1991 Dodge D350 Problems
RepairPal has identified the most common problems with the 1991 Dodge D350 based on complaints from actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.
A condition may develop where the fuel gauge reads empty with too much fuel still in the fuel tank. Our technicians tell us that installing a new wire harness that provides a common ground for the fuel gauge and sending will correct this issue.
The powertrain control module (PCM) may fail resulting in a lack of AC cooling. The lack of cooling could be caused by evaporator freeze-up due to the AC compressor staying on continuously or conversely, not coming on at all. Proper diagnoses of the PCM should be performed before replacing it for this concern.
Diesel engines may develop a hard start or no start condition due to any one of the following issues: Low fuel pressure, air entering the fuel system, and loss of fuel system prime. Our technicians tell us that the rubber inlet hose at the back of the injection pump and the lift pump are common causes for these concerns. Lack of fuel to the injection pump can damage the pump due to lack of lubrication, when this occurs it is not uncommon to replace the lift pump, injection pump, and fuel injectors.
The fuse may blow repeatedly for the HVAC blower motor or the motor may stop working all together. Our technicians tell us that can often be repaired by replacing the blower motor switch with a revised switch and installing a wiring harness with a relay assembly.
The blower motor may operate erratically and the blower switch operation has a sticky or mushy feeling, the detents almost non existent. Our technicians tell us that the blower switch should be removed and inspected for overheating. This is common if the blower motor is frequently operated on high speed as the current flow through the switch tends to melt internal the components. Also carefully inspect all of the switch connector terminals for discoloration due to overheating and replace as required. A poor electrical contact at the connector will also cause the switch to overheat.
The AC/heater (HVAC) system may unexpectedly switch to the defrost mode when accelerating. This system is operated by engine vacuum and should be inspected for any vacuum leaks if this problem develops. There is also a revised vacuum check valve available to address this concern.
Oil leaks from the valve cover gaskets, timing cover gasket, distributor o-ring, and rear main seal area are common. The leak at the rear main seal area is generally not the seal itself but the bearing cap to the engine block seal. An oil leak could also be internal to the distributor, if oil is found inside the distributor then the distributor should be replaced.
Moderate to severe engine damage may result from using non-DaimlerChrysler approved oil filters. Our technicians tell us that the neoprene compounds used in the manufacture of the unapproved filters may separate from the filter and lodge in the piston cooling nozzle blocking the oil spray from the affected nozzles.
Pinched or restricted transmission oil cooler lines can cause transmission failure due to lack of lubrication. Our technicians recommend complete inspection of the transmission cooler and lines if this type of failure is noted.
Carbon buildup on the top of the piston is common. Over time this can lead to symptoms varying from light ticking to knocking noises. Performing a fuel injector cleaning procedure can often help the condition by removing some of the piston top deposits.
Vehicles equipped with 12" diameter rear brakes may encounter premature rear brake shoe wear. If it is found that the brake system is functioning as designed the repair would be to replace the affected brake shoes with revised parts.
Cracking or popping sounds from the cowl area may be a result of cowl cracks at the lower corners of the windshield. The fenders must be removed to see the cracks. If cracks are found, a reinforcement kit is available to correct the condition.