The first-gen Durango (1998-2003) was Dodge's body-on-frame SUV sharing DNA with the Dakota pickup. Solid axles front and rear make it tough, but cooling system and transmission weaknesses plague high-mileage examples, especially V8 models.
Transmission Overheating & Cooler Line Failure
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Burnt ATF smell, dark or varnished fluid, Harsh 2-3 shifts or slipping under load, Cooler lines rusting through at radiator connections, leaking ATF
Fix: Replace transmission oil cooler and lines (2-3 hrs labor), flush system. If internal damage occurred, rebuild or replace 46RE/45RFE transmission (12-16 hrs labor). Cooler line rust is endemic; inspect every oil change.
Estimated cost: $400-800 for cooler/lines; $2,200-3,800 for transmission rebuild
Plenum Plate Gasket Failure (3.9L & 5.2L Magnum V8s)
Common · medium severity
Typical onset: 60,000-120,000 mi
Symptoms: Coolant consumption with no visible leak, White smoke on startup, sweet smell in oil, Misfires on multiple cylinders, rough idle
Fix: Remove intake plenum, replace lower gasket and often intake manifold gasket set (5-7 hrs labor). Magnum engines have coolant passages under the plenum; gasket deteriorates and dumps coolant into crankcase or cylinders. Hughes Engines and Fel-Pro make updated gaskets.
Estimated cost: $600-1,100
Crankshaft Position Sensor Failure
Common · high severity
Typical onset: 70,000-150,000 mi
Symptoms: Intermittent stalling, usually hot, restarts after cooling, No-start with cranking but no spark or fuel pulse, Check engine light with P0320 or P0340 codes
Fix: Replace crank position sensor at bellhousing (0.5-1 hr labor). Heat from exhaust and transmission causes premature failure. Carry a spare in the glove box on high-mileage rigs; it's a 10-minute roadside fix if you have a 10mm socket.
Estimated cost: $120-220
Front Ball Joint Wear
Common · medium severity
Typical onset: 60,000-100,000 mi
Symptoms: Clunking over bumps, wandering steering, Uneven or cupped tire wear on inside edge, Play felt when prying on tire at 12/6 o'clock
Fix: Replace upper and lower ball joints, both sides (4-6 hrs labor). Dana 44 front axle uses press-in joints; uppers fail more often but do both sides together. Alignment required afterward. Moog or Spicer quality; avoid cheap offshore units.
Estimated cost: $650-1,100
Exhaust Manifold Cracking (5.2L & 5.9L)
Occasional · low severity
Typical onset: 90,000-180,000 mi
Symptoms: Ticking or tapping noise on cold start, fades when warm, Exhaust smell in cabin or under hood, Visible cracks between ports on cast-iron manifold
Fix: Replace cracked manifold(s) and gaskets (3-5 hrs labor per side). Passenger side more common due to steering shaft clearance and heat retention. Dorman replacements available but OE Mopar or used OEM preferred for longevity.
Estimated cost: $450-850 per side
Fuel Pump Failure
Occasional · high severity
Typical onset: 100,000-160,000 mi
Symptoms: Stalling or stumbling under acceleration, Long crank time, especially after sitting overnight, Whining noise from tank area before failure
Fix: Drop 25-gallon tank, replace fuel pump module and strainer (2-3 hrs labor). Tank straps rust in salt states; add 0.5-1 hr and parts if corroded. Run tank low before job to save your back. Use OE Mopar or Bosch pump; avoid no-name eBay units.
Estimated cost: $500-800
HVAC Blend Door Failure
Occasional · low severity
Symptoms: Heat or A/C works only on one side or not at all, Clicking or grinding noise from dash when adjusting temp, Air blows cold in heat mode or vice versa
Fix: Plastic blend door actuator or door itself breaks. Heater box removal requires full dash disassembly (8-12 hrs labor). Some techs cut access holes behind glove box for door repair (4-6 hrs), but it's a band-aid. Aftermarket metal door kits available from HVAC specialty shops.
