1996 Dodge RAM 2500 Problems

What owners report

Owners of this model year most often write about brakes, the automatic transmission, and dash-mounted electrical and lighting components. Many reports come at higher mileage (the median is around 145,000 miles), so a good share reflect wear and age rather than early-life failures. The single most consistent pattern is a headlight switch and dash wiring that overheats, plus transmission cooler lines and a front-end shake reported at highway speed.

1. 1
   Electrical system

   Headlight switch and dash wiring overheating

   Mentioned in 15 of 60 sampled complaints

   Owners describe headlights, marker lights and dash lights going out while driving, sometimes with a burning smell, and the headlight switch or pigtail melted or pulling loose from a cracked dash. Several report replacing the switch multiple times, and some say the dealer told them the vehicle was not covered by a campaign that applied to similar trucks. A few describe smoke or fire in the dash or steering column area. Reported from roughly 50,000 to over 300,000 miles, often on trucks driven at night or while towing.

   2 related service bulletins

   What to check: Turn on the lights and feel the switch and connector for heat, and look for melted plastic or scorched wiring under the dash. Ask whether the switch or harness has been replaced and whether a relay kit was added.

   2 excerpts from owner complaints in NHTSA records

   “On the morning of 12/7/09 I started my truck to warm it up with the heating fan on high when at some point, somewhere in the wiring harness under the dash overheated and started the interior on fire. Destroying my vehicle. The windshield and driver door windows were broken from the heat but luckily remained intact and not letting air inside to fuel the fire and it eventually extinguished itself.”

   NHTSA complaint #10296258, filed 2009-12, 145,000 miles

   “The steering column on this truck has gotten very hot under the ignition switch area. So hot in fact that the wires and plastic column cover have smoked and melted through. I feel there may be a fire soon. The dealership says nothing is wrong with my model year but the melted hole in my steering column says otherwise I've read there was a recall of this nature but was told in no uncertain terms that they would not be helping me. Help...”

   NHTSA complaint #10510595, filed 2013-05, 225,000 miles
2. 2
   Transmission and drivetrain

   Automatic transmission cooler line leaks and fluid loss

   • 24 complaints (8%)
   • median 105,500 mi at 9.1 yrs old (6 state mileage, few)
   • filed 1997–2010

   Owners describe transmission fluid spraying or pouring out from the cooler lines and fittings, sometimes onto the hot exhaust with smoke, especially while towing or under load. Several mention a specific cooler-line campaign and say the dealer declined to apply it to their truck. Others report harsh or delayed shifting and shops recommending a rebuild for internal seal failure. Reported from about 99,000 to 190,000 miles, often while towing a trailer or climbing a grade.

   1 related service bulletin

   What to check: Inspect the cooler lines and fittings at the radiator for seepage, cracks or hardened hose, and check fluid level and color. Ask whether the cooler lines have ever been replaced.

   2 excerpts from owner complaints in NHTSA records

   “1996 a518 Dodge ram transmission went out. I have heard that they are awful transmissions and I believe that there needs to be a recall on the a518 transmission for 1996 Dodge ram trucks!”

   NHTSA complaint #10134637, filed 2005-08, 72,000 miles

   “Recall 97v084000 concerning transmission cooling line. While pulling a 5th wheel trailer up a incline at 30 MPH vehicle stopped while in motion, and white smoke came from under the hood. Vehicle was towed to a repair shop. Dealer was notified. Dealer informed consumer that this vehicle was not covered under that recall.”

   NHTSA complaint #10097569, filed 2004-10, 106,000 miles
3. 3
   Brakes

   Brake pedal goes hard or to the floor; rusted lines

   • 53 complaints (18%)
   • median 134,604 mi at 8.7 yrs old (9 state mileage, few)
   • 10 mention a crash, fire or injury
   • filed 1995–2019

   Complaints describe a hard brake pedal with longer stopping distance, a pedal sinking to the floor, and brake lines rusted through, in some cases with the booster hose found oily. Owners also report front-end vibration under braking traced to disc and ball joint wear, and one notes the parking brake did not hold. Some say the vehicle was outside a related campaign because of its VIN. Mostly reported between about 55,000 and 225,000 miles, on trucks used for towing and in road-salt climates.

   What to check: Have the brake lines, booster hose and check valve inspected for rust or oil contamination, and test that the pedal stays firm when held. Ask about recent brake and ball joint service.

