1997 Dodge RAM 2500 Problems

What owners report

Owners of this model year most often write about the brakes, transmission and front suspension, and many of the brake reports involve rusted steel lines rather than worn pads. A second cluster concerns the dashboard plastic cracking apart, and several lighting complaints describe the headlight switch failing or melting. Reports in the sample are spread widely in mileage, from near-new to well past 200,000 miles, so age and corrosion appear to matter as much as use.

1. 1
   Brakes

   Dashboard plastic cracking apart

   • 10 complaints (5%)
   • median 162,500 mi at 11.7 yrs old (6 state mileage, few)
   • filed 2005–2016

   Owners report cracks starting at the windshield base and defrost vents that spread across the dash, with sections breaking loose and leaving sharp edges. Some complaints mention the vehicle identification plate no longer being secured to the dash. According to the complaints, dealers quoted the repair to the owner and no assistance was offered. Often described as starting after several years and worsening over time, with reports from around 100,000 miles upward.

   What to check: Check the top of the dash near the windshield and around the defrost vents for hairline cracks, and confirm the VIN plate is still fastened.

   2 excerpts from owner complaints in NHTSA records

   “My 1997 Dodge 2500 dash board has cracked leaving two piece that look like shards of glass. I am very concerned in a collision that these pieces could cause serious injury. This has been an on going issuewith Dodge and they have refused to take ownership of the problem. This situation is very dangerous with the way the dash cracks. The dash splits from front to back creating dagger type pieces. Please help fix this problem.”

   NHTSA complaint #10343448, filed 2010-07, 190,000 miles

   “I was writing this complaint about the dashboards on Dodge ram pickups in the 94-02 model years. I have a 1997 Dodge RAM 2500 that has had multiple cracks in the dashboard with a series forming a hole at the base of the windshield. My VIN was no longer secured to the dashboard. I have taken the truck to Dodge, and they told me that they would replace it, but I would be out of pocket. There were multiple people I knew that have had the exact problem as well.”

   NHTSA complaint #10190089, filed 2007-05, 245,000 miles
2. 2
   Electrical system

   Headlights cut out or switch melts

   • 10 complaints (5%)
   • median 117,000 mi at 8.4 yrs old (8 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 2001–2015

   Complaints describe headlights flickering or going out entirely while driving, sometimes with smoke or a burning smell at the dash near the headlight switch. Owners report replacing the switch, and in some cases the multifunction switch, more than once with the problem returning. According to the complaints, dealers said no recall applied to the 2500. Reported across a wide mileage range, from a few thousand to well past 200,000 miles, and most often noticed at night.

   What to check: Test the headlights on both high and low beam for a while and feel the switch area for heat; ask whether the headlight or multifunction switch has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “While driving home late one evening in late november 2004, the lights on my Dodge RAM 2500 went completely out. With this loss of lighting I was forced off the road, fortunately I was able to safely stop the vehicle without serious consequence. The fault was the main light switch failure (shorting out) creating a short and small fire in the dash. This is the third switch I have replaced in this vehicle. I researched this type of failure and have found that is a fairly common occurrence in the ram trucks. …”

   NHTSA complaint #10102749, filed 2004-12, 248,000 miles

   “Travelling at night with high beams engaged when all lights went out. I made an emergency stop by the side of the freeway and the lights came back on. I proceeded and a few minutes later it happened again. Eventually I determined that it I left the high beams off it would not happen. Took truck to dealership and they diagnosed and replaced the multi function switch. Problem recurred about 1 month later. Replaced multi function switch on my own this time. Problem recurred again after about 6 months, this time hot/burning wires could be smelled. …”

   NHTSA complaint #10690359, filed 2015-02, 68,650 miles
3. 3
   Suspension

   Front ball joints worn or loose

   Mentioned in 5 of 60 sampled complaints

   Complaints describe worn upper and lower ball joints found during inspections or routine service, sometimes with clunking over bumps or when braking. Some owners also report violent shaking after hitting a bump or pothole, with repairs to the front tracking components not resolving it. One service bulletin covers ball joints with excessive rotational friction in the assembly. Mostly reported under 100,000 miles, with several around 70,000 to 90,000 miles.

   1 related service bulletin

   What to check: Ask for the ball joint inspection history, jack the front end and check for play in each joint, and note any shake after driving over bumps.

   2 excerpts from owner complaints in NHTSA records

   “While driving at any speed consumer heard a clanking sound when the brakes were depressed. Two certified mechanics determined that the control arm upper ball joint bolt was loose.”

   NHTSA complaint #10067269, filed 2004-07, 110,000 miles

   “The contact owns a 1997 Dodge RAM 2500. The contact stated that when driving at any speed and traveling over a road bump or pothole, the vehicle would shake uncontrollably. The contact replaced the front end tracking bar several times however the failure was not corrected. The contact also stated that he had to shut the engine off in order to regain control of the vehicle. The manufacturer was made aware of the failure. The vehicle was not repaired. The approximate failure mileage was 3,500 and the current mileage was 119,600. …”

   NHTSA complaint #10555084, filed 2013-12, 3,500 miles
4. 4
   Brakes

   Rusted brake lines bursting or leaking

   • 13 complaints (6%)
   • median 113,000 mi at 10.0 yrs old (8 state mileage, few)
   • filed 2000–2019

   Complaints describe the steel brake lines corroding until they rupture or seep fluid, with reports of the pedal going to the floor or the truck losing stopping ability while braking at low speed or on the highway. Some owners found fluid on the engine or under the truck, and several had all remaining lines replaced after one failed. Owners report dealers treating the corrosion as normal wear or pointing to the vehicle's history in northern road-salt states. Mostly reported between roughly 70,000 and 165,000 miles, often on trucks used in winter road-salt areas.

   What to check: Have a shop inspect the hard brake lines along the frame and near the master cylinder for rust pitting, and ask whether any have already been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Traveling at 40 MPH, heard a pop , rear break line ruptured, due to early corrosion of galvinized brake lines. No rear brakes. Was able to get of road. Dealership asked if its a northern truck, says it's non-warranty. Repair pending - estimates range from $600 to thousands (dealer)”

   NHTSA complaint #10106354, filed 2005-01, 97,950 miles

   “Vehicle lost braking while applying the brakes at 25 MPH. Consumer was able to stop the vehicle without any incidents. Vehicle was towed to a repair shop, and mechanic determined that the problem was an erupted metal brake line due to corrosion. Dealer and the manufacturer were not notified. Broken brake line was replaced. The rest of brake lines had to be replaced because of severe corrosion and danger of bursting.”

   NHTSA complaint #10106943, filed 2005-03, 118,000 miles

Buying note. Inspect the brake lines, front ball joints and headlight switch carefully, since these are the most common reports for this year, and check the dash for cracking. Service records showing recent brake line and front-end work are worth asking about before buying.

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.