Weak link: Steering box sector shaft movement
Models affected: '94-'01 trucks
What happens: The vehicle exhibits road wander and general poor road feel due to sector shaft play.
Sturdy fix: Windecker Machine makes a DSS brace that greatly reduces the aforementioned wander by providing additional support for the sector shaft. It also helps to minimize frame flex at the steering box mounting point. The brace bolts on with no drilling or welding, contains all mounting hardware, and features a durable powdercoat finish.
Contact: Windecker Machine Ltd., 306/842-3790, www.solidsteel.ca
Weak link: Fifth gear nut
Models affected: '94-and-up trucks with an NV4500 transmission
What happens: Over a period of time, the 5th gear nut backs off the output shaft. Because the 5th gear output shaft is only partially splined, when the nut backs off, the gear slides off the splines onto the non-splined portion, and you lose 5th gear.
Sturdy fix: One way to fix the problem is to remove the transmission tailhousing, reinstall the gear and install a new aftermarket nut with locking set screws. Or, you could reuse the stock nut and tack-weld it into position. The strongest fix is to remove the transmission and replace the output shaft assembly with a fully splined shaft. Standard Transmission offers a shaft (shown) that integrates a locking mechanism to hold the gear in place in addition to a nut and lock washer.
Contact: Standard Transmission Parts, 800/783-8726, www.standardtransmission.com
Weak link: Locking mechanism and seal on the vent windows
Models affected: Most trucks and SUVs with vent windows
What happens: The factory locking mechanism and seals wear out over time. As they wear, they will no longer put enough compression on the window seals to seal correctly. The result is wind noise and water leakage.
Sturdy fix: Dodge dealers offer a rebuild kit for these locking mechanisms, but they are pricey. They also reuse the pot metal lever and outside cover, so if yours are worn, this may not help. The hot ticket is to procure the vent windows from an '84-or-newer model. On these, the ramps that the locking lever seals against are taller, which will restore the compression.
Contact: www.dodgeconnection.com
Weak link: Wheel bearing/spindle design
Models affected: '74-'79 trucks and SUVs with Dana 44 front axle
What happens: The wheel bearings on the aforementioned axle are too close together. The load and leverage of larger-diameter tires will often cause these bearings to fail.
Sturdy fix: One way to solve the problem is to replace everything from the steering knuckles out, using parts from an '80-'93 Dodge truck (shown). This conversion will change the front axle to a 5-on-5.5-inch bolt pattern, however, so you'll have to keep two sets of tires unless you change the rear axle from the 5-on-4.5 pattern to the new 5-on-5.5. This setup will also allow you to keep your full-time transfer case. Another option is to install a part-time conversion kit from a company like Mile Marker. The parts in this kit will eliminate the weak wheel bearing design.
Contact: Mile Marker, 800/886-8647, www.milemarker.com
Weak link: Cracks in the body sheetmetal under the passenger seat
Models affected: '74-'88 SUVs
What happens: The latch plate that holds the passenger seat down is bolted to the body. Over time, the latch plate causes the sheetmetal to crack and break. This is especially prevalent in rust-prone parts of the country.
Sturdy fix: Brace the area with a piece of bar stock. Use the latch plate as a template to drill the bar stock and add a bolt on the outer edges at lease 3-4 inches from the plate to help spread some of the load.
Contact: Do-it-yourself fix.
This is the third installment of a series that will examine some of the common problems of popular four-wheel-drive vehicles. Past installments included Chevy fullsize trucks and SUVs (May '04) and Ford fullsize trucks and SUVs (August '04). In future issues we're going to put the spotlight on Toyota, Jeep, and other four-wheel-drive trucks and SUVs.
In addition to all of the great companies listed in this story, there are a number of Dodge-specific sources available on the Web. For those of you needing parts, www.dodgeconnection.com is a valuable source for '72-'80 components. If you need general Dodge info, visit www.dodgeram.org.