Problem Reports
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1996 Dodge Ram 2500 Problems
Rerouting Ignition Coil/Spark Plug Wires Can Solve Misfire/Surge Problems
On the 3.9L V6 and 5.2L V8, rerouting the ignition coil wire and spark plug wires can help solve a misfire and/or surge problem that occurs at approximately 45 mph. A service bulletin was published that outlines the specifics of the repair. It states the rerouting procedure should be performed before other repairs are done for misfires, surging or spark knock.
Worn or Mis-Indexed Distributor Shaft Can Cause Surging/Bucking on Acceleration
A surging or bucking during acceleration can be caused if the distributor is moved or mis-indexed. This is a result of the cam and crank position sensors being out of synchronization. Wear of the oil pump drive gear can cause similar symptoms because it allows excessive free play in the distributor drive. The distributor drive gear and bushing should be replaced if the rotor tip moves back-and-forth more than 3/16th of an inch when checking drive gear free play.
HVAC Air Flow Switching to Defrost When Accelerating
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.
Intake manifold may leak vacuum or coolant
The intake manifold gaskets may leak. Coolant loss may be noticed as coolant leaks into the engine oil and/or there may be a rough idle or whistling noise. The intake gaskets need to be replaced if they are leaking coolant internally to prevent engine damage.
Engine oil leaks at distributor may be misdiagnosed
On the 3.9L V6 and 5.9L V8 the engine oil leaks at the distributor can be misdiagnosed as leaks from the intake manifold seal, oil pan gasket, or rear crankshaft (rear main) seal. A revised distributor is available if oil is found inside the distributor.
Increased Oil Consumption Due to Intake Manifold Gasket Leak
On 3.9L V6 and 5.9L V8 engines, the intake manifold gasket may leak and cause increased oil consumption and a spark knock during acceleration; the gasket should be replaced.
Engine Will Crank But Not Start Due to Fuel Return Line Leak
If the engine is difficult to start or cranks but does not start, it can be caused by a leak in the return side of the fuel system. This type of leak can allow air to enter the injection pump resulting in starting issues. A rubber hose on the back of the injection pump, connecting the pump to the steel hard line, that can be the source of this type of leak.
Vehicle Drifts/Pulls to One Side When Brakes Are Applied
Some models could have a severe drift or pull to one side when the brakes were applied. If this is not caused by a dragging brake caliper, there is a service bulletin describing the step-by-step diagnosis and many possible solutions. Our technicians note the most common solutions are performing a four wheel alignment, checking torque on suspension components, installing shims between the wheels and hubs, and replacing the suspension arms.
Check Engine Light Due to Pinched Leak Detection Pump Vacuum Lines
If a Check Engine Light illuminates indicating leak detection pump (LDP) failure, the cause is often pinched or disconnected vacuum lines to the pump. Vacuum lines should be inspected before replacing the leak detection pump. Contamination (carbon or debris) in the pump can cause failure and any hoses should be cleared before a new pump is installed.
Coolant Loss and Engine Overheating
Engine overheating can result from coolant leaks which are commonly found at the thermostat housing gasket, water pump, heater return tube O-ring at the water pump, intake manifold gasket, and timing cover gasket. Our technicians recommend a complete inspection of the cooling system after any repairs are made to be sure there are no other leaks.
Replace Timing Cover Gasket to Prevent Oil/Coolant Seepage
Oil or coolant may seep at the timing cover gasket; replace the gasket with a revised gasket.
Avoid chatter by using correct axle fluid and additive
To avoid chatter from the rear axle while turning corners, it is important to use the correct axle fluid with the correct Trac-Loc additive (if equipped).
Inspect for pulley alignment if drive belt is damaged on inside edge
New cover available if driver's side hinge cover for center armrest breaks
New covers are available if the driver's side hinge cover for the center armrest breaks.
Replace leaf spring tip liners to stop noise when driving over bumps
When driving over bumps a clicking or squeaking from the rear leaf springs may be fixed by replacing the (leaf) spring tip liners and installing a spring clinch clip (kit available from the dealer).
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