The 2002 Dakota is a capable mid-size truck let down by notorious automatic transmission failures and front suspension ball joint issues. The 4.7L and 5.9L V8s are generally solid, but the 46RE/45RFE transmissions are ticking time bombs that overshadow most other concerns.
46RE/45RFE Automatic Transmission Failure
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Harsh 2-3 or 3-4 shifts, especially when cold, Slipping under load or delayed engagement into gear, Burnt transmission fluid smell, dark red or brown fluid, Transmission overheating warning or limp mode
Fix: Rebuild or replacement required. Governor pressure solenoid and overdrive solenoid commonly fail first, but internal clutch pack wear follows. Rebuild takes 12-16 hours if you pull it yourself, 18-22 at a shop including R&R. Used transmissions are a gamble—rebuilds with updated parts are the smarter play.
Estimated cost: $2,200-3,800
Upper and Lower Ball Joint Failure
Common · high severity
Typical onset: 60,000-100,000 mi
Symptoms: Clunking or popping from front end over bumps, Wandering steering or loose feel at highway speeds, Uneven tire wear on inside or outside edge, Play in wheel when lifted and pushed/pulled at 12 and 6 o'clock
Fix: Both upper and lower ball joints wear prematurely, especially on 4WD models. Uppers are pressed into control arms—some techs replace the whole arm to save labor. Lowers require pressing or C-frame tool work. Plan 3-4 hours per side for both joints, add alignment time. Do both sides together or you'll be back in six months.
Estimated cost: $600-1,200
Plenum Pan Gasket Leak (3.9L V6 / 5.9L V8)
Common · medium severity
Typical onset: 70,000-120,000 mi
Symptoms: Coolant loss with no visible external leaks, White smoke from exhaust on cold start that clears up, Rough idle or misfire, especially when engine is hot, Oil that looks milky or coolant that smells like fuel
Fix: The intake manifold plenum gasket fails and allows coolant into the crankcase or combustion chambers. Requires removing intake manifold, cleaning mating surfaces, replacing gasket and often valve cover gaskets while you're in there. 6-8 hours labor. Not a head gasket—easier fix, but just as annoying. Use the updated Mopar gasket kit, not aftermarket junk.
Estimated cost: $800-1,400
Dash Cracking and Instrument Cluster Failure
Common · low severity
Symptoms: Cracks along top of dashboard near windshield and defroster vents, Gauges that intermittently drop to zero (speedo, tach, fuel), Odometer display fading or going blank, Warning lights staying on or flickering randomly
Fix: The dash cracks are cosmetic but universal—there's no fix short of a cover or replacement dash (~$300-600 for a good used one, 4-6 hours labor). The cluster issues are usually bad solder joints on the circuit board. Rebuilders will fix it for $150-250 with 2-3 day turnaround, or DIY resolder if you're handy. Cluster R&R is 1 hour.
Estimated cost: $200-400
Rear Axle Seal and Bearing Leaks
Occasional · medium severity
Typical onset: 90,000-150,000 mi
Symptoms: Gear oil seeping or dripping from rear axle tubes onto brake backing plates, Rear brake contamination causing reduced stopping power, Howling or growling noise from rear end, worse on turns, Visible oil on inside of rear wheels
Fix: Chrysler 9.25" rear ends leak from axle seals and bearings. Requires pulling axle shafts, replacing seals and bearings, cleaning brake shoes if contaminated. 2-3 hours per side, but if the bearings chewed up the axle tubes you're looking at used axle assembly or machine work. Check fluid level regularly—running low grenades the ring and pinion.
Estimated cost: $400-700
Fuel Pump Failure
Occasional · high severity
Typical onset: 100,000-160,000 mi
Symptoms: No start or extended cranking, especially when hot, Engine stumbles or hesitates under acceleration, Stalling at idle after driving, restarts after cooling, Whining or buzzing noise from fuel tank area
Fix: In-tank pump fails from wear and heat. Requires dropping the tank (easier said than done if it's full or rusty). 3-4 hours labor for pump replacement, includes fuel level sender. Use OEM or quality aftermarket (Delphi, Bosch)—cheap pumps fail within a year. Straps and hoses are usually corroded, budget extra for those.
Estimated cost: $600-950
Owner tips
Service transmission fluid every 30,000 miles with ATF+4—it's cheap insurance against the inevitable rebuild
Grease ball joints every oil change if they have fittings; if not, inspect annually and replace at first sign of play
Use Mopar coolant or equivalent—the 3.9L and 5.9L are sensitive to the wrong antifreeze causing gasket failures
Check rear diff fluid level every 15,000 miles—these leak and owners ignore it until the diff howls
If the plenum gasket hasn't been done yet on a V6 or 5.9L V8, budget for it—it's when, not if
Buy only if the transmission has been rebuilt with receipts or you can negotiate $2,500 off for the inevitable rebuild—otherwise it's a $3,000 surprise waiting to happen.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
EXTERIOR LIGHTING · 09E012000
2009-04-07
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
SUSPENSION:FRONT:HUB · 08E064000
2008-10-20
SKF IS RECALLING 2,805 HUB UNITS, PART NO. BR930361, SOLD AS A SERVICE PART FOR 1997-2004 DODGE DAKOTA VEHICLES AND 1999-2003 DODGE DURANGO VEHICLES EQUIPPED WITH 2-WHEEL DRIVE & REAR AXLE ABS. DUE TO A SPECIFICATION ERROR, THE ROTOR PILOT FOR THE HUB UNIT MAY BE TOO LONG. THIS RESULTS IN THE WHEEL TO NOT BE SEATED FULLY AGAINST THE HUB FLANGE FACE DURING MOUNTING.
