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 ↗2005 Dodge Magnum engine problems
moderate 75 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
75
Recalls
0
Avg fix
$3,100
1injury
When does it fail?
Of the 75 engine complaints filed for the 2005 Dodge Magnum, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Of the 4 model years of Dodge Magnum we track for engine problems, this one carries the most owner complaints on file — 75.
Owners have filed 75 engine complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
Valve Body. These may cause over drive cycling.
full bulletin at NHTSA ↗NAG1 (5A580) Valve Body As per Warranty Bulletin D-13-22, please use R2108213A$ 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 ↗Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications. An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine.
full bulletin at NHTSA ↗Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications. An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2005 Dodge Magnum experiences widespread engine failures that Dodge service managers dismiss as extremely rare, yet owners report finding hundreds of cases online. The most consistent catastrophic failure is dropped valve seats in HEMI engines—valve seats separate from the cylinder head with absolutely no prior symptoms (no overheating, smoke, oil burning, or rough running), then the engine simply won't start. Owners take their cars to lube shops, start them up, and hear the diagnosis: engine dead, replacement needed, $4,000 to $6,000 out of pocket, and most vehicles are already past warranty. Newer HEMI models reportedly use pressed and pinned valve seats instead, which Dodge fixed the design but never recalled the 2005–2007 models.
A second widespread failure pattern is stalling after refueling, which owners link to a faulty rollover valve in the fuel tank. The engine stalls multiple times after a full tank, sometimes on the highway, sometimes in traffic, with total loss of steering and braking—a serious safety hazard. Some owners limit themselves to half-tank fills to avoid it. Fuel tank replacement runs around $2,000.
Low-speed stalling without a fuel-related cause also crops up across multiple complaints: engine dies at traffic lights, during turns, in parking garages, intermittently and without pattern. Dealerships cannot duplicate the problem. The 3.5L engine produces loud valve cover noise at startup, and one owner's research suggests a sheared dowel pin on the rocker arm shaft causes oil starvation to the top end. Water ingestion through weak engine bay sealing and cracked intake manifolds round out the engine complaints. Throughout the narratives, owners note they perform all scheduled maintenance, yet catastrophic failures arrive with zero warning.
Same Dodge Magnum engine reports on nearby years: 2006 · 2007 · 2008
Failure modes owners describe
Dropped valve seat (HEMI engines)
Valve seat separates or drops from cylinder head, causing sudden engine failure with catastrophic loss of compression. Owners report no warning signs—no overheating, smoke, oil burning, or rough running before failure. Engine becomes non-functional and requires complete replacement. Occurs typically after 100,000+ miles but some fail earlier.
When: After 100,000 miles typically; narratives show range from 4,000 to 137,000 miles; most failures out of warranty
Symptoms owners cite: Engine will not start; Loud knocking or banging noise on startup attempt; Complete loss of power; Check engine light (some reports)
Codes mentioned: P0300 (multiple misfires mentioned in some complaints)
Repairs/costs cited: Engine replacement required, typically $4,000–$6,000+ per owners. Some dealers cite engine backorder through Chrysler.
Recalls/TSBs owners mention: Dodge claims issue is 'really, really, really rare' (1 in a billion per service managers). Newer HEMI models (post-2007) use pressed and pinned valve seats instead of glued design. No recall issued for 2005–2007 HEMI models.
Fuel tank rollover valve malfunction causing stalling
Vehicle stalls intermittently after refueling, related to suspected rollover valve failure in fuel tank. Stalling occurs at various speeds, most commonly immediately after filling tank or when tank is full. Loss of power steering and braking accompanies stalls, creating significant safety hazard. Some owners manage by keeping tank only half-full.
When: Typically occurs within minutes to hours of refueling; first occurrence can be within 3 months of purchase
Symptoms owners cite: Engine stalls after refueling; Stalls during acceleration or turns; Stalls on highway at speed; Loss of power steering; Loss of braking assist; No check engine light illumination (most cases); Hard restart or multiple restart cycles needed; Jerking or sputtering before stall
Repairs/costs cited: Fuel tank replacement cited as fix; cost approximately $2,000+ per owners. One owner reports fuel pump replacement with lifetime warranty did not resolve issue. Another reports siphoning 5 gallons temporarily stopped symptom.
