1990 DODGE W250

Typical onset: 100,000-150,000 mi

Symptoms: Slipping between gears under load, especially 2nd to 3rd, Burnt transmission fluid smell, Delayed engagement when shifting into drive or reverse, Transmission overheating, oil cooler lines leaking

Fix: The factory A727 (3-speed) or early A518 (4-speed overdrive) was never built for Cummins torque, especially if the truck has been worked hard or modified. Rebuild requires 12-16 hours labor with upgraded clutches, bands, and often a new torque converter. Many shops recommend auxiliary transmission cooler install at same time (add 2 hours). Transmission oil cooler lines and fittings commonly leak and contribute to overheating.

Estimated cost: $2,800-4,200

Typical onset: 150,000-200,000 mi

Symptoms: Hard starting when engine is hot, Loss of power, truck won't rev past 2000 RPM, Black smoke and rough idle, Fuel leaking from pump housing or return lines

Fix: The Bosch VE rotary pump on early 12-valve Cummins is known for internal wear, especially if fuel filters weren't changed religiously or if low-quality diesel was used. Replacement involves 6-8 hours labor for pump R&R and timing adjustment. Many owners upgrade to a P7100 P-pump from later models during this repair for reliability, but that's a major modification requiring custom work.

Estimated cost: $1,800-2,800

Typical onset: 120,000-180,000 mi

Symptoms: Heavy rod knock on cold start that quiets when warm, Low oil pressure at idle (under 10 psi), Metal shavings in oil during changes, Excessive blowby from valve cover breather

Fix: The 5.9L 360 gas V8 develops worn main and rod bearings after years of heavy truck duty. Full rebuild requires engine pull (8-10 hours), machine work on crank and block, new pistons/rings, bearings, timing chain, and gaskets. Total rebuild time is 20-28 hours depending on how deep you go. Many owners opt for a running used engine swap instead (10-12 hours) to save on machine shop costs.

Estimated cost: $3,500-5,500

Typical onset: 80,000-150,000 mi

Symptoms: Clunking from front end over bumps, Steering wander and vague on-center feel, Wheel wobble felt through steering wheel, Grease leaking from knuckle seals

Fix: The Dana 60 front axle uses kingpins instead of ball joints, which wear out and require complete knuckle rebuild. Per side: remove hub, bearings, seals, press out old kingpin bushings, ream and install new bushings, fit new kingpins with proper preload. Figure 4-6 hours per side. Wheel bearings often need replacement at same time. This is heavy, messy work that requires special tooling.

Estimated cost: $1,200-2,000

Symptoms: Truck runs fine until tank drops below 1/4, then loses power or stalls, Air in fuel system, hard starting after sitting, Fuel gauge reads correctly but engine acts fuel-starved

Fix: The steel fuel pickup tube inside the tank corrodes through, especially where it's submerged in old diesel. Once it rusts, it sucks air instead of fuel when tank level drops. Requires tank removal (3-4 hours), pickup tube replacement or tank replacement if badly rusted inside. Often discovered after chasing air leaks elsewhere in fuel system.

Estimated cost: $600-1,200

Symptoms: Cab squeaks and rattles over rough roads, Visible gaps between cab and frame, Body mounts compressed to thin rubber discs or rusted through, Bed bounces independently from cab

Fix: After 30+ years, rubber cab and bed mounts are compressed, cracked, or completely disintegrated. Replacement requires supporting cab or bed, removing old mounts (often rusted bolts need cutting), installing new rubber mounts and hardware. Cab mounts: 4-6 hours. Bed mounts: 2-3 hours. Not safety-critical but affects ride quality and accelerates body panel cracking.

Estimated cost: $400-800