Consequence: IMPROPER SEATING OF THE WHEEL CAN RESULT IN EXCESSIVE VIBRATION, BRAKE ROTOR NOISE, DIFFICULTY REMOVING THE WHEEL AFTER INSTALLATION AND OPERATION OF THE VEHICLE, AND POSSIBLY WHEEL-END SEPARATION DURING VEHICLE OPERATION. SHOULD WHEEL-END SEPARATION OCCUR, THE DRIVER COULD LOOSE CONTROL OF THE VEHICLE, POSSIBLY RESULTING IN A CRASH.
Remedy: SKF WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE HUB UNITS FREE OF CHARGE. THE RECALL BEGAN ON NOVEMBER 5, 2008. OWNERS MAY CONTACT SKF VSM NORTH AMERICA CUSTOMER SERVICE AT 1-800-644-8999.
POWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFT · 07V555000
2007-12-04
ON CERTAIN VAN AND PICKUP TRUCKS EQUIPPED WITH AUTOMATIC TRANSMISSIONS, THE IGNITION/PARK SHIFT INTERLOCK SYSTEM MAY BECOME INOPERATIVE. THIS CAN ALLOW THE SHIFTER TO BE MOVED OUT OF THE "PARK" POSITION WITH THE IGNITION KEY REMOVED (OR IN THE "LOCK" POSITION). THIS CAN ALSO ALLOW THE IGNITION KEY TO BE REMOVED WHEN THE SHIFTER HAS NOT BEEN PLACED IN THE "PARK" POSITION.
Consequence: EITHER OF THESE CONDITIONS COULD ALLOW THE VEHICLE TO ROLL AWAY CAUSING A CRASH WITHOUT WARNING.
Remedy: DEALERS WILL REPLACE THE GEARSHIFT BLOCKER AND BRACKET ASSEMBLY FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JANUARY 2008. OWNERS MAY CONTACT CHRYSLER AT 1-800-853-1403.
EXTERIOR LIGHTING · 06E065000
2006-07-17
CERTAIN AJ MOTORSPORT COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Consequence: LACK OF AMBER SIDE REFLECTORS IN THE LAMPS WILL DECREASE LIGHTING VISIBILITY TO OTHER DRIVERS AND MAY POSSIBLY RESULT IN A VEHICLE CRASH.
Remedy: AJ MOTORSPORT WILL NOTIFY OWNERS AND OFFER REIMBURSEMENT FOR THE LAMPS. THE RECALL BEGAN ON JULY 31, 2006. OWNERS MAY CONTACT AJ MOTORSPORT AT 626-618-2026.
EXTERIOR LIGHTING · 06E026000
2006-03-23
CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Remedy: PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.
ENGINE AND ENGINE COOLING · 06E024000
2006-03-15
CERTAIN REPLACEMENT K&N FUEL PERFORMANCE KITS, P/NOS. 57-1509, 57-1511, 57-1511-1, 57-1517, 57-1517-1, 57-1527, AND 57-1530. ALSO, A SMALL PERCENTAGE OF THESE KITS WERE SOLD UNDER THE MOPAR PERFORMANCE PARTS BRAND NAME (P/NOS. P5007069 AND P5007070). ALL KITS WERE MANUFACTURED FROM APRIL 20, 1999, THROUGH SEPTEMBER 23, 2004. THESE ASSEMBLIES WERE MANUFACTURED AS REPLACEMENT EQUIPMENT FOR CERTAIN DODGE PICKUP TRUCKS AND SUVS. A SMALL PIECE OF MATERIAL FROM THE TUBE WALL COULD BE SUCKED INTO THE ENGINE THROTTLE BODY, WHICH COULD CAUSE THE THROTTLE TO BECOME JAMMED IN THE OPEN POSITION.
Consequence: A JAMMED OPEN THROTTLE COULD CAUSE UNINTENDED ACCELERATION OF THE VEHICLE, POSSIBLY RESULTING IN A CRASH OR INCREASED STOPING DISTANCES WHEN BRAKING.
Remedy: K&N WILL PROVIDE OWNERS WITH A FREE REPAIR KIT ALONG WITH REPAIR INSTRUCTIONS. THE RECALL BEGAN ON APRIL 20, 2006.
