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 Durango engine problems
moderate 261 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
261
Recalls
0
Avg fix
$3,100
4crashes
2fires
3injuries
When does it fail?
Of the 261 engine complaints filed for the 2005 Dodge Durango, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Of the 16 model years of Dodge Durango we track for engine problems, this one carries the most owner complaints on file — 261.
Owners have filed 261 engine complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
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
The 2005 Durango's core problem is engine stalling—the engine shuts off unpredictably with zero warning, killing all power steering, power brakes, and electrical control while the vehicle coasts. Owners describe stalling during turns, highway merges, stop-and-go traffic, or sitting idle. It happens at 3,200 miles or 100,000+ miles; frequency swings from weekly to once every few months. The vehicle always restarts immediately, often leaving no fault codes behind. Dealerships tell owners they cannot fix what they cannot see on a diagnostic scan. Chrysler service advisors have dismissed internet complaints as unreliable despite hundreds of documented cases.
Owners have replaced spark plugs, O2 sensors, EGR valves, throttle control modules, ignition coils, transmission fluid, gaskets, sensors, and wiring—none fix the stalling. PCM reflashes and software updates provide temporary relief, if any. Dealers demand owners leave the vehicle for extended periods at hourly diagnostic rates, then return it unchanged.
Secondary failures compound the hazard: fuel tank overflow when filling up (persisting even after 2005 recalls), water intrusion into the engine through a cowl design flaw causing hydro-lock or rod damage, manifold gasket cracking as early as 39,000 miles, electrical melting of wiring harnesses, and transmission hesitation. One owner reported a $8,000 engine replacement; another lost power at 75 mph on the interstate with children aboard.
Multiple owners report near-accidents—stalling in intersections, on highway on-ramps, near school buses, and while children rode inside. Owners express fear of driving and have parked vehicles rather than risk injury. Several cite finding 90–800+ identical complaints online yet manufacturers and dealerships deny knowledge of a defect.
Same Dodge Durango engine reports on nearby years: 2006 · 2007
Failure modes owners describe
Engine stalling without warning during driving
Engine shuts off unexpectedly while vehicle is in motion—at low speeds, turns, highway speeds, or while stopped—with no warning lights, check engine light, or fault codes. Loss of power steering and power brakes occurs, creating immediate hazard. Vehicle restarts normally after stalling. Occurs repeatedly over months or years; frequency varies from occasional to multiple times per week.
When: Occurs from first few months of ownership through 80,000+ miles; reported from 3,200 miles to vehicles with over 100,000 miles
Symptoms owners cite: Engine stalls randomly with no warning lights or codes; Loss of power steering and power brakes during stall; Loss of all electrical power when stalling; Vehicle restarts immediately without issue; Stalls often while turning, especially at low speeds or right turns; Stalls during deceleration, backing up, or at stop lights/idle; Stalls occasionally at highway speeds (60-75+ mph); Frequency unpredictable—may happen multiple times per day or weeks apart; RPM fluctuation at idle before stalling
Codes mentioned: P0300 (random misfire code, reported once), No codes generated in majority of cases, Stored codes not related to stalling (EGR, throttle, camshaft/crankshaft sensor codes mentioned in some cases)
Repairs/costs cited: Dealerships replace spark plugs, O2 sensors, EGR valve, ignition coils, throttle control modules, transmission fluid, transmissions, gaskets, sensors, wiring—none resolve the issue. One case mentions $2,000 in dealer repairs with no resolution. Software/PCM reflash attempted with no lasting success. Multiple dealership visits result in 'cannot replicate' response. Owners report fuel injector cleaner, air filter replacement also ineffective.
Recalls/TSBs owners mention: Dodge service advisors claim no awareness of widespread issue; dealers cannot diagnose without codes or ability to replicate. One dealer stated 'internet is our worst enemy.' Chrysler told owners warranty does not cover the problem after expiration. One dealer acknowledged they knew Dodge was researching a fix but had none available. Service bulletins and reflashes applied without success. One owner reported Chrysler offered lemon law replacement but with mileage penalty.
Fuel tank overflow/filler neck check valve failure
Fuel tank inlet check valve does not close properly, causing gasoline to spill when filling tank to full capacity. Owners report fear of fire hazard. One case mentions recall was performed in 2005 but overflow persists.
When: Reported approximately 1 year into ownership; persists for years
Symptoms owners cite: Gas spills out of fuel tank when filling up; Overflow occurs at every fill-up when tank filled completely; No metal piece/valve closing off fuel inlet after nozzle withdrawal
Repairs/costs cited: One owner notes a recall was performed in 2005 (part# 2885312, RO# 426595) but problem persists. Another case reports difficulty getting dealership to address—customer told recall on their VIN was not listed despite fuel overflow occurring.
Recalls/TSBs owners mention: Chrysler customer care told owners VIN had no applicable recalls; directed customers to dealership at customer expense. One 2005 recall repair (fuel tank filler tube inlet) did not resolve overflow.
Manifold gasket cracking
Intake or exhaust manifold gasket cracks early in vehicle life, causing engine ticking and multiple secondary failures including transmission fluid leaks.
When: At 39,305 miles on 2005 Durango SLT 4.7L engine
Symptoms owners cite: Terrible ticking sound from engine and transmission; Engine constantly cutting off and stalling; Vehicle struggling to stay running; Very little power output; Check engine light comes on and off intermittently; Transmission fluid leaking
Repairs/costs cited: Manifold gasket replacement attempted (stock# 2885312, RO# 426595); customer reports dealer service did not resolve multiple cascading problems—vehicle continued same symptoms after repair attempts.
