1996 Dodge RAM 3500 Problems

What owners report

Owners of this model year most often write about brake performance: premature pad and rotor wear, pulling to one side, and in some cases a pedal that fades or goes low, which several complaints link to rusted brake lines. A second recurring theme is a violent front-end shake over bumps, reported at both low and high mileage. Many complaints were filed years after purchase on high-mileage trucks, so wear and corrosion are part of the picture alongside the component failures described.

1. 1
   Brakes

   Brake pedal fades or goes to the floor; line corrosion

   • 29 complaints (23%)
   • median 109,376 mi at 12.1 yrs old (4 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1996–2010

   Complaints describe the brake pedal sinking toward the floor with the vehicle still moving, sometimes requiring repeated pumping before the truck slows. Several owners say the vehicle pulled hard to one side under braking and that repeated dealer visits with new pads, calipers or a master cylinder did not settle it. Others report the cause was found to be rusted or burst brake lines, and in a few cases the rear brakes were said to be contributing little. Reported from just a few years old onward, and again on trucks past 100,000 miles where corrosion in the lines was cited.

   What to check: Have a shop inspect the hard brake lines for rust along their full length and pressure-test the system; also check for a spongy or slowly sinking pedal and uneven rear braking.

   2 excerpts from owner complaints in NHTSA records

   “Brakes pull to right, calibers and pads have been replaced. Rear brakes don't seem to work well antilock allows you to roll to far. Steering column goes bad after warranty is up ( 100,000 miles ). Fuel pump shut down solenoid and relay have also gone out on both of my trucks. Automatic transmission failures have occurred on both trucks at the 70000-75000 miles .”

   NHTSA complaint #10023089, filed 2003-06

   “While driving at any speed applied brakes, vehicle steered to left or right. Sometimes vehicle would start to shake, would not stop. Needed to keep pressure on brakes in order to stop. Dealer ships had vehicle in shop 6 times, replaced pads/rotors and did an alignment. This defect can cause an accident.”

   NHTSA complaint #817668, filed 1997-10
2. 2
   Suspension

   Front-end shake over bumps (death wobble)

   • 16 complaints (13%)
   • median 81,545 mi at 16.0 yrs old (4 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1996–2015

   Complaints describe a violent, uncontrollable shake of the front end after hitting a bump or a rough patch of pavement, with drivers having to slow to a near stop before it clears. Owners report replacing ball joints, track bars and adding steering stabilizers without a lasting cure, and several say the dealer could not identify a cause. Some link the shake to wear in the steering linkage and stabilizer bar mounts. Reported at low mileage (from about 45,000) as well as past 95,000 miles, usually triggered by bumps at highway speed.

   1 related service bulletin

   What to check: Test drive over broken pavement at highway speed and watch for the wheel shimmying; ask whether ball joints, track bar bushings and the steering stabilizer have been replaced and inspect them for play.

   2 excerpts from owner complaints in NHTSA records

   “1996 Dodge 3500 4x4 dually has a front end shake at any speed have put new balljoints in put a new track bar in than put a double front steering stabilizer on and the truck still shakes after it does it once and you have to try and get out of highway traffic and stop it will just randomly keep doing it bump or not just a rough road.”

   NHTSA complaint #10399485, filed 2011-05, 136,000 miles

   “Steering wobbles/shakes violently when driving. Often initiated by a minor irregularity in road pavement. Requires coming to a full stop to eliminate the wobble. Recurs often. Difficult to exceed 30mph in order to avoid shaking. No noticeably bad or broken suspension parts.”

   NHTSA complaint #10501390, filed 2013-03, 98,090 miles
3. 3
   Brakes

   Front brakes wear out quickly

   • 10 complaints (8%)
   • typically at 1.8 yrs old
   • filed 1996–2003

   Owners report front pads and rotors needing replacement far more often than expected, with several describing repeat service at roughly 7,000 to 15,000 mile intervals. In some accounts the dealer replaced pads, rotors and calipers repeatedly without identifying why the wear kept recurring. A related report describes the front brakes overheating because the rear brakes were not engaging. Reported at low mileage, with several owners citing replacement intervals under 15,000 miles.

   What to check: Ask for brake service records to see how often pads and rotors were replaced, and check rotor thickness and pad life on a test drive; confirm the rear brakes are actually working.

