1994-2009 Dodge Ram 3500 Problems: 5 Known Issues

1994-2009 Dodge Ram 3500 Problems: 5 Known Issues | Au7o

NHTSA Recalls20 recalls

AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

Chrysler (FCA US LLC) expanded the affected population to include 73,712 2005-2009 RAM 2500 trucks produced at the St. Louis North Assembly Plant. With this change, Chrysler is recalling certain model year 2004-2008 RAM 1500, 2005-2009 RAM 2500, 2006-2009 RAM 3500, 2007-2010 RAM 3500 Cab Chassis, 2008-2010 RAM 4500 and 5500 Cab Chassis, 2004-2009 Dodge Durango, 2007-2009 Chrysler Aspen, 2007-2012 Jeep Wrangler, 2008-2012 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2012 Chrysler 300, 2006-2012 Dodge Charger, 2005-2011 Dodge Dakota, and 2006-2009 Mitsubishi Raider vehicles originally sold, or ever registered, in AL, CA, FL, GA, HI, LA, MS, SC, TX, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Chrysler is also recalling 2004-2008 RAM 1500, 2005-2009 RAM 2500, 2006-2009 RAM 3500, 2007-2009 RAM 3500 Cab Chassis, 2008-2009 RAM 4500 and 5500 Cab Chassis, 2004-2009 Dodge Durango, 2007-2009 Chrysler Aspen, 2007-2009 Jeep Wrangler, 2008-2009 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2009 Chrysler 300, 2006-2009 Dodge Charger, 2005-2009 Dodge Dakota and 2006-2009 Mitsubishi Raider vehicles originally sold, or ever registered, in AZ, AR, DE, Washington D.C., IL, IN, KS, KY, MD, MO, NE, NV, NJ, NM, NC, OH, OK, PA, TN, VA, and WV, or "Zone B." Lastly, unless included in "Zone A" or "Zone B" above, Chrysler is recalling certain 2005-2008 RAM 2500, 2006-2008 RAM 3500, 2007-2008 RAM 3500 Cab Chassis, 2008 RAM 4500 and 5500 Cab Chassis, 2004-2008 Dodge Durango, 2007-2008 Chrysler Aspen, 2007-2008 Jeep Wrangler, 2008 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2008 Chrysler 300, 2006-2008 Dodge Charger, 2005-2008 Dodge Dakota, and 2006-2008 Mitsubishi Raider vehicles originally sold, or registered, in AK, CO, CT, ID, IA, ME, MA, MI, MN, MT, NH, NY, ND, OR, RI, SD, UT, VT, WA, WI, and WY.

Campaign #16V35200024/05/2016

AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

Chrysler (FCA US LLC) is recalling certain model year 2005-2009 Dodge Ram 2500, 2004-2008 Dodge Ram 1500 and Durango, 2006-2009 Dodge Ram 3500, 2008-2010 Dodge Ram 4500 and 5500, 2007-2008 Chrysler Aspen, 2005-2010 Chrysler 300, 300C, 300S, and SRT8, 2006-2010 Dodge Charger, 2005-2008 Magnum, 2005-2011 Dodge Dakota, and 2006-2009 Mitsubishi Raider vehicles. The affected vehicles are equipped with a dual-stage driver frontal air bag that may be susceptible to moisture intrusion which, over time, could cause the inflator to rupture.

Campaign #15V31300027/05/2015

AIR BAGS

Chrysler Group LLC (Chrysler) is recalling certain model year 2004-2005 Dodge Ram 1500, 2500, and 3500, 2004-2005 Dodge Durango, 2005 Dodge Dakota, 2005 Dodge Magnum and 2005 Chrysler 300, 300C and 300 SRT8 vehicles originally sold, or ever registered, in geographic locations associated with high absolute humidity. Specifically, vehicles sold, or ever registered, in Alabama, Florida, Georgia, Hawaii, Louisiana, Mississippi, Texas, Puerto Rico, U.S. Virgin Islands, Saipan, Guam, and American Samoa are addressed by this recall. Upon deployment of the passenger side frontal air bag, excessive internal pressure may cause the inflator to rupture.

Campaign #14V77000003/12/2014

STEERING:LINKAGES:TIE ROD ASSEMBLY

Chrysler Group LLC (Chrysler) is recalling certain model year 2008-2012 RAM 2500 4X4 and 3500 4X4 trucks, 2008-2012 Dodge RAM 3500 4x2 Cab Chassis, and model year 2008 Dodge RAM 1500 Mega Cab 4x4. The left tie rod assembly may break.

Campaign #13V52900006/11/2013

STEERING:LINKAGES:TIE ROD ASSEMBLY

Chrysler Group LLC (Chrysler) is recalling certain model year 2003-2008 Dodge RAM 2500 4x4 and 3500 4x4, model year 2007-2008 Dodge RAM 3500 4x2 Cab Chassis and model year 2006-2008 Dodge RAM 1500 Mega Cab 4x4 trucks manufactured February 12, 2002, through February 13, 2008. The left tie rod assembly may break.