Recalls/TSBs owners mention: Dealer performed repeated repair attempts but problems persisted. Customer claims pressure on dealers to minimize warranty costs.
Engine water intrusion through cowl design defect
Water seal design defect at windshield wiper arm area allows rainwater to flow down front windshield, under cowl, directly onto engine block. Water enters cylinders via air intake manifold, causing hydro-lock or eventual rod damage/engine failure.
When: Occurs when vehicle parked in rain; can cause immediate hydro-lock on next start or gradual engine damage
Symptoms owners cite: Water intrusion into engine after rain exposure; Hydro-lock condition preventing vehicle start after rain; Bent or fractured connecting rod when engine examined; Engine block puncture from rod damage; Loss of power at highway speeds from internal engine damage
Repairs/costs cited: One owner noted water flowed visibly under cowl when windshield was hosed during wash, confirming design flaw. Engine replacement required in at least one case ($8,000 cost cited elsewhere).
Recalls/TSBs owners mention: Described as 'known problem by Dodge/Chrysler' with refusal to address it. Multiple complaints on Edmunds forums and YouTube regarding same issue.
Transmission hesitation in reverse
Multi-second hesitation or delay when shifting into reverse after vehicle sits overnight or during workday, even after transmission service.
When: Approximately 1 year into ownership; persists after transmission filter replacement via technical service bulletin
Symptoms owners cite: Several second hesitation when placing vehicle in reverse after sitting; Persists in both forward and reverse after transmission service; Occurs intermittently; dealership cannot replicate
Repairs/costs cited: Dealership performed transmission filter replacement per technical service bulletin; hesitation improved slightly but recurred 1,500 miles later.
Recalls/TSBs owners mention: TSB provided for transmission filter replacement; dealer applied repair with limited lasting effect.
Electrical arcing/computer failure from intake manifold melting
Wiring harness and intake manifold melt due to electrical arcing or thermal fault, destroying engine components and causing continued check engine light.
When: Approximately 72,000 miles; occurred after multiple repairs for check engine light
Symptoms owners cite: Interior of vehicle felt hot with smoke inside; Wiring harness melted; Intake manifold melted; Check engine light continuing to illuminate after component replacement
Codes mentioned: Check engine light (cause unknown)
Repairs/costs cited: Dealer replaced lifters, wiring harness, intake manifold, and oxygen sensor. Check engine light persisted; vehicle not repaired.
Recalls/TSBs owners mention: Dealer performed component replacements but vehicle remained unrepaired with continuing check engine light.
Fuel system leak - EVAPORATIVE emissions
Evaporative emission system leak causing check engine light; fuel tank replacement required but leak recurred after prior repairs.
When: Approximately 112,680 miles
Symptoms owners cite: Check engine light illuminated
Codes mentioned: Evaporative emissions system leak
Repairs/costs cited: Fuel tank replaced; vehicle required new O-ring and lock ring. Failure recurred despite two prior repairs.
Recalls/TSBs owners mention: Dealer diagnosed need for fuel tank replacement and emission system components. Vehicle was not ultimately repaired; owner did not authorize work after prior failures.
Unintended acceleration at low speed
Vehicle attempts to accelerate forward on its own while brake pedal is fully depressed, particularly during stop-and-go traffic at low speeds.
When: Daily occurrence during school drop-off traffic, parking lot navigation, or red light situations
Symptoms owners cite: Vehicle tries to nudge or jump forward even with brake pedal fully pressed; Occurs during slow stop-and-go traffic; Happens when stopped at stop signs, lights, school zones
Repairs/costs cited: No repairs mentioned; owner requests resolution of safety issue.
Recalls/TSBs owners mention: No response documented.
Check engine light intermittent illumination
Check engine light comes on and off intermittently with no corresponding fault codes or ability to diagnose root cause.
When: First month to year of ownership in multiple cases
Symptoms owners cite: Check engine light illuminates then goes off after a day or two; No codes present on computer scan; Intermittent illumination with no pattern
Repairs/costs cited: Diagnostic scans reveal no codes; dealers unable to diagnose.
Recalls/TSBs owners mention: No actionable response; dealers state they cannot fix without codes.
Synthesized from 261 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 4 most recent
Loss of power when getting on freeway. Engine chugs, rough idle, no power to merge with traffic on freeway. Check engine light came on. Checked codes and found p0308 and p2099. Changed all 8 spark plugs, plugs 4, 6, 8, 3, 5, and 7 show sings of setting in water. Found out Dodge has two service bulletins to keep this from occurring, sb 18-006-05 rev a and 18-024-06. Do we need crashes on the…
Tl* the contact owns a 2005 Dodge durango. The contact stated that while driving at approximately 5 MPH, the vehicle stalled without warning. The vehicle was able to restart. The contact also stated that there was a ticking noise when driving. The vehicle was taken to a dealer where it was diagnosed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was not…
My car stalls at different times and I lose all ability to steer and has come very close to causing a serious accident. The dealership has never been able to find a problem but it has happened at least 20 times in the last two years and left no codes. The dealership just says no codes no answer. *tr
After coming to a complete stop at a stop sign and allowing children to cross in the crosswalk, my vehicle try's to accelerate/jump forward even though my foot has the brake pedal completely pushed down. The schools in my town get packed with traffic and you have to kinda of stop and go at a slow pace for long periods of time. My 2005 Dodge durango try's to nudge forward on its own when slowly…
Had engine trouble with your 2005 Dodge Durango?
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 Durango?
It's a documented issue but not catastrophic. 261 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 223 complaints that reported odometer mileage, most engine failures cluster between 19,800 and 85,000 miles, with the median around 55,000. A quarter of owners report trouble before 19,800; a quarter make it past 85,000. 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/Durango.
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.