   2 excerpts from owner complaints in NHTSA records

   “Consumer complaining of brake lining wearing out too soon at 10,000 miles. Consumer believes condition is not normal for this situation. Vehicle been in/out of dealer shop for more then three times and condition still occurs. Problem has not been resolved. Dealer will not repair without cost to the consumer.”

   NHTSA complaint #824632, filed 1998-06

   “Consumer experiencing excessive wear of the front brake shoes pads. Has replaced the pads and shoes every 7,000 miles. Consumer has contacted the dealer, dealer has replaced the shoes and pads, dealer unable to determine the cause of the problem. Please provide any further details.”

   NHTSA complaint #821728, filed 1998-02
4. 4
   Body and structure

   Cracks and broken welds in front frame

   • 9 complaints (7%)
   • typically at 5.5 yrs old
   • filed 1998–2002

   Owners describe cracks and separation in the front frame area near the suspension and stabilizer bar mounts, sometimes found during an oil change or alignment. In some complaints the frame or its welds had separated enough that the front wheel was held mainly by the stabilizer bar and tie rod. Owners report contacting the manufacturer and being told the truck's age or mileage put it outside any assistance. Typically found on trucks over about six years old and past 80,000 miles, often discovered during routine service.

   4 related service bulletins

   What to check: Have a shop put the truck on a lift and inspect the front frame rails, crossmember welds and stabilizer bar mounts for cracks or prior weld repairs.

   2 excerpts from owner complaints in NHTSA records

   “Dealership service dept found that the left front frame was totally broken and the right front side was cracked and almost totally broken in same area. They say that it can possibly be welded but no guarantee would hold. We ask that they contact chrsyler to see if anything could be done about it, because we feel that this is not something that should happen. They said chrsyler refused to do anything about it, and said since it was 6 years old, and had that many miles on it that they wouldn't do anything. …”

   NHTSA complaint #765617, filed 2002-08

   “I am reporting a defect on a original frame weld. The stabilizer bar that is connected to the frame that keeps your vehicle from shaking has separated. I have had 3 welders look at this vehicle to repair it and they all say they wont for they dont want to be held responsible for it, be cause if I would have been going at a higher rate of speed I probably would have injured. I contacted chrysler and they stated to me that I should consider the mileage, well I have not had one problem with my engine and without a frame a engine is really no good. …”

   NHTSA complaint #745615, filed 2001-05
5. 5
   Exterior lighting

   Headlight switch overheating, flickering lights

   • 7 complaints (6%)
   • median 155,000 mi at 14.4 yrs old (4 state mileage, few)
   • 3 mention a crash, fire or injury
   • filed 2002–2013

   Complaints describe headlights flickering or going out, a burning smell, and in some cases smoke or fire from the instrument panel area near the headlight switch. Owners mention the switch itself overheating, and some report the connector melted. Several note the vehicle had already been serviced under the headlight switch recall and that the problem returned or the repair was disputed. Reported across the life of the truck, from about 5 years old to beyond 200,000 miles.

   Recall 99V024000

   What to check: Ask whether the headlight switch recall work was completed and whether a relay was added; run the lights for several minutes and check the switch and connector for heat, discoloration or a burning smell.

   2 excerpts from owner complaints in NHTSA records

   “Low beam headlight failure---checked on line found recall # 819---went to chrysler dealer---was advised that the recall had been done on that VIN# and chrysler had no obligation---I pulled the headlight switch and found that it was damaged, the connector melted and no relay pack specified in the recall fix-----it was appears the recall was pencil whipped and the repair was never made------how do you insure that recalls are really done and how many more like mine are out there????????”

   NHTSA complaint #10315963, filed 2010-03, 140,000 miles

   “Consumer pulled over to shoulder 0ff road and left vehicle running to assist another motorist. When he returned to vehicle, there was smoke inside coming from underneath dashboard. Vehicle was towed to dealership. Mechanic told him that headlight switch needed to be replaced.”

   NHTSA complaint #8001900, filed 2002-01

Buying note. On a truck this old, condition and service history matter more than the model's reputation: have the brake lines and front frame inspected on a lift, and get a highway test drive to check for front-end shake. Ask for records on brake work and recall service.

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.