2002 Cummins Known problems
10-11-2005, 11:41 PM
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2002 Cummins Known problems
Hey all, new to the board. I am just about to make my purchase on a 2002 Dodge Ram 2500 cummins diesel. I know there was a casting defect on the heads at some point with these diesels, but do not know the details. Does anyone know the scoop. Also any other potential problems I should be on the lookout for when going over this truck. P.S. it has ridiculously low mileage. Thanks in advance
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Jon
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Jon
10-11-2005, 11:54 PM
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The cracking you refer to is the 53 block. The 02 doesn't have them and if it does, it's very, very rare. Other than that, check the fuel pressure on the lift pump, track bar, ball joints, make sure the tranny shifts good, and that's about all I can think of. Just basic maintenance really. How many miles are on the truck?
10-12-2005, 01:13 AM
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I am a mechanic, and will be checking thoroughly for "Basic maintenance" problems. I was just curious as to any specific Dodge "querks" to be on the look out for...my last Dodge diesel was a 1991, I've been out of the loop for a while. If you can believe it, this 2002 has only 8,000 miles! checked the history and it all checks out. The truck just wasnt used. There isnt even a scratch in the bedliner, yet 
10-12-2005, 01:19 AM
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The biggest issue with the second gens is the fuel system. Even in stock form, it sucks. But the good news is if you dont mind spending some money and doing a little work to it, your problems will be fixed and that truck will last for many, many miles.
Like blue mentioned, the front ends can be troublesome, and the auto trannys can have issues in stock form. Other than that BUY IT. You wont regret it.
Like blue mentioned, the front ends can be troublesome, and the auto trannys can have issues in stock form. Other than that BUY IT. You wont regret it.
10-12-2005, 01:24 AM
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I have been reading quite a bit about the fuel delivery systems, and plan on definitely putting the time and hard earned cash into my "new baby." I also plan on doing the smart thing (one of the few times ever for me) and build up the truck from the transmission back, instead of my usual...more power first then build up the tranny to hold it. I have no doubts I wont regret this purchase, with the shortbed, It'll still be "managable" in town without looking to overbearing. And with the Quad cab I will still be able to fit everybody in it, without all the extra body length of 4 full size doors. When I complete the deal this weekend, I will be sure to post some pics, for my new favorite board!
10-12-2005, 11:33 AM
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FWIW, I have nearly 101,000 miles on my crappy fuel system. Think Stanadyne!
2 things that come to mind:
Front axle. Vent on the cover means a full time rotating front driveshaft; a mid year revision. Vent on the axle is the old style axle.
Front driveshaft. I had a bad driveshaft and U-joint which were replaced at 70,000 miles under my 7/100,000 drivetrain warranty. I think there is an internal bulletin regarding thse parts. Mine was replace by a new part number.
2 things that come to mind:
Front axle. Vent on the cover means a full time rotating front driveshaft; a mid year revision. Vent on the axle is the old style axle.
Front driveshaft. I had a bad driveshaft and U-joint which were replaced at 70,000 miles under my 7/100,000 drivetrain warranty. I think there is an internal bulletin regarding thse parts. Mine was replace by a new part number.
10-12-2005, 12:12 PM
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check for codes by turning the key on/off on/off on...codes will display on the odometer provided there are any. watch out for p0216 (i know its only 8000 miles but you never know)...
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10-14-2005, 12:52 AM
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meaning?
Originally Posted by pgilles
check for codes by turning the key on/off on/off on...codes will display on the odometer provided there are any. watch out for p0216 (i know its only 8000 miles but you never know)...
10-14-2005, 11:21 PM
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Greasemonki welcome aboard! Make sure you put on guages, at least pryo and fuel. keep watch of the fuel pressure. Mine was 15psi at idle 10 wot, at 39000 miles lp died! 
