GEAR MOTOR, Transfer Case The gear motor assembly is shipped in AWD/2WD position. The transfer case needs to be positioned in AWD/2WD position to properly assemble gear motor to T-Case. Please reference Star Online publication S2121000003 for further details. Do not have the transfer case in in another position other than AWD/2WD and rotate the motor to align the bolt holes as this could result in damage to the gear motor.
full bulletin at NHTSA ↗2005 Dodge Dakota engine problems
moderate 17 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
17
Recalls
0
Avg fix
$3,100
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
GEAR MOTOR, Transfer Case The gear motor assembly is shipped in AWD/2WD position. The transfer case needs to be positioned in AWD/2WD position to properly assemble gear motor to T-Case. Please reference Star Online publication S2121000003 for further details. Do not have the transfer case in in another position other than AWD/2WD and rotate the motor to align the bolt holes as this could result in damage to the gear motor.
full bulletin at NHTSA ↗Service - Four Piece Oil Pan Gasket All Cummins Equipped Vehicles ONLY - The replacement oil pan gasket can be a four piece gasket rather than a single piece gasket. This applies to Cummins 5.9L and 6.7L engines only. Installation: 1. Clean the oil pan T-joints.~ 2. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar® Silicone Rubber Adhesive Sealant or equivalent. 3. Apply a 2-mm [0.063-in] bead of Mopar Engine Sealant RTV Silicone Rubber Adhesive, to the oil pan flange.~ 4. The four piece gasket will need to be assembled to make a complete oil pan gasket. 5. Lay the oil pan gasket(s) onto the oil pan flange.~ 6. Ensure the oil pan gask
full bulletin at NHTSA ↗Valve Body. These may cause over drive cycling.
full bulletin at NHTSA ↗NAG1 (5A580) Valve Body As per Warranty Bulletin D-13-22, please use R2108213A$ valve body for all Warranty (W), Mopar (M) and Mopar Vehicle Protection (F) claims.~ Assembly also includes Filter (52108325AA) and Gasket (52108332AA).~
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2005 Dodge Dakotas report the engine runs rough at highway speeds with fuel economy dropping from 18.5 to 15 mpg. The most dangerous complaint pattern: the engine stalls without warning at idle, during turns, or while decelerating—RPMs swing erratically from near-stall to 3,000 before the engine dies. This happens at random, forcing owners to restart in traffic and losing power steering at the worst moment. Dealerships cannot reproduce or fix it, even after multiple visits.
Additional failures include premature breakage of exhaust manifold bolts on both sides, letting exhaust fumes into the cabin. Rocker arms fall off the cylinder head due to loose valve guides. Head bolts break, causing ticking and potential carbon monoxide leaks into the cab. One truck ingested water during rain, snapping a piston. Serpentine belts and tensioners fail early. Owners report being told problems are "normal" or that Chrysler will not authorize repairs without a diagnostic code—leaving trucks unfixed and owners frustrated.
Same Dodge Dakota engine reports on nearby years: 2006
Failure modes owners describe
Rough idle and miss at cruise
Engine runs rough at speeds 25-85 mph and light throttle cruising, described as 'fish bite' or 'beaming' by dealers. Fuel economy declined from 18.5 to 15 mpg. Repeated resets of engine computer by dealers without actual repair.
When: 3-4 weeks into ownership
Symptoms owners cite: rough idle; miss at light throttle; power loss; poor fuel economy
Repairs/costs cited: Dealers reset computer repeatedly, claimed no fault found
Stalling at idle and during deceleration
Engine shuts off or stalls randomly at stop lights, while turning, or during deceleration. RPMs erratic during stops, fluctuating from a few hundred to over 3000 before stalling. Vehicle must be shifted to park and restarted. No check engine light illuminates. Occurs approximately 12 times in some cases, with instances of multiple stalls in a single day.
When: Various mileages; one case at 9,000 miles, another at 64,275 miles
Symptoms owners cite: random stalling; loss of power steering due to stall; erratic idle RPM; stalling at stop light; stalling during turns
Repairs/costs cited: Multiple dealership visits unable to diagnose or repair. One case blamed poor maintenance and incorrect oil use.
Recalls/TSBs owners mention: Manufacturer refused parts replacement when no error code present. One case warranty expired, refused assistance.
Exhaust manifold bolt and stud failure
Exhaust manifold bolts and studs break prematurely, causing ticking noise and exhaust fumes to leak into passenger cabin. Problem occurs on both left and right side manifolds. Dealers acknowledge this as common.
When: Various points in vehicle ownership
Symptoms owners cite: ticking noise from exhaust; exhaust fumes entering cabin; broken bolts and studs
Recalls/TSBs owners mention: Dealer stated this is a common problem with this vehicle type; no recall mentioned
Rocker arm failure and loose intake valve guides
Rocker arm falls off due to loose intake valve guide or elongated aluminum head. One case involved driver-side rocker arm on cylinder head falling into valve cover during highway driving at 50 mph. Loose valve seats and guides allow excessive play.
When: 50 mph highway driving; one case mentioned
Symptoms owners cite: tapping/ticking noise from engine; rocker arm falling loose; rocker arm in valve cover
Repairs/costs cited: Rocker arm fell loose during highway driving; valve seat and guide were also loose
Engine head bolts breaking
Bolts break off in the cylinder head, causing ticking noise. Owner reported drowsiness and headaches while driving, suspected carbon monoxide from exhaust leak through broken bolt holes. Repair cost estimated at $800-$1,000 from Chrysler.
Symptoms owners cite: ticking noise; sleepiness while driving; headaches; broken bolts in head
Repairs/costs cited: $800-$1,000 repair cost quoted by Chrysler
Water ingestion and piston damage
During rain, water is sucked through air intake and forced to back of engine into pistons. Water breaks number five piston when it has nowhere to go. Engine light illuminates and vehicle starts missing.
When: Wet weather operation
Symptoms owners cite: engine light illumination; engine missing; broken piston
Repairs/costs cited: Dealership required to pull head and replace number five piston; not covered under warranty
Recalls/TSBs owners mention: Repair not covered under warranty
Serpentine belt and tensioner failure
Serpentine belt and tensioner require replacement early in vehicle ownership. Problem identified early but required Chrysler authorization before repair could be performed, causing one-week delay.
When: 200 miles from purchase
Symptoms owners cite: belt rubbing noise
Repairs/costs cited: Serpentine belt and tensioner replaced; could cause loss of power steering and AC if not fixed
Engine overheating and oil radiator cooler failure
Vehicle overheated after summer operation. Diagnostics identified need for oil radiator cooler.
When: 140,000 miles
Symptoms owners cite: overheating; check engine light
Repairs/costs cited: Oil radiator cooler needed
Engine flash/PCM issue
Vehicle stalled without warning at various speeds but restarted each time. Dealership determined problem was with flash (engine computer), but stated no repair was available.
Symptoms owners cite: stalling at various speeds; restarting after stall
Repairs/costs cited: No repair available per dealership
Synthesized from 17 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had engine trouble with your 2005 Dodge Dakota?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2005 Dodge Dakota?
It's a documented issue but not catastrophic. 17 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Across the 14 complaints that reported odometer mileage, most engine failures cluster between 17,500 and 140,000 miles, with the median around 62,000. A quarter of owners report trouble before 17,500; a quarter make it past 140,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Dodge/Dakota.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.