Recalls/TSBs owners mention: NHTSA investigation noted; some VINs covered under undisclosed recall/TSB, others not. Fuel pump replacement offered as alternative with lifetime warranty (one case). Dodge service unable to duplicate problem when no check engine code present.
Engine stalling at low speed (non-fuel tank related)
Engine stalls while driving at low speeds—during turns, at stoplights, entering intersections, in parking garages—with no apparent pattern. Vehicle often restarts easily on first try. Occurs intermittently over months or years. Loss of power steering and brakes during stall creates hazard.
When: First occurrence noted within 3 months to several years of ownership; affects vehicles from early miles to 130,000+
Symptoms owners cite: Stalls at low speed or while turning; Stalls at traffic lights; Stalls while accelerating from stop; No warning light; Easy restart; Loss of power steering and brakes during event; Intermittent, not reproducible in dealership
Repairs/costs cited: Multiple dealers unable to diagnose. Computer reprogramming attempted (unsuccessful in some cases). PCM replacement tried without resolution. One owner reports extensive dealership visits (8–10 times in 6 months) without diagnosis. No effective repair identified in narratives.
Recalls/TSBs owners mention: Dealership unable to duplicate customer's concern (standard response). Computer software update installed in one case (related to Pacifica found to have same issue). No recall identified.
3.5L engine rocker arm/valve train noise and wear
High-pitched valve cover and rocker arm noise at startup. Owner reports bracket-mounted rocker arm shaft with steel dowel pin shears, causing shaft rotation and misalignment. Results in improper oil delivery to rocker arms, excessive wear, and potential top-end failure.
When: 45,000 miles reported; issue described as progressive
Symptoms owners cite: High-pitched noise from valve cover area on cold start; Loud rocker arm noise
Repairs/costs cited: $345 per side in parts, approximately $1,500 total labor and parts per owner estimate. Dealer considered this 'typical' for 3.5L engine and not covered.
Recalls/TSBs owners mention: Dodge service acknowledged as 'typical 3.5L motor' issue; offered discounted labor on customer-purchased parts. No recall or TSB actively offered.
Cracked intake manifold
Intake manifold develops crack, causing loud banging and knocking noise from engine. Engine may stall and lose power. Typically discovered during diagnostic after stalling incidents.
When: 58,000 miles reported
Symptoms owners cite: Loud banging and knocking noise; Engine stalling; Loss of power; Illuminated check engine light
Repairs/costs cited: Extended warranty dispute; unclear if covered or final repair status. Intakes manifold replacement required.
Recalls/TSBs owners mention: Extended warranty coverage disputed—first denied, then approved (conflicting information in narrative).
Timing chain or internal engine failure (no prior warning)
Engine suddenly fails during startup attempt with no prior symptoms. Diagnosis suggests timing chain failure or internal engine damage. No warning signs before complete loss of function.
When: Failure on startup; vehicle was recently serviced; 137,000 miles noted in one case
Symptoms owners cite: Engine will not start; Loud banging noise on startup attempt or shortly after startup
Repairs/costs cited: Engine replacement required; costs approximately $6,000 per owner, sometimes exceeding vehicle value.
Recalls/TSBs owners mention: Recalls noted for 'newer version of HEMI' but owner suspects applies to 2005 model. No specific manufacturer response documented.
Engine overheating without warning and stalling
Engine overheats suddenly with no prior warning signs, causing vehicle to stall at highway speed. Cooling module diagnosed as failure point. Loss of steering control and braking.
When: 98,500 miles
Symptoms owners cite: Sudden overheating; Engine stall at speed; No warning before stall
Repairs/costs cited: Engine replacement required; cooling module identified as root cause.
Recalls/TSBs owners mention: None documented; manufacturer not contacted by owner.
Radiator hose detachment and coolant loss (hydro-lock)
Upper radiator hose comes completely off without warning, dumping coolant. Vehicle briefly drivable but engine seizes from coolant loss. No prior symptoms, warning lights, or diagnostic codes.
When: 63,000 miles on well-maintained vehicle
Symptoms owners cite: Radiator hose failure; Coolant loss (no visible leak or smell initially); Engine seizure
Repairs/costs cited: Engine replacement required due to seizure from coolant loss.
Recalls/TSBs owners mention: No TSB or recall notification received by owner. Possible cooling system TSB referenced but not confirmed.
