Taking a proactive approach to try and combat some of the head gasket and transmission issues I hear about these trucks. If any of you would be so kind as to tell me if I am on the right track with some of this info I have collected and help out with some that I am not able to find on the net.
The truck:
2002 Dodge Ram 1500.
4.7 liter, auto tranny, 2wd.
I assume I do not have the Dana 60?

I have collected that the cooling system capacity is 5.5 quarts. Is this correct? What kind of antifreeze would I require? I will be using the premixed kind so I dont have to worry about procuring distilled water and what not. Also will change the thermostat. Any special procedures or tips for this? I have only flushed on cooling system before but that required running vehicle and refilling while hot. All the aluminum in this engine has got me nervous.

The trans capacity is also 5.5 quarts? When I do this I will change the filter as well and switch to ATF+4. Any problems with the fluid that will be left in the torque converter and the new ATF+4? This is something that will take place in the next couple months.

The diff., which I assume is not the Dana 60 because it is not 4wd will take under 3 quarts of gear oil. I am planning on pumping old stuff out with a lower gear unit pump and putting it back in the same way unless gasket is leaking. I also am going with synthetic 75w90. Is this the correct weight? I know it has to be GL-5. I will also need a LSD additive? Where would I get this additive?

Thanks for any help, advice, or ideas. Am I on the right track or missing the boat? Also, can someone tell me where to download an online copy of the owners manual for this truck? I have the original book but the pages are all seperated and mixed up. A free download would be perfect Thanks again.

BTW, I have nicknamed my truck the "Gray Goat", because it is gray and my little girl was looking at the steering wheel and pointed out that there was a "goat" looking back at her LOL.

 

Okay, I did a bit of thinking last night and a little research this morning. Where are you guys finding 180 degree thermostats? The only ones I can find here at the parts houses is 195 degree. As far as the transmission goes, how do you drain the fluid out of the torque converter? Would it be okay to drain whats in the pan and change filter than go back later and change whats in pan again and do this a few times until it is all ATF+4? Can it be mixed with whatever is in there?

For the coolant, I am still kind of nervous as far as that goes.

I gather that a lot of diff fluids have the LSD additive in it already, I assume it says so on the bottle?
Thanks again.

 

The cooling system is a bit over 16 quarts.

Not sure if it's ATF+4. If it is, it won't be a "switch". Drop 'n' drain takes about seven quarts. You may find two filters; the traditional flat one and a spin-on.

You only need the friction modifier if you have LSD. The modifier will be on a shelf near the diff fluid, which is probably 75w-140. It's a good idea to pull the diff cover and take a look at the innards. If it's a LSD, you'll want to look for broken pieces of the clutch pack retainers.

 

Thanks Mike. I saw the trans. filter kit and noticed the spin on as well. I dont know what is in the trans at the time but would like to go back with ATF+4. Just wondering if there would be any issues with what is left in the torque converter if the fluid that is currently in there is indeed ATF 3. Any suggestions or procedures for flushing the coolant? Thanks....

 

75w-90 is what is spec'd for the 02's but I'm pretty sure you can use 75w-140 as that is what the 03 and later use in the differential. It looks like the rear differential takes about 2 1/2 qts. so you will need to buy 3 and it's a chrysler 9.25. If you have and lsd (check your glove box for a sitcker that will say antislip rear or call a dealer to get a build sheet) you want to pull the cover and make sure everything is intact. If you don't have one I would take it to a shop if you want to have it pump out b/c I think their pumps have more suction and will be able to pull most of the metal that is on the magnet.

For the transmission check the bottle of atf4 to see if it's compatible w/ atf3, but I think the truck had atf4 as the original fill anyway. The manual I have states 5 1/2 qts for the automatic tranny on a 2wd for a drain and refill.

Now for the cooling system has it ever been serviced before? You may want to do some time of special flush since it may have been in there too long and become corrosive. If changed at the proper 5 year/100k mile interval all you will need to do is buy the coolant and distilled water or a 50/50 mix and drain, fill w/ water and run until it reaches temp, drain, and refill w/ the proper mix. Napa sells a HOAT coolant which the exact same as the mopar coolant under the name Zerex g-05. Also make sure when you drain your cooling system to drain the radiator and pull the plugs on the block each time you drain it to get as much out as possible.

Here is a link I found to an 03 service manual, it should give you most of the info you need http://pdftown.com/PDF-Dodge-Ram-200...ce-Manual.html

 

Thanks Chambers, I appreciate that link. I have the truck at my mechanic right now having ball joints replaced. I went out and bought 3 quarts of Royal Purple 75w90 and 16 quarts of Valvoline ATF+4, as Royal Purple ATF was out of stock. I also bought the tranny filter and he will do the fluid changes on that while ball joints are being done. I looked at the coolant. It appears to be clean but looks pink in color. My mechanic said to be real careful about what color is put in, something about it thickining up over time if not compatable. I decided to research that a little more and do that rad flush myself.

 

The pink coolant is the same as zerex g-05 just a different color. Once you flush it out and change it to zerex it will be more of a yellow color, but don't worry they are both HOAT (Hybrid Organic Acid Technology) coolant. Here is a nice color coded chart to help you out http://www.valvoline.com/pdf/Zerex_CoolantChart.pdf