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Dodge Durango 5.7 Hemi Engine Failure



  • I finally to got the bad engine from the mechanic that did the work for us.

    A full review of the finding is posted on a Chrysler related message board here:
  • Forget that link,
    Go directly to this page:
  • dmacklindmacklin Posts: 1
    My 2004 Dodge Durango engine went on Saturday and the dealer told me the same happened to mine. Is there anything that can be done for this misfortune?
  • Call Chrysler customer service. It may take a couple of calls the first person I contacted was awful and very smartmouthed the second time I called I got a gentleman that realy knows what customer service is about. We had to take my girlfriends Durango to a Dodge dealer to have inspected and due to the low mileage and the aparent care taken of the Durango Chrysler is covering 75 percent of parts and labor. Only problem now is no motors are available so they are collecting new parts and building a new motor. We are on week three of the repair and still waiting on parts. The service manager has been great though.
  • I'm glad to hear that Chrysler is addressing the issue. I didn't even attempt to call Chrysler since our had over 130K and we were the 2nd owners.
    Considering the very, very, minimal wear on the internals of this Hemi I have decided to fix it. Yes I mean fix the block. For those who have some welding skills there are special materials available now for repairing cast iron. All I need to do is repair the hole in the block, replace one rod and one piston. There IS NO applicable bearing, ring, or cylinder bore ware I can find. I will reuse everything.
    I considered upgrading to forged rods but the price is pretty high. Aftermarket parts for these engines are ridiculous. I will probably take the rest of the stock rods and have them sonic checked but that is it.
  • akcamaiakcamai Posts: 9
    I just bought the travel trailer to go along with my 2004 Durango that has 106,500 miles on it. Would like to know how you make out. I would like to know if anyone else is pulling a trailer with theirs. My trailer is a 28ft Jayco weighing about 7,900. I don't want to trash my Durango and won't be going far since we live in Alaska and the beach is about 150 miles away.
  • Wow Carol,

    I hate to be negative since the specs for the Durango are well within what you need to pull that travel trailer.
    But all I can do is to reiterate what I have found by researching this rod failure issue.
    It seems to happen in '03 and '04 hemi powered truck applications and not cars.
    This DOES NOT MEAN your engine will fail. But knowing the facts gives you some options to consider. You might consider a car warranty that covers engine failures since your vehicle is well outside the manufactures warranty. Or, you might consider trading up to a Diesel 4 door (roomy) pickup that is the absolute best for trailer towing.
    The up side is the Hemi Durango with the optional tow package is a great vehicle to pull a trailer. I pulled a 20" car hauler with an antique car on it and it pulled it effortlessly. The 545RFE transmission in Hemi Durango has proven itself to be an excellent transmission. It is probably one of the best since the days of the bulletproof 3 speed automatics that powered most of the Chrysler vehicles since the late 1950s till the late 80s when the 4 spd automatics started to show up.
  • mjbuddmjbudd Posts: 9

    hoping you could help me out. My 04' durango w/ 104k miles just had it's engine blow while my husband was driving it on the highway. I'm so upset to find out this is a problem that Chrysler is aware of, thank god i was not in the car w/ my 2 year old son at the time.

    where can i find those previous cases on the nhtsa website and how did you contact chrysler to make this complaint. Did you just call a 800 #. Any help would be so much appreciated.

  • yes you can call chrysler customer service, i do belive its a 800 number, they will ask alot of questions, but the main thing will be records of service, they are willing to help if you have proof of oil changes and service,. good luck
  • mjbuddmjbudd Posts: 9
    I contacted chrysler and they refuse to do anything. I have made a formal complaint w/ the national highway and transportation and consumer protection. I encourage all owners to make formal compliants, it's the only way to bring this problem to the public eye and force chrysler to take responsibility.
  • We just had our second engine blow, so no, I would say it is definitely not worth it, we are so upset that we may never buy north american again.
  • mjbuddmjbudd Posts: 9
    Oh my god, i'm so sorry to hear that, can't imagine how frustrated you must be.

    Do you mind if i ask...did you put another 04 dodge motor in? What was the mileage?

    We are in the process of deciding what to do w/ our blown motor. Someone told us that the engine is failing because of the manifold. Has anyone else heard anything about this?

    We are considering putting a jasper motor in, i'm too scared to put another dodge motor in for this very reason. I feel like it would just be a ticking time bomb.
  • drrighteousdrrighteous Posts: 49
    A JASPER motor is just a rebuilt engine. It likely uses OEM Chrysler parts.
    The #1 reason for these failures is the connecting rods. The part number of the original rod has rolled in the Chrysler parts system, so a new rod (better) being used. This problem is primarly '04 Hemis, '05 Hemis are compatible but later ones are not direct bolt ins.
  • mjbuddmjbudd Posts: 9
    thanks for the info. the benefit of the JASPER motor is it comes w/ a 3 year warrantly.

    what do you mean by the part # has rolled in the chrysler parts system?
  • drrighteousdrrighteous Posts: 49
    It means there is a new version (part number) of the connecting rod/piston combo. When you purchase a replacement part, you are not getting the part as went in the original engine. Since the later Hemi engines vehicles don't suffer from the rod failure issues, that leads me to think this is an improve version.
  • gormlg1gormlg1 Posts: 1
    My 2004 Durango had a hole in the engine also. never any prior problems, loved the vehicle. driving down road, check engine light flashed, car died, towed to shop. cylinder #4 blew hole thru side of engine. Dodge says 'sorry, out of warranty' because it's got 91,855 miles on it!!!! I talked to case manager and supervisor and still same answer. Since somehow you got them to pay due to outside of warranty, can you share any info on a contact number/or name that you spoke to? my email is Despite my comments about several similar situations noted on here and that NHTSA website (including my own) they still deny there being any problem...any info you could do to help would be soooo much appreciated. Another engine with a 3yr/100k mile warranty is going to cost us about 7k (in NJ). THANK YOU
  • tbird37887tbird37887 Posts: 4
    The main thing that helped on my girlfriends Durango was the purchase history she had with Chrysler and the dealership where we went. The shop foreman has a lot to do with the call on fixing the vehicle. we had all the maintenance records in the vehicle when it was towed in. We called the 800 customer service number the first time no luck the second we got a knowledgeable young man who sent us to senior management. The appearance of the vehicle also played into the fact they repaired this Durango it still looks brand new! The only complaint I have with the repair is due to so many engines being replaced there are none available so the had to get a block and build from "scratch" so we got 1 year 12k mile waranties on individual parts instead of the three year 50k waranty. I would not give up, keep calling and trying but see if you can get through to senior management.
  • joswijoswi Posts: 1
    How are we going to sue Dodge?

    There is no way that "slodge" in any car or truck will destroy it completely with only 62,000 miles!
  • burdawgburdawg Posts: 1,521
    I think you mean "sludge", and yes, it is possible, but that's not the problem with the 5.7 hemi anyway, is it?
  • rockcutterrockcutter Posts: 1
    edited May 2011
    This is quite a conversation.
    I just had a phone call from the Dodge dealer, stating that I had a rod bearing failure, at 78,500 miles.

    After setting for a few days I went to start my Durango, and it had a funny sound coming from under the car. From what I gather it's the bearing on cylinder number eight. The cost to fix it over $4000 for a short block
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