Estimated cost: $800-1,600 depending on access method
Owner tips
Flush cooling system every 30k and use Zerex G-05 (gold) coolant—Magnum engines are picky about inhibitor chemistry
Change transmission fluid and filter every 30-40k, install auxiliary cooler if towing regularly
Grease front driveshaft slip yoke every oil change to prevent clunk and wear
Inspect frame rails and rear spring hangers for rust if in salt belt—structural rot kills these before mechanical failure
Keep a spare crank position sensor in the vehicle after 100k miles
Buy one if you need towing capacity and can wrench—they're tough trucks when maintained, but nickel-and-dime issues pile up fast on neglected examples, especially transmissions.
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.
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CERTAIN REPLACEMENT K&N FUEL PERFORMANCE KITS, P/NOS. 57-1509, 57-1511, 57-1511-1, 57-1517, 57-1517-1, 57-1527, AND 57-1530. ALSO, A SMALL PERCENTAGE OF THESE KITS WERE SOLD UNDER THE MOPAR PERFORMANCE PARTS BRAND NAME (P/NOS. P5007069 AND P5007070). ALL KITS WERE MANUFACTURED FROM APRIL 20, 1999, THROUGH SEPTEMBER 23, 2004. THESE ASSEMBLIES WERE MANUFACTURED AS REPLACEMENT EQUIPMENT FOR CERTAIN DODGE PICKUP TRUCKS AND SUVS. A SMALL PIECE OF MATERIAL FROM THE TUBE WALL COULD BE SUCKED INTO THE ENGINE THROTTLE BODY, WHICH COULD CAUSE THE THROTTLE TO BECOME JAMMED IN THE OPEN POSITION.
Consequence: A JAMMED OPEN THROTTLE COULD CAUSE UNINTENDED ACCELERATION OF THE VEHICLE, POSSIBLY RESULTING IN A CRASH OR INCREASED STOPING DISTANCES WHEN BRAKING.
Remedy: K&N WILL PROVIDE OWNERS WITH A FREE REPAIR KIT ALONG WITH REPAIR INSTRUCTIONS. THE RECALL BEGAN ON APRIL 20, 2006.
SERVICE BRAKES, HYDRAULIC · 06E022000
2006-03-13
CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAND NAMES OF NAPA, RAYBESTOS, AIMCO, AC DELCO, CARQUEST, BENDIX, AND WAGNER. ONLY PRODUCTS THAT WERE MANUFACTURED FROM JULY 27, 2005 THROUGH JANUARY 17, 2006 (DATE CODES 0529 THROUGH 0602) ARE SUBJECT TO THIS RECALL. WHEN SUBJECT TO VERY COLD TEMPERATURES, AN INTERNAL SEAL IN THE MASTER CYLINDER COULD LOSE FLEXIBILITY AND MAY CAUSE BRAKE FLUID TO LEAK.
Consequence: LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTANCE, WHICH CAN RESULT IN A VEHICLE CRASH.
Remedy: AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2006. OWNERS CAN CONTACT AFFINA GROUP CUSTOMER SERVICE AT 1-800-323-0354.
AIR BAGS · 01V153000
2001-05-08
VEHICLE DESCRIPTION: PICKUP TRUCKS. SOUND DEADENER MATERIAL INSIDE THE STEERING WHEEL COULD BECOME DETACHED FROM THE COVER AND HOUSING.
NOTE: THE RAM PICKUP TRUCKS WERE BUILT AT THE WARREN ASSEMBLY PLANT ("S" IN THE 11TH VIN POSITION) FROM MAY 16, 2000 THROUGH OCTOBER 23, 2000; ST. LOUIS NORTH ASSEMBLY PLANT ("J" IN THE 11TH VIN POSITION) FROM MAY 19, 2000 THROUGH OCTOBER 23, 2000; LAGO ALBERTO ASSEMBLY PLANT ("M" IN THE 11TH VIN POSITION) FROM MAY 23, 2000 THROUGH OCTOBER 23, 2000; AND SALTILLO ASSEMBLY PLANT ("G" IN THE 11TH VIN POSITION) FROM MAY 23, 2000 THROUGH OCTOBER 23, 2000.
IMPORTANT: VEHICLES THAT HAVE ALREADY HAD THE PROPER CLOCKSPRING INSTALLED, ACCORDING TO WARRANTY RECORDS, HAVE BEEN EXCLUDED FROM THIS RECALL. IN ADDITION, 1997-2000 MODEL YEAR VEHICLES THAT HAVE HAD A SUSPECT REPLACEMENT CLOCKSPRING INSTALLED, ACCORDING TO WARRANTY RECORDS, HAVE BEEN ADDED TO THIS RECALL.
