Engine/Transmission (1994 - 1998) 1997 2500 4x4 weak points.

[barracudabad64]

I'm looking at purchasing my first Dodge Diesel and have found a 1997 4x4 extended cab with manual trans. So being a first time buyer I'm looking for help on some of the weak points on the 1997 trucks, I. E. front suspension, transmission so on. I'm not pulling a big heavy 5th wheel trailer or working the truck hard. I have a 22ft bumper trailer and a 16ft car trailer that I haul my 64 Barracuda on from time to time.

So anything to check or questions to ask would be greatly appreciated also anything that may have been done to the truck to avoid.



Thanks for the help.

George

 

[DonFitzwater]

If it has a NV4500 you should know about the 5 gear failure. Read up on it and you may want to upgrade prior to failure. 2nd gen front ends... ... ... ... ... ..... I could go on for days but the basics are track bars, steering stabilizers and tie rods... ... ... ... ... ... ... ..... and steering gear boxes... ... ... ... ... . and you may want to upgrade to a steering stabilizer that boxes in the sector shaft of the steering gear. That is usually a good upgrade with regards to handling performance.

Other than those things and a few other small issues these are good trucks that perform well.

 

[jgillott]

Very, very good choice for a first Cummins. The 12-valves 2nd gens have a great reputation for reliability and the ability to run for hundreds of thousands of miles without anything but routine maintenance. The 12-valve backed by the NV-4500 trans and DANA axles is a stout platform. I'm getting excited for you just thinking about it. I wonder if the wife would allow me to have another project... ... ...


Areas that have shown issues over the years.

As mentioned... .

-5th gear nut

-Track bar and other front end parts

-fuel shut off solenoid

The great news is that the TDR community has developed solid fixes for practically anything that could happen to that truck.

Good luck with your purchase.

 

[MLee]

AND don't forget the KDP (Killer dowel pin). If this thing gets loose, if it hasn't been done already Get in there and tab it, ASAP. The 97's were vulnerable for this to cause damage to the engine. Hopefully it has been done. I am finding that a lot of folks out there don't know anything about it.

 

[Joseph Donnelly]

The same day you get it, fix the killer dowel pin, and check (almost certainly replace) the exhaust manifold because they shrink lengthwise and can break the mounting bolts or ears on the head. While the front cover os off, replace the front seal (loctite behind it, dry to the crank), and remove, loctite, and reinstall the case to block mounting bolts. You can see three, two near the dowel pin, one over the oil pump. The fourth is seen and accessed through a window in the cam gear. The fifth is behind the gear part of the cam gear, but a bent open ended wrench will go through a window so you can at least tighten it. You will be almost overwhelmed if you search the website; also check the turbo diesel buyers guide on the home page.

 

[barracudabad64]

WOW, Thanks to all for the information and I will be going to the home page and start looking for advice on these repair or upgrades. I will most likely without
delay be purchasing a factory service manual as soon as I purchase a truck. I now have some question to ask the owner as far as the upgrades and all. I
would suspect that some of these have been done but will ask and also check them out when I get one home. It may take a while as I really hope to find
a low mileage and prefer a one owner but that may be stretching things a little. I just received my first TDR magazine and have been reading it and
start figuring out what all the abbreviation are. What a great magazine and web sight the TDR has. It is a real life saver for us newbies. I can thank you
all enough for the help. I'll post what I end up buying when I find one.

Thanks
George

 

[Texis]

Best truck I have ever owned. I'm 53 and have owned 11 4x4 pickups & jeeps. 395,000 still running strong, Killer Dowel Pin is still in there... need to get to that one some day. Interesting think about the KDP, I have ask 2 Dodge Cummins mechanics about it and neither had any stories or knew anything about this reported failure point? The failures "may" not be a common as we all like to believe, after all an engine doesn't get the reputation for being a million mile motor if too many of them come apart. Also, interesting that the Cummins 6bta 200hp-330hp 12V P7100 pumped marine engines have the same dowel pin assembly. . never hear a word out of the boating crowd about the "KDP" and I am very active in that circle. HOPE I DON'T REGRET THIS POST NEXT WEEK LOL!

The bad: Front hubs suck, vacuum front axle engagement assembly sucks, dash cracks badly, AC clutches go out, front ends components wears out (what heavy truck doesn't wear out front ends parts?) They are not fast in stock form, or particularly strong in the tow department compared to a modern diesel truck.

The good: Engines may run forever with the P7100 pumps. Rear Dana 70 is a good unit. AC compressors are good, Trucks actually hold up very well in general.

My experience: Bought it in 2002 for $10,800 with 132,000 miles on it. Currently has 395,000.

I have replaced / fixed:
1) 1 auto trans (went out at 260K)
2) 1 radiator (leaking at 380K)
3) New dash
4) 1 fuel pump (mechanical. . out at 350K)
5) 3 water pumps ($80 bucks each. . 30 minute job)
6) 1 starter (replaced when I bought it)
7) Bunch of front brake pads and several rotors
8) 1 freeze plugs (rusted out. . dripping when I bought it)
9) 3 AC clutches
10) 1 fan clutch
11) new track bar (last week)
12) New control arm bushings (last week)
13) a couple of sets of shocks
14) Column shifter assembly broke (replaced with a B&M floor shifter. . which I really like)
15) 1 head light dash switch assembly
16) 2 run solenoids

Best thing I have changed; the front axle rebuild including new 1. 5" Moser solid axles and a DLUX lock/free hubs. That mod hit me for around $1,800. I really got tied of replacing the unit bearings (every 50-70K for the aftermarket units) and 4x4 not working when I wanted it.

"All-in-all". . as I stated, best truck I have ever owned. I don't know of another 4x4 diesel truck that could run like this one has, for as long as this one has, for as little work that I have put back into it... all smiles here. Cheap truck to keep on the road!

It is a 15 year old truck, so figure you will have to fix "something" from time to time. These trucks can either be maintained in like new condition, or just driven. I'm somewhere in the middle... she doesn't get washed in hunting season!

Good luck, don't back away from a decent condition 97 5. 9 12V