Campaign #13V52800006/11/2013

+ 15 more recalls. Check all on NHTSA.gov

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Frequently Asked Questions

What are the most common Dodge Ram 3500 problems?

According to Au7o's analysis of 800+ owner reports, the 1994-2009 Dodge Ram 3500 has 5 documented issues. The most frequently reported are: Cummins 5.9L Killer Dowel Pin (KDP) - Catastrophic Engine Risk, Steering Linkage Tie Rod and Drag Link Wear (Death Wobble), Rear Axle Seal Leak (Dana 80/AAM 11.5). Of these, 2 are rated critical and should be addressed promptly.

Is the Dodge Ram 3500 reliable?

The 1994-2009 Dodge Ram 3500 has 5 known issues documented across 800+ owner reports. 2 issues are rated critical: Cummins 5.9L Killer Dowel Pin (KDP) - Catastrophic Engine Risk and Steering Linkage Tie Rod and Drag Link Wear (Death Wobble). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Dodge Ram 3500 problems?

Repair costs for known Dodge Ram 3500 issues range from $15 to $8,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Cummins 5.9L Killer Dowel Pin (KDP) - Catastrophic Engine Risk, typically costs $15-$8,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What year Dodge Ram 3500 is the most reliable?

Reliability varies across model years of the Dodge Ram 3500. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 1994-2009 Dodge Ram 3500 with 5 documented issues documented across 800+ owner reports.

What is the 1994-2002 Dodge Ram 3500 Cummins 5.9L Killer Dowel Pin (KDP) - Catastrophic Engine Risk?

The same catastrophic Killer Dowel Pin (KDP) issue that affects the Ram 2500 applies to all Cummins 5.9L-equipped Ram 3500 trucks. A steel dowel pin in the timing gear housing can vibrate loose and fall into the timing gears, destroying the engine with no warning. This is widely… Repairs typically run $15-$8,000. Severity: high.

What is the 2003-2008 Dodge Ram 3500 Steering Linkage Tie Rod and Drag Link Wear (Death Wobble)?

The Ram 3500's solid front axle steering components — tie rod ends, drag link, and track bar — wear out under the heavy-duty loads, causing death wobble: a violent front-end oscillation triggered by bumps at highway speed. The issue is more severe with aftermarket lifts. Repairs typically run $300-$1,200. Severity: high.

What is the 1994-2009 Dodge Ram 3500 Rear Axle Seal Leak (Dana 80/AAM 11.5)?

Ram 3500 dually and single rear wheel trucks commonly develop rear axle seal leaks from the Dana 80 (1994-2002) or AAM 11.5 (2003-2009) rear axles. The axle shaft seals and pinion seal are the most common leak points. Leaking gear oil can contaminate the rear brake shoes/pads and… Repairs typically run $100-$500. Severity: medium.

What is the 1994-2008 Dodge Ram 3500 Front Axle U-Joint Failure (4WD)?

The front axle shaft u-joints wear out under heavy-duty use and 4WD engagement. The Dana 60 front axle u-joints are subjected to severe angles and loads, especially with aftermarket lifts or heavy front-end accessories. Repairs typically run $150-$500. Severity: medium.

What is the 1994-2008 Dodge Ram 3500 Steering Gear Box Leak and Play?

The power steering gear box develops internal seal leaks and excessive play. The heavy front end weight and solid axle design accelerate wear. Leaking fluid leads to low power steering assist and potential pump damage. Repairs typically run $400-$1,200. Severity: medium.

1994-2009 Dodge Ram 3500 Problems: 5 Known Issues

All 5 Known Issues

Cummins 5.9L Killer Dowel Pin (KDP) - Catastrophic Engine Risk#

Common Symptoms

How to Fix

What you need to fix it

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Steering Linkage Tie Rod and Drag Link Wear (Death Wobble)#

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How to Fix

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Rear Axle Seal Leak (Dana 80/AAM 11.5)#

Common Symptoms

How to Fix

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Front Axle U-Joint Failure (4WD)#

Common Symptoms

How to Fix

What you need to fix it

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Steering Gear Box Leak and Play#

Common Symptoms

How to Fix

What you need to fix it

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Other Dodge Models

Frequently Asked Questions

What are the most common Dodge Ram 3500 problems?

Is the Dodge Ram 3500 reliable?

How much does it cost to fix common Dodge Ram 3500 problems?

What year Dodge Ram 3500 is the most reliable?

What is the 1994-2002 Dodge Ram 3500 Cummins 5.9L Killer Dowel Pin (KDP) - Catastrophic Engine Risk?

What is the 2003-2008 Dodge Ram 3500 Steering Linkage Tie Rod and Drag Link Wear (Death Wobble)?

What is the 1994-2009 Dodge Ram 3500 Rear Axle Seal Leak (Dana 80/AAM 11.5)?

What is the 1994-2008 Dodge Ram 3500 Front Axle U-Joint Failure (4WD)?

What is the 1994-2008 Dodge Ram 3500 Steering Gear Box Leak and Play?