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2002 Dodge Ram 3500

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By Research the Car 6 min read

The 2002 Dodge Ram 3500 is a heavy-duty pickup truck known for its towing and hauling capabilities. Engine options included the 5.9L Cummins Turbo Diesel inline-six, the 5.9L Magnum V8, and the 8.0L Magnum V10. The Cummins, a favorite for its reliability and power, produced 235-245 hp and 460-505 lb-ft of torque depending on the year and specific configuration. Transmission choices were typically a 5-speed manual or a 4-speed automatic. Owners generally appreciate the Ram 3500 for its ruggedness and workhorse nature, particularly the Cummins diesel model. Common complaints often revolve around the vehicle’s age, leading to increased maintenance and repair needs, as well as some known issues with certain components.

Engine

5.9L Cummins Turbo Diesel

  • “Killer Dowel Pin” (KDP)
    • Description/Symptoms: The dowel pin holding the timing gear housing in place can loosen and fall out, potentially causing significant engine damage as it migrates through the gears. Symptoms may include a ticking noise or eventual engine failure.
    • Solution: Install a KDP kit which secures the dowel pin to prevent it from falling out.
    • Estimated Cost to Fix: $100 - $500+ depending on whether it’s preventative or corrective.
    • Recalls: None Found
  • Lift Pump Failure
    • Description/Symptoms: The lift pump, responsible for supplying fuel to the injection pump, is prone to failure. Symptoms include hard starting, loss of power, and potential damage to the injection pump if it runs dry.
    • Solution: Replace the lift pump. Some owners upgrade to aftermarket, higher-quality pumps or relocate the pump closer to the fuel tank.
    • Estimated Cost to Fix: $150 - $500+ depending on the pump type and location.
    • Recalls: None Found
  • VP44 Injection Pump Failure
    • Description/Symptoms: The VP44 injection pump can fail due to heat and lack of fuel pressure from a failing lift pump. Symptoms include hard starting, stalling, loss of power, and a check engine light.
    • Solution: Replace the VP44 injection pump, and address any issues with the lift pump to prevent recurrence.
    • Estimated Cost to Fix: $1,000 - $2,500+
    • Recalls: None Found

5.9L Magnum V8

  • Intake Manifold Gasket Leaks
    • Description/Symptoms: The intake manifold gasket can develop leaks, leading to vacuum leaks, rough idling, and poor performance.
    • Solution: Replace the intake manifold gasket.
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found
  • “Cracked Heads”
    • Description/Symptoms: The 5.9L Magnum V8 is known to have issues with the heads cracking. Common Symptoms include coolant in the oil, white smoke coming from the exhaust, and overheating.
    • Solution: Replace the cylinder heads
    • Estimated Cost to Fix: $1,500 - $3,500
    • Recalls: None Found

8.0L Magnum V10

  • Exhaust Manifold Bolts
    • Description/Symptoms: The exhaust manifold bolts are known to corrode or break. This will lead to exhaust leaks, rough idling, and poor performance.
    • Solution: Replace the exhaust manifold bolts.
    • Estimated Cost to Fix: $200 - $600
    • Recalls: None Found

Transmission

47RE 4-Speed Automatic

  • Overdrive Failure
    • Description/Symptoms: Overdrive unit failure is a common issue. Symptoms include a failure to shift into overdrive, slipping in overdrive, or complete loss of overdrive.
    • Solution: Rebuild or replace the transmission, paying close attention to the overdrive unit.
    • Estimated Cost to Fix: $1,500 - $4,000+
    • Recalls: None Found
  • Torque Converter Failure
    • Description/Symptoms: Torque converter failure can cause shuddering, slipping, and difficulty shifting.
    • Solution: Replace the torque converter. Consider upgrading to a heavy-duty unit for increased durability.
    • Estimated Cost to Fix: $500 - $1,500
    • Recalls: None Found
  • Valve Body Issues
    • Description/Symptoms: The valve body is a critical part of the transmission. Problems with the valve body can cause slipping, hard shifting, or a failure to shift at all.
    • Solution: Rebuild or replace the valve body.
    • Estimated Cost to Fix: $300 - $1,000
    • Recalls: None Found

NV4500 5-Speed Manual

  • 5th Gear Nut Failure
    • Description/Symptoms: The nut holding the 5th gear on the main shaft can back off, leading to loss of 5th gear.
    • Solution: Replace the nut with an updated, stronger design and ensure proper torque. Some owners reinforce the nut with thread locker or other methods.
    • Estimated Cost to Fix: $300 - $1,000 depending on the extent of damage.
    • Recalls: None Found

Suspension

  • Ball Joint Failure
    • Description/Symptoms: Ball joints are subject to wear and tear, especially in heavy-duty applications. Symptoms include clunking noises, loose steering, and uneven tire wear.
    • Solution: Replace the ball joints. Consider using heavy-duty or greaseable ball joints.
    • Estimated Cost to Fix: $300 - $800+ per axle.
    • Recalls: None Found
  • Steering Linkage Wear
    • Description/Symptoms: The steering linkage components, such as tie rod ends and drag links, can wear out, leading to loose steering and wandering.
    • Solution: Replace worn steering linkage components.
    • Estimated Cost to Fix: $200 - $600+
    • Recalls: None Found

Electrical

  • Instrument Cluster Issues
    • Description/Symptoms: The instrument cluster can experience failures, such as gauges not working correctly or the entire cluster going dark.
    • Solution: Repair or replace the instrument cluster.
    • Estimated Cost to Fix: $200 - $800+
    • Recalls: None Found
  • Wiring Harness Issues
    • Description/Symptoms: The vehicle is two decades old, so the wiring harness is old and is prone to issues such as corrosion. This corrosion can lead to issues such as electrical shorts.
    • Solution: Replace the corroded wiring
    • Estimated Cost to Fix: $300 - $1,000
    • Recalls: None Found

Exterior

  • Rust
    • Description/Symptoms: The vehicle is two decades old, so rust is a common issue. The most common spots of rust include around the wheel wells, rocker panels, and the bottom of the doors.
    • Solution: Cut the rust out and weld new metal on.
    • Estimated Cost to Fix: $500 - $2,000+
    • Recalls: None Found
  • Door Handle Failure
    • Description/Symptoms: The exterior door handles are prone to breaking.
    • Solution: Replace the broken door handles
    • Estimated Cost to Fix: $50 - $200
    • Recalls: None Found

Interior

  • Dashboard Cracking
    • Description/Symptoms: The dashboard is prone to cracking, especially in warmer climates.
    • Solution: Replace the dashboard.
    • Estimated Cost to Fix: $300 - $1,000+
    • Recalls: None Found

Summary

The 2002 Dodge Ram 3500, while a capable truck, is prone to several issues stemming from its age and design. The Cummins diesel engine, although robust, can suffer from lift pump and VP44 injection pump failures, as well as the infamous “Killer Dowel Pin” issue. The 47RE automatic transmission is known for overdrive problems and torque converter issues, while the NV4500 manual can experience 5th gear nut failure. Suspension components like ball joints and steering linkage are also common wear items. Electrical gremlins can manifest as instrument cluster failures. Overall, potential buyers should be aware of these issues and factor in the cost of repairs and preventative maintenance. The severity and cost of repairs can range from a few hundred dollars for minor fixes to several thousand for major engine or transmission overhauls.

Dodge, Ram 3500
Dodge Ram 3500 2002
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