Consequence: WHEN THIS OCCURS, THE MATERIAL COULD INTERFERE WITH THE CLOCKSPRING RIBBON AND CAUSE AN OPEN CIRCUIT. THE DRIVER AIR BAG SYSTEM WILL BECOME DISABLED, AND THE AIR BAG WARNING LAMP WILL ILLUMINATE ON THE INSTRUMENT PANEL.
Remedy: DEALERS WILL REPLACE THE CLOCKSPRING ASSEMBLY. OWNER NOTIFICATION BEGAN JUNE 18, 2001. ALSO SOME 1997-200 MODEL YEAR VEHICLES THAT, ACCORDING TO WARRANTY RECORDS, HAVE HAD A SUSPECT REPLACEMENT CLOCKSPRING INSTALLED, WILL ALSO BE INCLUDED IN THIS CAMPAIGN. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS · 99V341000
1999-12-02
VEHICLE DESCRIPTION: SPORT UTILITY VEHICLES. THE REAR BRAKE TUBE CAN CONTACT AN UNDERBODY CROSSMEMBER EVENTUALLY WEARING A HOLE IN THE TUBE.
Consequence: IF THE TUBE WERE PERFORATED, THERE WOULD BE A REDUCTION IN BRAKING FROM THE REAR WHEELS, INCREASING STOPPING DISTANCES.
Remedy: DEALERS WILL INSTALL A RUBBER ISOLATOR ON ALL VEHICLES THAT DO NOT INDICATE TUBE CONTACT. VEHICLES THAT SHOW CONTACT AND HAVE LESS THAN 45,000 MILES AND NO SIGNS OF RED RUST WILL HAVE THE RUBBER ISOLATOR INSTALLED WITH SILICONE TO PROTECT THE TUBE WHERE THE COATING HAS WORN OFF. VEHICLES THAT EXHIBIT CONTACT, AND HAVE MORE THAN 45,000 MILES OR SHOW SIGNS OF RED RUST, WILL HAVE THE BRAKE TUBE REPLACED WITH THE PRODUCTION TUBE AND ISOLATOR.
VEHICLE DESCRIPTION: SPORT UTILITY VEHICLES. THE FUEL TANK STRAP CAN SEPARATE DUE TO FATIGUE DURING OPERATION. IF THIS OCCURS, THE TANK WILL BE UNSUPPORTED, INCREASING THE RISK OF A FUEL LEAK.
Consequence: FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE DOUBLE TOGGLE LOCK FUEL TANK STRAPS WITH SINGLE TOGGLE LOCK DESIGN. NOTE: AFFECTED VEHICLES BUILT THROUGH MAY 21, 1998, ALSO REQUIRE THE REAR BRAKE TUBE INSPECTION/REPAIR. AS A RESULT, THE FUEL TANK STRAP AND BRAKE TUBE REPAIR WILL BE PERFORMED ON THESE VHEICLES IN A SINGLE SERVICE PROCEDURE UNDER RECALL 99V-341/DAIMLERCHRYSLER #841. AFFECTED VEHICLES BUILT FROM MAY 22, 1998 THROUGH SEPTEMBER 25, 1999, ONLY REQUIRE THE FUEL TANK STRAP REPAIR, WHICH WILL BE PERFORMED UNDER RECALL 99V-342/DAIMLERCHRYSLER #842.
VEHICLE DESCRIPTION: LIGHT DUTY PICKUP TRUCKS. THE FASTENER WHICH SECURES THE GENERATOR CABLE TO THE POWER DISTRIBUTION CENTER (PDC) HAS AN INSUFFICIENT CLAMP LOAD, RESULTING IN A LOOSE CONNECTION AND ELECTRICAL ARCING AT THE CONNECTION.
Consequence: THIS CONDITION COULD CAUSE A FIRE IN THE ENGINE COMPARTMENT.
Remedy: DEALERS WILL RETIGHTEN THE GENERATOR CABLE AND BATTERY CABLE FASTENERS TO THE PROPER TORQUE SPECIFICATIONS.
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