CERTAIN AFTERMARKET AIRTEX ELECTRIC FUEL PUMPS INSTALLED FOR USE AS REPLACEMENT EQUIPMENT FOR CERTAIN 1997-2004 JEEP WRANGLER; 1997-2001 JEEP CHEROKEE; 1997-2004 JEEP GRAND CHEROKEE; AND 2000-2003 DODGE DAKOTA VEHICLES. THE PLASTIC ELECTRICAL GROMMET CONNECTORS AT THE TOP OF THE FUEL PUMP MODULE ARE NOT COMPATIBLE WITH AUTOMOTIVE FUELS AND MAY DEGRADE CAUSING A POTENTIAL LEAK PATH FOR FUEL.
Consequence: IN THE PRESENCE OF AN IGNITION SOURCE, A FUEL LEAK COULD RESULT IN A FIRE.
Remedy: AIRTEX WILL NOTIFY ITS CUSTOMERS AND WILL REPLACE THE AFFECTED FUEL PUMPS FREE OF CHARGE. THE RECALL BEGAN ON JANUARY 25, 2006. OWNERS MAY CONTACT AIRTEX CUSTOMER SERVICE DEPARTMENT AT 1-800-880-3056.
ON CERTAIN SPORT UTILITY VEHICLES AND PICKUP TRUCKS EQUIPPED WITH FOUR-WHEEL DRIVE (4X4), IF MOISTURE LEAKS INTO THE FRONT SUSPENSION UPPER BALL JOINT, EVACUATION OF THE LUBRICANT AND CORROSION OF THE JOINT MAY CAUSE THE JOINT TO WEAR OVER AN EXTENDED PERIOD OF TIME. THIS COULD CAUSE A CLUNKING NOISE IN THE FRONT SUSPENSION, WHICH MAY NOT ALWAYS BE HEARD BY THE VEHICLE OCCUPANTS.
Consequence: EXCESSIVE WEAR IN THE UPPER BALL JOINT MAY ALLOW IT TO SEPARATE, WHICH COULD RESULT IN LOSS OF CONTROL OF THE VEHICLE.
Remedy: DEALERS WILL REPLACE THE FRONT SUSPENSION UPPER BALL JOINTS. THIS SAFETY IMPROVEMENT CAMPAIGN BEGAN ON DECEMBER 21, 2004. OWNERS CAN CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
VISIBILITY:WINDSHIELD WIPER/WASHER · 04V216000
2004-05-05
ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES, THE WINDSHIELD WIPER MODULE MOTOR MAY BE SUSCEPTIBLE TO WATER INTRUSION THAT COULD CAUSE INTERNAL CORROSION AND RESULT IN PARTIAL OR COMPLETE LOSS OF FRONT WINDSHIELD WIPING CAPABILITY.
Consequence: DRIVER VISIBILITY COULD BE REDUCED, WHICH COULD RESULT IN A CRASH.
Remedy: DEALERS WILL REPLACE THE FRONT WINDSHIELD WIPER MODULE. OWNER NOTIFICATION BEGAN ON JULY 12, 2004. OWNERS SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
EQUIPMENT:OTHER:LABELS · 03V505000
2003-12-10
ON CERTAIN MINIVANS AND 4X2 PICKUP TRUCKS, THE VEHICLE CERTIFICATION LABEL MAY HAVE GROSS AXLE WEIGHT RATINGS (GAWR) THAT EXCEED THE MAXIMUM TIRE LOAD CAPACITY AS DEFINED IN FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."
Consequence: IMPROPERLY LOADING YOUR VEHICLE CAN CAUSE TIRE FAILURE AND RESULT IN A CRASH.
Remedy: OWNERS WILL BE PROVIDED WITH VEHICLE CERTIFICATION LABEL OVERLAYS CONTAINING CORRECTED INFORMATION RELATIVE TO VEHICLE GAWR AND TIRE SIZE. OWNER NOTIFICATION BEGAN MARCH 1, 2004. OWNERS SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-992-1997.
ELECTRICAL SYSTEM:WIRING · 03V389000
2003-10-10
ON CERTAIN PICKUP TRUCKS EQUIPPED WITH MANUAL TRANSMISSIONS, THE HEADLAMP AND DASH WIRING HARNESS MAY BE CHAFED BY THE ACTUATION OF THE CLUTCH PEDAL. THIS COULD RESULT IN ABNORMAL OPERATION OF THE WIPERS, TURN SIGNALS, HORN OR LIGHTING SYSTEMS.
Consequence: THIS COULD AFFECT DRIVER VISIBILITY, COULD PREVENT A DRIVER FROM SOUNDING A WARNING BY USING THE HORN, AND, WHEN THE TURN SIGNALS ARE INOPERATIVE, THE DRIVER CANNOT USE THEM TO SIGNAL INTENT TO TURN, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL REROUTE THE WIRE HARNESS AND REPAIR THE HARNESS IF NECESSARY. OWNER NOTIFICATION BEGAN NOVEMBER 3, 2003. OWNERS SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-992-1997.
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