEAKER -
INSTALLATION, REAR
.................8A-20
4 INDEXBR/BE
Description Group-Page Description Group-Page Description Group-Page