Caught it right away and quit driving truck. ) Dealer replaced. Once warrenty is over I'll upgrade to after market pusher--- Fass? Dealer told me if I put in a pusher pump and larger fuel lines it would void warrenty. Even though 98.5 - 02 have fuel system problems, I still love this truck!!! 
Gary
Caught it right away and quit driving truck. ) Dealer replaced. Once warrenty is over I'll upgrade to after market pusher--- Fass? Dealer told me if I put in a pusher pump and larger fuel lines it would void warrenty. Even though 98.5 - 02 have fuel system problems, I still love this truck!!! Gary
10-15-2005, 08:38 AM
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I'm in the same boat waiting for the warranty to die so I can improve the weak spots in the DC designs... But so far I've had few problems...
I would check for...
- 1 LP pump failed
- 1 VP44 pump failed (Because of failed LP pump)
- 1 Thermostat
- 1 Front driveshaft (Replaced for a grinding noise)
- 1 Rear pinion seal replaced (Leakage)
I would check for...
- Error Codes
- Fuel pressure is strong
- Trac Bar is tight
- Vacuum Pump seal leak
10-16-2005, 08:42 PM
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Well, I just picked her up saturday afternoon, by sunday nite (the time I am writing this) I've put just shy of 1,000 miles on it. Man this truck can pull!! I had an old 12v several years ago and thought that had some grunt, Wow the 24v is sa'weet! Everything on this truck is PERFECT. I will be posting pics and new posts, as I get to "tinkering." first will probably be trans upgrades, a Banks Torque converter. Then we'll start bombing it, Maybe, so far this truck has plenty of power for what I need it for. I have a fuel pressure gauge and EGT gauge on its way, cause as all you other "oil burners" know, Diesels hate heat!. I will probably install a larger waste gate and exhaust, and a few other "dodads" to better improve efficiency. Thanks again for all your help!
10-16-2005, 11:10 PM
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With all due respect friend, you can probably do much better for less money by selecting a Torque converter other than Banks. There's more to beefing these trannies than just a TC.
Also, your truck has a tiny turbo, so if you uprate the power, keep it around 300hp (total) or less.
There's no need for larger exhaust with the tiny turbo.
A good air intake system is always an improvement.
High quality gauges are a must. FP and PYRO minimum, tranny temp and boost if you can swing it.
I'm biased, but I LOVE the 2002s!!!!
H
Also, your truck has a tiny turbo, so if you uprate the power, keep it around 300hp (total) or less.
There's no need for larger exhaust with the tiny turbo.
A good air intake system is always an improvement.
High quality gauges are a must. FP and PYRO minimum, tranny temp and boost if you can swing it.
I'm biased, but I LOVE the 2002s!!!!
H
10-16-2005, 11:41 PM
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I would never take offense to any suggestions, HOHN. I appreciate any and all input. I know there is much more to beefing the tranny then the TC, but from my research the TCs are the "first" part of the problem, without doubt the internals will be getting some "lovin" too. My only reason for increasing the exhaust size, is to decrease the EGT. I also don't plan on agressively adding power to the cummins either. I'm going to install upgrades with the sole purpose of increasing efficiency and making the engine last longer. I want to see 300k+ miles out of this truck before any real internal repairs!
10-18-2005, 01:01 PM
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greasemonki,
Great find on a 2002. We got a 2002 3500 with 9100 when we purchased it last november. See sig for mods. So far only towed a cargo trailer down from WA state to Casa Grande AZ. That was before the quadila power module. with the TC lock up feature had good engine brakeing going down hill.
If you are not sure what all in on your new truck, have the dealer print out the vin number.
Have fun with your new truck.
Davey
Great find on a 2002. We got a 2002 3500 with 9100 when we purchased it last november. See sig for mods. So far only towed a cargo trailer down from WA state to Casa Grande AZ. That was before the quadila power module. with the TC lock up feature had good engine brakeing going down hill.
If you are not sure what all in on your new truck, have the dealer print out the vin number.
Have fun with your new truck.
Davey