Weak link: Floppy Tilt-Steering Column
Models affected: '74-'93 trucks and SUVs
What happens: The bolts that join the tilt joint to the steering column loosen, resulting in unsafe and annoying flopping of the steering wheel.
Sturdy fix: Disassemble the steering column to the tilt assembly. You'll be removing most of the steering column, including the turn-signal switch and ignition key assembly, so you'll need a steering-wheel puller and a lock-plate press. Remove the four bolts that connect the tilt assembly to the steering column. Coat the threads of the bolts with thread-locking compound and reassemble the column.
Contact: Do-it-yourself fix.
Weak link: Catalytic converter
Models affected: '94-'01 trucks
What happens: The internal brick in the catalytic converter loosens, comes apart, and blocks off the exhaust system. The result can be a significant loss of performance.
Sturdy fix: Your first call should be to your Dodge dealer, because catalytic converters are often warrantied to 80,000 miles. Another option is to get a high-flow catalytic converter from a company like Summit Racing.
Contact: Summit Racing, 800/230-3030, www.summitracing.com
Weak link: Electrical system
Models affected: '74-'93 trucks and SUVs
What happens: According to our sources, these vehicles have weak electrical systems, and this in turn produces less-than-ideal power to the headlights.
Sturdy fix: You can replace the headlamp wiring with a kit from a company like Painless Performance (kit 30815 shown), or you can install relays in the headlight circuit to allow full battery current to reach the headlights. Relays are also a necessity if you install aftermarket H4 bulbs. Using two Bosch (or equivalent) 30-amp relays, wire them as follows:
High beam relay
Terminal 30: Battery
Terminal 87: Blue headlight wires
Terminal 85: Ground
Terminal 86: Red wire from factory wiring
Low beam relay
Terminal 30: Battery
Terminal 87: White headlight wires
Terminal 85: Ground
Terminal 86: Black/red wire from factory wiring
Terminal 87a (if present) is not used
Use 10-gauge wire for the battery and ground side and 14-gauge for splicing into the factory wiring. Make sure your connections are tight and use heat-shrink tubing for a waterproof, insulated connection.
Contact: More info on relay installation can be found at www.ramchargercentral.com. For info on the wiring kit, contact Painless Performance, 888/350-6588, www.painlesswiring.com
Weak link: Hood design
Models affected: '72-'79 trucks and SUVs
What happens: The way the hood is designed, large quantities of water accumulate in the recesses. When the hood is opened, that water gets dumped on the engine distributor.
Sturdy fix: An 8x12 sheet of flexible rubber can be screwed to the air cleaner lid so it hangs down behind the distributor, thus channeling the water away from the distributor. If you have a fancy chrome air cleaner, you probably don't want to drill a hole in it, so another option is to screw a 6x8 sheet of flexible rubber to the firewall just above the distributor. It will hang down over the top of the distributor and towards the carburetor.
Contact: Do-it-yourself fix.
Weak link: The fuse box
Models affected: Vehicles using glass fuses, mainly '74-'80 trucks and SUVs
What happens: Over the course of time the fuse clips develop corrosion and thereby resistance. This can cause the fuse clips to actually melt through the box. This is especially prevalent on the blower-motor fuse clips, as it is the most commonly used high-amp fuse. This is compounded by the fact that the switch used for the three-speed fan fails regularly, and when it does, it can overheat the wiring.
Sturdy fix: The wisest thing to do is replace the fuse box with an aftermarket unit from a company like Painless Performance. They offer 12- and 18-circuit boxes that allow you to use your existing wiring but graduate to modern, blade-style fuses. When you do this, it is recommended that you check/replace the fan speed switch, the switch wiring, and the thermal resistor panel in the heater box for signs of overheating.
Contact: Painless Performance, 888/350-6588, www.painlesswiring.com