Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Dodge Ram 2500 owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl contact owns a 2002 Dodge Ram 2500. The contact experienced issues with the 6-speed manual transmission in his vehicle. The clutch would fail while driving at various speeds. In addition, the gears would slip as if the clutch were depressed and the contact smelled a burning odor while driving in reverse. He took the vehicle to multiple dealers more than ten times. One of the dealers installed a new clutch, but it failed 10,000 miles later. At approximately 34,000 miles, the dealer repaired the clutch again; however, the issue recurred. The manufacturer offered no assistance. The current mileage was approximately 37,000 and failure mileage was approximately 500. Updated 1/5/09 the consumer also stated when backing up his trailer there was a burning smell coming from the clutch area. …
Have had nothing but trouble with my 02 Ram 2500 truck. Rear brake pads had nothing but rust holding the pads in place, had the turbo and fuel pump replaced, u-joints and yoke on 4wd shaft worn out and hanger bearing on rear drive shaft worn out at about 70,000mi, tail gate cable broke after only two years, when clicking from high beam to low beam occasionally all lights go out, cannot use heated mirrors because they will blow a fuse and I won't have any heat, and now all ball joints and tie rod ends are worn and need replaced. I bought this truck new with only 75 miles on it, when I had the fuel pump and turbo replaced at around 78,000 miles, my mileage increased from about 350 miles per tank to about 550 miles per tank of fuel. Highway driving is much higher mpg. Fuel gage no longer works, empty at half tank of fuel now. Was quarter tank and empty. …
While accelerating the truck start the decelerate and reaccelerate multiple times within a 2-3 second time period and the check engine light came on for large EVAP leak. This issue happened a number of times throughout a couple week time period. When I brought it to the dealer they said there was debris in the tank that could have clogged the lines, flushed out the lines and continued on. The issue happened again a couple of weeks later and continued for weeks. I brought it back to the dealer they said the pump was bad and needs to be replace, replaced pump continue on. After about 8 months the issue came back and check engine light came back on for large EVAP leak. Had system check for leaks and found none. The issue still continue months later a random intervals. Luckily the acceleration issue has been mostly when I was accelerating from low speeds and from stop lights. …
(2) vp44 fuel injection pump failures, (1) fuel lift pump failure: at approximately 56,000 miles of service, the first vp44 fuel injection pump failed (documented Chrysler p216 code was loaded into the pecm), again at approximately 78,000 miles, the vp44 fuel injection pump again failed, as did the diesel fuel lift pump. The vehicle was repaired by the dealer(s). This mechanical defect is consistent throughout the industry, and the cost of repairs at the Chrysler dealership is more than $3,000.00 per incident for a total of more than $6,000.00 in accrued costs if I were to pay for this out of pocket. My concern is that when the warranty period is over, the reliability of the vehicle will be the same: another and then anther fuel injection pump will need to be replaced. Note: incident dates below are approximate but can be authenticated and corrected if needed.
I own a 2002 Dodge Ram p u, cummins diesel, and manual trans.. And have replaced the tpu " throttle positioning unit" (sensor) 3 times now, @ a cost of over 700.00 each time. Not only is this an expensive repair, but a potentially and very dangerous defect in these trucks. What occurs is a fluctuation , and the ability to control the accelerator with the pedal, from a fluctuating ability, to an all out loss of power whatsoever... The engine will accelerate, and the idle will rise creating a dangerous situation, then eventually the engine will not respond at all to the pedal... I use my pickup to haul and tow many different trailers, including our 40 ft. 5th wheel, and have had several close calls when I loose power altogether. There needs to be a recall on this unit... Sensor, as it is not only expensive, it is more importantly very dangerous.
Tl* the contact owns a 2002 Dodge Ram 2500. The contact stated that while attempting to park, he applied the brakes but the vehicle would not stop. A clicking noise was heard and the vehicle eventually stopped. The vehicle was taken to an authorized dealer where they noticed that the front suspension was damaged. The front suspension system was replaced by the dealer. The manufacturer was made aware of the failure and informed the contact that the vehicle was no longer under warranty. The failure mileage was 64,000. Updated 08/15/11 the consumer stated he had no power for approximately two to three miles. A diagnosis revealed the left front bearing hub and anti-lock speed sensor were bad and needed to be replaced. Also, the turbo charger was broken and the fuel injection pump was bad. Updated 05/03/12
Dt: 2002 Dodge Ram 2500 hd quad cab 4 wheel drive slt. The truck has been in the repair shop at least 15 times for not having any power. This happened mainly when towing a trailer. Prior to purchasing the truck the dealer replaced the fuel injection pump and fuel pump. They have been replaced 3 times last year. The dealer said that transmission was not programmed for the size tires that were on the vehicle. Also, turbo- charger was bad, and they replaced it, but, it did not work. Took back vehicle o dealer, and they replaced all parts again. The last time that consumer took vehicle to dealer, the dealer stated there was nothing else to be done. This vehicle has a 5.9 liter ho cummings engine, turbo diesel, manual transmission. The truck has no power when pulling a trailer.
Tl contact owns a 2002 Dodge Ram 2500. The contact stated that the clutch locked up and the vehicle was inoperable. While driving 55 MPH, it seems as if the clutch releases and the rpms increase before the vehicle begins to drive normally. The contact took the vehicle to a dealer approximately twelve times, but they can never duplicate the failure. The clutch has been replaced twice. The failure occurs intermittently. The current mileage was 35,000 and failure mileage was 500. Updated 01/24/08 the dealer stated wiring plug fuse blown, alarm will go off with key in ignition or not, pdc cover broken, difficult to start in cold weather, noticed a burning smell, and fuel injection. Updated 01/24/08
On 1998.5 - 2002 Dodge Ram pick up with the 5.9 cummins diesel there is a real problem with vp-44 injection pump failures. Several vp re builders lay the problem to heat failure & vibration due to solder joints crystallizing. These pumps are not cheap & the problem was so bad that fed x forced Bosch the manufacture of these pumps to do something about it. Not everyone has the money to replace one of these pumps. You never know when one of these pumps are going to fail. If you are on the highway or in an intersection & it would fail tat then becomes a traffic hazard. I had on go bad 9/17/2004 & now I have another going bad now. They cost around $2500.00 to $3000.00 to replace.
Tl* the contact owns a 2002 Dodge Ram 2500. The contact stated that the dash board was cracked and was starting to collapse. Also, the contact mentioned that the left fuel pump would intermittently fail and cause the vehicle to independently decelerate. The vehicle was taken to the dealer where the technician diagnosed that the dash board, fuel tank and injector pump needed to be replaced. The manufacturer was not made aware of the failure. The vehicle was not repaired. The failure mileage was 70,000 and the current mileage was 92,000.
Fuel System complaints in other Ram 2500 years
Frequently asked questions
How common are fuel system problems on the 2002 Dodge Ram 2500?
NHTSA has 24 complaints about the fuel & propulsion system of the 2002 Dodge Ram 2500, 15% of the model year's 155 complaints. The component named most often is delivery › fuel pump (4 mentions).
Is there a recall for 2002 Dodge Ram 2500 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2002 Dodge Ram 2500. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2002 Dodge Ram 2500 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 64,000 miles, and 25% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.