2002 DODGE RAM VAN

Typical onset: 120,000-180,000 mi

Symptoms: Harsh or delayed shifts, especially 2nd to 3rd gear, Slipping under load or when hot, Metal shavings in fluid, burnt smell, Complete loss of forward gears in severe cases

Fix: Rebuild or replacement required. The 46RE (5.2L) and 47RE (5.9L) are known for overdrive clutch pack failures and governor pressure sensor issues. Expect 12-16 hours labor for a complete rebuild with hard parts kit, plus torque converter. Transmission cooler replacement is mandatory during this job to prevent repeat failures.

Estimated cost: $2,200-3,800

Typical onset: 80,000-140,000 mi

Symptoms: Rough idle and stalling when warm, Engine stumble on acceleration, Lean codes (P0171/P0174) with no vacuum leaks found elsewhere, Coolant smell from engine bay without visible external leaks

Fix: The lower plenum gasket deteriorates and causes vacuum leaks or coolant intrusion into cylinders. Requires removal of upper plenum, throttle body, and fuel rail. 4-6 hours labor. Use Hughes Engines or Fel-Pro updated gaskets, not Mopar OEM which will fail again. This is a when-not-if issue on these Magnum V8s.

Estimated cost: $650-1,100

Typical onset: 100,000-160,000 mi

Symptoms: Check engine light with P0750 or P0755 codes, Transmission stuck in 3rd gear (limp mode), No overdrive engagement on highway, Intermittent issues that worsen in hot weather

Fix: The overdrive solenoid pack and internal wiring harness connectors corrode or short out. Can be replaced without full teardown—drop the valve body (4-5 hours). Often misdiagnosed as needing full rebuild when it's just electrical. Replace both solenoid pack and harness connector as a set.

Estimated cost: $550-950

Typical onset: null

Symptoms: Transmission fluid dripping from front of vehicle, Fluid level dropping without visible pan leaks, Crusty rust at cooler line connections to radiator, Pink or red fluid mixing with coolant in severe cases

Fix: Steel transmission cooler lines rust through at bends and mounting points, especially in salt states. The radiator-mounted cooler can also leak internally, mixing coolant and ATF (death sentence for transmission). Replace lines and add external auxiliary cooler. 2-3 hours labor for lines, 4-5 if radiator is also compromised.

Estimated cost: $400-900

Typical onset: 120,000-180,000 mi

Symptoms: No-start condition with crank but no fire, Engine stalling at operating temperature, Loss of power under acceleration or uphills, Fuel pressure below 49 psi at key-on

Fix: In-tank pump assembly fails, often the pump motor itself. Requires dropping the 35-gallon fuel tank (3-4 hours labor). Always replace the sock filter and check tank for rust/sediment. If rust is present, tank replacement adds another $300-500. Common failure point at high mileage.

Estimated cost: $550-850

Typical onset: null

Symptoms: Rear doors sag and don't close flush, Excessive play in door when opened, Door won't stay latched on bumps, Grinding or binding when opening/closing

Fix: The heavy rear doors wear out hinges and latch mechanisms due to weight and repeated cycles. Hinges can be welded and re-drilled or replaced with heavy-duty aftermarket units. Latch assemblies need replacement. 2-3 hours per door. Not safety-critical but annoying and lets weather in.

Estimated cost: $300-600

Typical onset: 90,000-140,000 mi

Symptoms: Clunking over bumps from front end, Wandering or loose steering feel, Excessive tire wear on inner edges, Grease boot torn with visible rust on stud

Fix: Heavy payload and rough roads kill lower ball joints. These are load-bearing on the Dodge van front end. Replacement requires press or ball joint service kit. 3-4 hours for both sides plus alignment. Moog Problem Solver K7397 or equivalent heavy-duty parts recommended.

Estimated cost: $550-850