1980 PLYMOUTH TRAIL DUSTER

Typical onset: 80,000-120,000 mi

Symptoms: Rattling on cold start that quiets after warmup, Check engine light or poor running due to retarded timing, Complete no-start if chain jumps or breaks, Metal shavings in oil filter

Fix: Replace timing chain, gears, and tensioner; inspect cam and crank sprockets for wear. Requires front cover removal. 4-6 hours labor with experienced tech, more if guide rails are damaged or oil pump needs replacement simultaneously.

Estimated cost: $600-1,200

Symptoms: Hesitation on acceleration, flat spots, Hard starting when hot (heat soak vapor lock), Black smoke and poor fuel economy, Stalling at idle or when coming to a stop

Fix: These carbs are ethanol-intolerant and require complete rebuild with modern gasket kits, or replacement with Edelbrock aftermarket. Thermoquad especially problematic due to warped phenolic body. Rebuild: 2-3 hours. Many owners convert to Edelbrock 1406 and electric fuel pump.

Estimated cost: $350-800

Symptoms: Visible rust perforation behind rear wheels on frame rails, Sagging rear end or uneven ride height, Clunking over bumps as spring perch separates, Leaf spring shackles pulling through rusted frame

Fix: Frame sections must be cut out and plated/welded, or entire spring hanger area replaced. Not a bolt-on fix. Requires frame jig work at a qualified welder/fabricator. 8-16 hours depending on extent of rot. This is a structural safety issue—truck can't be driven if severe.

Estimated cost: $1,200-3,000

Typical onset: 60,000-100,000 mi

Symptoms: Intermittent stalling and no-restart, Surging at highway speeds, No spark condition with no warning, Computer module mounted on air cleaner overheats and fails

Fix: Lean Burn ECU and pickup coil in distributor are common failures. Many techs eliminate entire system and retrofit standard electronic ignition from pre-1976 Mopar with new distributor, coil, and ballast resistor. Retrofit takes 3-4 hours but solves problem permanently.

Estimated cost: $400-700

Symptoms: Delayed or harsh 2-3 upshift, Trans stays in lower gear too long, over-revving engine, Sluggish acceleration, Linkage rod disconnected or bent at carburetor

Fix: Carter carb throttle linkage and kickdown rod wear or seize from corrosion. Inspect and lubricate entire linkage from carb to transmission. If bent or broken, replacement rods still available. Adjustment critical—incorrect setting causes premature transmission wear. 1-2 hours labor.

Estimated cost: $150-350

Typical onset: 70,000-110,000 mi

Symptoms: 4WD not engaging or grinding when engaged, Front hubs won't lock manually, Clicking from front axle in 4WD, Grease leaking from hub assembly

Fix: Warn or Selectro manual locking hubs wear internally; springs and detent pins fail. Entire hub assembly replacement recommended over rebuild due to parts availability. Replace both sides. 2 hours labor for pair.

Estimated cost: $300-550

Symptoms: Fuel gauge reads empty or pegged full regardless of actual level, Fuel smell near rear of truck, Difficulty filling tank—pump clicks off repeatedly, Visible rust perforation at filler neck

Fix: Steel tank and sending unit corrode from inside out, especially if truck sat with old fuel. Filler neck rusts at rubber hose junction. Tank drop required; replace sending unit, inspect tank interior. If tank is rusty inside, replacement mandatory. 3-4 hours labor.

Estimated cost: $400-800