The 2002 Durango is a body-on-frame SUV sharing DNA with Dakota pickups. The 4.7L V8 is the sweet spot, but transmission durability and front suspension wear are platform-wide concerns that define ownership costs after 100k miles.
45RFE/545RFE Transmission Failure
Common · high severityTypical onset: 90,000-150,000 mi
Symptoms: Harsh 2-3 or 3-4 shifts, flaring on upshifts, Slipping in overdrive under load, Metal shavings in pan during fluid service, Check engine light with solenoid pack codes
Fix: Solenoid pack replacement buys time (4-6 hrs labor) but most need full rebuild or reman unit by 120k. R&R is 8-10 hours plus 2-3 for torque converter if needed. The cooler line fitting at radiator leaks and contaminates fluid — always inspect during any trans work.
Estimated cost: $2,800-4,500
Upper and Lower Ball Joint Failure
Common · high severityTypical onset: 80,000-120,000 mi
Symptoms: Clunking over bumps, especially when turning, Wandering steering, poor return to center, Uneven tire wear on inside edges, Play visible during suspension inspection
Fix: Factory uppers are riveted into the control arm — replacement means full upper control arms (1.5 hrs per side). Lowers are pressed in, about 2 hrs per side with proper tooling. Budget 6-8 hours for all four corners plus alignment. This is a recall item on some VINs but often needed even post-recall.
Estimated cost: $1,200-1,800
4.7L V8 Valve Seat Recession and Cracked Heads
Occasional · high severityTypical onset: 120,000-180,000 mi
Symptoms: Coolant loss with no external leaks, white smoke on cold start, Misfires on cylinders 2, 4, 6, or 8 (exhaust side), Overheating with no obvious cause after typical repairs, Bubbles in coolant reservoir, combustion gas test positive
Fix: Early 4.7L PowerTech engines drop exhaust valve seats or crack between valve seats. Requires head removal, inspection, and machine work or replacement heads. Book time 14-18 hours for both heads plus machine shop markup. Some cases justify a reman long block instead (20-24 hrs).
Estimated cost: $3,500-6,500
Plenum Pan Gasket Leak (3.9L and 5.2L/5.9L V8)
Common · medium severityTypical onset: 60,000-100,000 mi
Symptoms: Rough idle, stumbling on acceleration, Check engine light for lean codes (P0171/P0174), Oil weeping at intake valley, oil consumption, Fuel odor in crankcase, milky oil cap residue
Fix: The pressed-steel pan under the intake manifold cracks or gasket fails, creating vacuum leaks and oil migration. Intake removal, gasket set, clean valley: 6-8 hours. Magnum engines (5.2/5.9) also prone to this. Aftermarket kits with aluminum pans exist and are recommended over OE replacement.
Estimated cost: $800-1,400
Front Driveshaft and U-Joint Binding
Occasional · medium severityTypical onset: 70,000-110,000 mi
Symptoms: Clunk or vibration during 4WD engagement, Binding sensation in tight turns with 4WD on, U-joint play detectable by hand, Grease flung on undercarriage from torn boots
Fix: Front driveshaft uses a double-cardan joint at transfer case and conventional U-joints at axle. Lack of greasing kills them early. U-joint replacement is straightforward (2-3 hrs), but if CV section is worn, whole shaft replacement is faster. Part-time 4WD system means this only shows when engaged.
Estimated cost: $400-900
Evaporator Core Leaks and HVAC Blend Door Failure
Occasional · low severityTypical onset: 100,000-140,000 mi
Symptoms: Loss of A/C refrigerant, oily residue on passenger floor, No airflow mode control or stuck on defrost, Clicking or grinding from behind dash when adjusting temp, Sweet coolant smell with heater on (heater core separate issue)
Fix: Evaporator is buried behind the entire dash. Full dash removal: 10-14 hours labor. Blend door actuators fail too, but that's 2-3 hours and accessible. If evap is leaking and you're already in there, do heater core and all actuators at once. Many owners skip A/C repair due to cost.
Estimated cost: $1,500-2,200
Fuel Pump and Sending Unit Failure
Occasional · medium severityTypical onset: 90,000-130,000 mi
Symptoms: No-start or long crank, especially when hot, Stalling or surging at highway speed, Fuel gauge erratic or stuck on empty/full, Whining noise from tank area during acceleration
Fix: In-tank pump accessed via bed removal or fuel tank drop. Tank drop is 3-4 hours, less if you catch it before rust makes bolts a nightmare. OE-style module includes pump and sender; aftermarket pumps alone are cheaper but require harness splicing. Straps and filler neck often corroded on northeastern trucks.
Estimated cost: $600-1,100
Buy a 4.7L 4WD model under 100k miles if the trans shifts clean and ball joints are tight — budget $2k in deferred maintenance and you'll have a capable truck, but avoid high-mileage examples unless transmission has been rebuilt with receipts.
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.