   2 excerpts from owner complaints in NHTSA records

   “I went to stop at a red light under normal conditions and the brake petal went to the floor and I rear ended an SUV. My vehicle was towed to a repair shop to find that three of the four brake lines rusted out and the one that stayed intact was leaking. I did heavy damage to the SUV as well as pushed in my bumper and damaged the hood. Also the application of the emeregency brake did nothing.”

   NHTSA complaint #10167911, filed 2006-09, 125,000 miles

   “While driving on a city street, I lost my power steering, causing me to almost have a rear end collision with the vehicle in front of me. I had my truck towed to a local dealership, they found my brake system to be contaminated and told me that all parts of the system with rubber in them would have to be replaced. After about a week and a half, I was informed that they could find all the parts except one, the combination or proportioning valve. …”

   NHTSA complaint #11208414, filed 2019-05, 175,000 miles
4. 4
   Suspension

   Front-end shake and worn front end parts

   • 24 complaints (8%)
   • median 143,000 mi at 9.9 yrs old (8 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1996–2020

   Owners describe violent front-end shaking or wheel hop at highway speed, especially after hitting bumps or grooved pavement, sometimes severe enough to require stopping. Others report clunking over bumps traced to worn upper ball joints, and some say the dealer called it normal for these trucks or declined campaign coverage. A few report cracked or torn front spring and shock towers at the frame. Mostly reported from about 58,000 to 236,000 miles, often at 45-60 mph on rough or grooved roads.

   What to check: Drive it at highway speed over uneven pavement and note any shake, and have the front end checked for ball joint play, worn steering parts and cracks at the spring towers.

   2 excerpts from owner complaints in NHTSA records

   “My 96 RAM 2500 has a major steering/handling problem at or about any high speed if I hit any potholes, rough spots, or if I turn my steering wheel to the left for a prolong period of time my steering wheel starts shaking like I have blown a tire violently shaking/hopping so erratic that it shakes a 20 lb backpack off of my passengers seat and on to the floorboard. I have to bring the truck to an immediate stop to elevate the problem. This works until the next bump or rough spot in the road. …”

   NHTSA complaint #10206158, filed 2007-10, 196,200 miles

   “Recall campaign 04v596000 concerning ball joint wear. Vehicle was making a clunking noise while driving over bumps, pot holes or uneven road surface. Vehicle was taken to a repair shop, and mechanic determined that both upper ball joints needed to be replaced. Manufacturer was contacted. Manufacturer informed the consumer that his vehicle probl was not covered under a recall.”

   NHTSA complaint #10117481, filed 2005-04, 102,000 miles
5. 5
   Electrical system

   Cracked dashboard and disintegrating interior trim

   • 11 complaints (4%)
   • median 145,000 mi at 14.1 yrs old (11 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2007–2021

   Complaints describe the dash top cracking and breaking into pieces, with vents falling out, sharp edges and wiring exposed, and switches such as the headlight and overdrive controls left hanging by their wires. Owners say replacement dash parts are hard to find and expensive, and some connect the broken mounting to electrical faults. Reported from about 50,000 to 226,000 miles, often on trucks kept in hot, sunny climates.

   What to check: Look over the dash top and around the switch panel for cracks, loose switches or exposed wiring, and confirm the lights, windows and locks still work from their mounts.

   2 excerpts from owner complaints in NHTSA records

   “The dash is a big pile of junk! Hard plastic with a vibrating diesel? Turns to pieces and falls into defroster ducts, floor, all in cab of truck! This is why you don't buy Dodge or you buy it for only cummins diesel power! Thats one of the only things that seldom breaks and needs fixing! Take the power train away and you would not sell another! Booo! No good dash!”

   NHTSA complaint #10491750, filed 2013-01, 196,000 miles

   “Dodge RAM 2500 pick up truck: dashboard has been slowly disintegrating to the point where certainly elements are holding only by one screw ' air-condition vents are falling out. Top of dashboard is 50% gone, broken in to small pieces and exposing electrical wires to the harsh sunlight. Some controls such as driver seat electrical window is no longer opening, RPM meter is only working intermittently. The underside, exposing all wires and controls is missing cover (disintegrated). …”

   NHTSA complaint #10299079, filed 2010-01, 50,000 miles

Buying note. Check the brake lines and booster, the transmission cooler lines, and the headlight switch and dash wiring carefully, since those are the areas owners write about most. Because most reports come at high mileage, service records for brakes, front-end parts and transmission work matter as much as the odometer reading.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.