In this thread, I would like to collect a list of common issues, with fixes if we have 'em.... to post either here, or in the faq section.... something we can point folks at for some of the usual things our trucks experience. Doesn't have to be quite as in-depth as the plenum thread......

Thinks like:

Vibration at 45 mph..... gets better if you turn off overdrive: Indicates an engine miss.

ABS and brake lite on for RWAL trucks: Generally the rear wheel speed sensor on the rear diff.

No upshift at WOT: 96 and newer trucks. Saturated governor pressure sensor, replace with borg warner heavy duty unit.

All contributions would be appreciated.

 

thump/rattle under driver or passenger feet. tighten lower shock bolt to 100+ pounds.

squeak on drivers side under dash. grease bushings in auto trans linkage.

won't rev up over some rpm. remove front O2 sensor to relieve pressure and verify clogged cat. then replace cat.

front axle CAD won't lock up front axle in 4wd. 1) fix vacuum lines, 2) disassemble cad and free up stuck shaft.

surging idle. replace TPS.

won't idle/stalls at idle. clean IAC port and/or replace IAC.

replacing plugs - remove and discard heat shield tubes to eliminate dirt, mud, gunk from around plugs and prevent debris from falling into cylinder. also avoids cross threaded plugs.

when replacing water pump - always replace timing cover gasket, timing set. water flows through timing cover and gasket is subject to failure over time.

low oil pressure - replace oil pump with melling high volume.

pinging/spark knock and/or oil usage. replace plenum gasket and plate.

cruise not working. check fuse, fix vac leaks.

cabin vents change from low to high under acceleration. fix vac leaks and/or replace check valves on passenger side.

service transmission every 1-2 years or 15-30K miles. install drain plug to make it easier. use ATF+4 only. don't use ANY additives, never, never, ever. watch for loose parts in pan, especially the OD snap ring which will need fixing or else you risk the OD assembly coming loose.

service front and rear diff every 1-2 years, more often if you drive in deep water or mud. watch for broken LSD clips in rear and remove as needed and don't worry about them.

grinding noise from t-case is broken rear snap ring. easy fix, install new snap ring or tcase-saver locking ring. other noises are more serious, possibly worn out chain. drain/refill t-case annually with ATF+4.

 

Weird vibrations in driveline or some weird 4x4 issues. Check the snap ring on output shaft of the transfer case...

Grinding or ticking noise from front wheels. Check wheel bearings or ujoints.

Maybe include a link to the tsb for proper spark plug wire routing.

Wet carpet on passenger side or foggy windshield with the smell of coolant. Heater core needs replaced.

 

A/C switches between front vents and defrost & Cruise control doesn't work properly: Vacuum leak in Cruise Control servo line from battery acid leak-install a gasket between the battery tray and the Battery Temperature Sensor, replace battery.

Squealing from front of the engine: Take the belt off and spin all pulleys, check for any noise, resistance to spin, or any play in the pulleys. Replace pulley as necessary. Also make sure belt tensioner gives proper tension and is not binding. Replace belt if it's frayed, glazed, or otherwise not in good condition. DON'T USE BELT DRESSING!

ABS & Brake light on 4WAL, truck does not brake correctly during regular use, squeaking sound when driving/braking/turning: Check front wheel bearings for any play. Jack front end, hold tire with hands at 6 and 12 o'clock and wiggle back and forth; any play requires replacement of wheel bearing/hub assembly.

No start after transmission replacement: Check crankshaft sensor & wiring, replace as necessary.

 

Flashers or headlights not working properly check the connector behind the multifunction switch for any wires that could have been pulled out.

 

A/c not working with full freon- Horn fuse blown-Disconnect one horn at a time to find short(Never woulda found this without the help of HeyYou!)

 

Dodge Death Wobble at highway speeds-

Can be caused by front end slop and improper caster angle due to lift/leveling kit without adjustable track bar and/or longer control arms. Sometimes multiplied by worn tires, especially BFGoodrich. Shocks and steering stabilizers are just band-aids!!

I've had 2012 work trucks- completely stock wobble due to stock bfg's and a worn track bar.

A few helpful links-
http://www.kevinsoffroad.com/how-to-...-death-wobble/

http://www.cumminsforum.com/forum/94...ses-fixes.html
1. Track bar
Ball Joints, Steering Gearbox, Worn BFGs, Wheel Bearings(unlikely yet possible), Correct alignment(caster angle), Pitman arm, Tie Rod Ends, control arm bushings (unlikely)

Hope this helps! I spent thousands tracking down a death wobble on my '06 cummins! I know it can be frustrating, feel free to PM any questions this way.

 

Clunk sound when changing between gears, check for play in drive shaft, if a lot of play, replace u joint.

 

This symptom can also indicate worn ball joints that are DIFM (due in for maintenance).

 

Dont forget the headlights not working usually being a burned up switch and the option to wire in a relay with replacement to prevent the issue from returning...