Engine hydro-lock from water ingestion (heavy rain)
Water enters engine through underbody after driving through large puddle in publicly maintained road. Engine hydro-locks and seizes.
When: 3,800 miles (very early in ownership); December, after driving through puddle
Symptoms owners cite: Engine stops after water ingestion; Engine unable to restart
Repairs/costs cited: Engine replacement required. Insurance covered damages; took weeks for engine build and shipment.
Recalls/TSBs owners mention: Dodge expert determined not covered under warranty; insurance claim required. Unclear if design flaw in engine bay ventilation or intake location.
Check oil light triggering engine shutdown with brake/steering loss
Check oil warning illuminates, engine shuts off without warning, causing loss of power steering and braking. Occurs randomly during light acceleration. Dangerous in traffic.
When: Occurs randomly during driving; multiple incidents in short timeframe (3 times in 5 minutes reported)
Symptoms owners cite: Check oil light illuminates; Engine shuts down suddenly; Loss of power steering; Loss of braking assist; Occurs on light acceleration
Repairs/costs cited: No repair information provided by owner.
Recalls/TSBs owners mention: None documented.
Multiple misfires and rough idle with incomplete repairs
Engine runs rough with hesitation and fast idle. Check engine light illuminates with misfire codes. Multiple repair attempts (fuel injectors, spark plugs, ignition coils replaced) fail to resolve issue.
When: Ongoing after multiple repair attempts
Symptoms owners cite: Rough idle; Hesitation during acceleration; Check engine light; Multiple misfire codes
Codes mentioned: P0300 (multiple cylinder misfire)
Repairs/costs cited: Fuel injectors replaced (2), spark plugs replaced, ignition coils replaced (3)—problem persisted across visits to two dealerships and independent mechanic.
Recalls/TSBs owners mention: None documented.
Wiring harness melting (interior temperature controls)
Wiring harness related to interior temperature controls repeatedly melts, catching fire risk. Issue recurs within 5 miles of each repair attempt across four service visits.
When: Multiple repair cycles; issue reoccurs within 5 miles each time
Symptoms owners cite: Wiring harness melts; Fire hazard; Harsh/premature transmission shifting (possibly related); Airbag failure warning lights
Repairs/costs cited: Wiring harness replaced multiple times; defect recurs. Fourth service appointment pending.
Recalls/TSBs owners mention: None documented; owner expresses fear of fire in vehicle.
Water contamination of transmission (cooling circuit failure)
Water enters transmission fluid through faulty cooling line routing from radiator, mixing transmission fluid with coolant. Transmission requires replacement and complete system flush.
When: Unknown mileage; vehicle stopped while driving
Symptoms owners cite: Vehicle stalls and will not move; Transmission fluid contaminated with water
Repairs/costs cited: Transmission replacement and system flush required.
Recalls/TSBs owners mention: None documented; owner also reports headlight failure (intermittent on/off while driving).
2.7L engine failure (seized)
Engine suddenly seizes, becoming completely non-functional. No prior symptoms despite scheduled maintenance. Complete engine failure.
When: 10,000 miles; vehicle driven normally then shut off and would not restart 5 years later
Symptoms owners cite: Engine locks/seizes; Unable to restart
Repairs/costs cited: Engine replacement cost approximately $6,000, exceeding vehicle value.
Recalls/TSBs owners mention: Owner alleges Chrysler/Dodge aware of 2.7L engine defect but continues sales without addressing. No official recall or assistance offered.
Synthesized from 75 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
Car stalls going around corners. 10th incident happened today. All within past year.
When the gas tank is filled, the motor cuts out and stalls when driving, I have to keep the tank at half way to avoid this. My wife filled it up and it stalled on her while she was making a left hand turn in traffic. My child was in the car as well. It appears that this organization as well as Chrysler was aware of this situation. I never received any notification and have been dealing with it…
Car stalls sometimes when at complete stop,or at red lites.put it in park and starts back up as if nothing was wrong.
Had engine trouble with your 2005 Dodge Magnum?
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 Magnum?
It's a documented issue but not catastrophic. 75 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 70 complaints that reported odometer mileage, most engine failures cluster between 51,250 and 110,000 miles, with the median around 79,000. A quarter of owners report trouble before 51,250; a quarter make it past 110,000. 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/Magnum.
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.