Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety. Notes: The second generation Durango was introduced in 2004 and instantly came under fire for, well, catching on fire.

From 2004-2006 electrical overloading in the driver's side instrument panel caused numerous reports of interior fires. The interior infernos became so commonplace that Chrysler eventually issued a recall.

The problems didn't stop there, however. Owners of the recalled vehicles complained about being treated unfairly and given take-it-or-leave-it low ball settlement offers. "They offered me $2000 under NADA retail as a settlement," said one owner, "and have been rude and hostile to deal with." Nothing says awesome service like treating your customers rudely after their cars have caught on fire.

Have we mentioned all the reports of complete engine failure due to oil sludge?


really awful
Crashes / Fires:
1 / 11
Injuries / Deaths:
1 / 0
Average Mileage:
73,140 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Dodge Durango engine problems

engine problem

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2004 Dodge Durango Owner Comments (Page 2 of 8)

« Read the previous 20 complaints

problem #134

Feb 142012

Durango 4WD 8-cyl

  • 107,000 miles


After returning home from a long distance 4 day weekend, where the vehicle for the most part ran fine. It stalled a couple of times while decelerating (which had happened a few times prior and our local mechanic couldn't locate the problem). There were no warning lights on and the vehicle ran fine. The next day after driving about 6 miles to work (again with no incident), I started the vehicle and drove about 100 yards and it sounded like rocks and rubber were flying all over under the hood (heavy knocking sound). Had it towed to the garage and have been told the oil has turned to sludge and that the motor threw a rod. The repair quote includes putting in a new motor and the cost is $4,000 - $5,000. We do not have the funds and still owe almost $8,000 on the vehicle. This is a crime!

- Chagrin Falls, OH, USA

problem #133

Feb 142012


  • 107,000 miles
The contact owns a 2004 Dodge Durango. The contact stated that while driving 5 mph, there was an abnormal knocking from the engine area. The contact had the vehicle towed to a nearby mechanic where the mechanic diagnosed that a rod had punctured the motor.the dealer was contacted and did not acknowledge the failure. The vehicle was not repaired. The failure and the current mileage was 107,000. The VIN was not available.

- Chagrin Falls , OH, USA

problem #132

Jan 292010

Durango 4WD 8-cyl

  • 76,000 miles
I do not know what happened this feels like this dream. One day my truck is running great and then bam oil every where. One day I started my truck up after about two weeks of letting it sit in the drive way and it had a ticking noise so I immediately turned it off. I called a mechanic he checked it and said it was a sticky lifter.I then called Dodge to get professional advice because my mechanic is not a certified Dodge mechanic. A service adviser at Dodge dealership on rt 112 in medford and he told me that if the problem started while the truck was sitting, to just start the truck and let it run for a while. So I did and maybe five minutes of it being on and ticking I heard a noise and saw oil on the ground. Now what do I do.........I have a hole in the engine block and a fully paid piece of junk. I have records of all my regular oil changes this truck was my baby I took great care of it, I loved it and its dead. I'm not the only one with this truck and this problem when will Dodge own up to its responsibility and recall the 5.7 breaks my heart every morning walking by my 2004 Dodge Durango to start up my old beat up 97 Nissan pathfinder with 246K its sad to say that this rusted old piece of junk gives me no problems with its motor or transmission, but my new truck crapped out at 116,000 cars not are suppose to die after 100K especially heavy duty trucks. I never even got the opportunity to carry a load or tow something. Dodge made it seem like this was something that was suppose to happen because the truck has 100K...that makes no sense to me and I wish I would have done more research on this truck. But right now I just pray that Dodge helps me out with this problem. This is my family vehicle that I invested hard earned cash into and now it is just sitting in my driveway rotting away. Can someone please help?

- Patchogue, NY, USA

problem #131

Dec 242011


  • 122,723 miles


Engine blew with out any sign no noise until it went poof and cloud of blue smoke and rod was through the block. If my husband wouldn't of been with me and my kids would of been in an accident cause I would of thought I just ran over something. It S scary to think we could of all died because of a bad rod that seems to be a problem in these 5.7 engines.

- Watsontown, PA, USA

problem #130

Feb 072010

Durango 4WD 8-cyl

  • 98,564 miles
After having bought the car used from a dealer I worked for checking to see that was one owner and service records were on file with another local dealer. Vehicle had been properly serviced and was continued to be serviced thru a Dodge dealer at 98,564 miles with no warning at all the motor threw a rod thru the side of the block. Replacement was made costing us $7000, none of which Chrysler would take responsibility for. Now 2 years later we are approaching 82000 miles on the 2nd motor again maintinanced properly and I'm experiencing that I can be driving on the interstate or anywhere and it will just die. I have 4 kids this is our main transportation and it is very dangerous as there is no steering or brakes when this happens. Please hold Chrysler accountable for these problems as your sight reflects over 650 complaints for the same things on this particular vehicle!! does someone have to die prior to them being held responsible?!

- New Market, TN, USA

problem #129

Feb 022012


  • 119,000 miles
The contact owns a 2004 Dodge Durango. While driving approximately 35 mph, the contact heard a loud clicking noise outside of the vehicle. The contact maneuvered to the side of the road and stopped. The vehicle was towed to an independent mechanic, who stated that there was a hole in the engine block due to a rod fracture. The vehicle had not been repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 119,000.

- Niceville, FL, USA

problem #128

Dec 172011


  • 104,000 miles


My passenger and I were sitting at a red light. The check engine of my 2004 Dodge Durango limited (5.7ltr) came on, then the battery light came on and both of those lights started to flicker. There was a loud squeal and a pop, then the engine stalled and I felt the brake pedal fall straight to the floor. White smoke started to emerge from the engine compartment, which quickly turned a thick black color. I couldn't even see through the smoke, as it was so dense. I grabbed my phone and proceeded to call roadside assistance to get the vehicle off of the road (the vehicle was blocking a lane of a major highway in my town). I started to smell burning plastic and thought, "am I on fire?". my passenger instructed me to lower my window because another driver was yelling something and making hand gestures. When I tried to use the windows, I noticed that I had lost all power. In a panic I opened the door and instructed my passenger to do the same. That was when we heard what the other drivers were screaming. "get out of the truck, it's on fire!". when I turned to get out of the vehicle, that was when I saw the flames flowing up the windshield about 4" long. We jumped out of the vehicle and ran across the road to the curb, turned to view the vehicle, seen that it was a large fire and decided to run about 200-300 feet away from it. Just in case it exploded. The firemen were there in under a minute, but the vehicle was engulfed in flames in about 30 to 45 seconds. I have a large family and it's a good thing they were not all with me, as is the case 90% of the time. I do not know if I would've had time to get three small children out of their carseats in time. This could've ended much worse than it did.

- Phyiladelphia, PA, USA

problem #127

Jan 012012


  • 120,000 miles
The contact owns a 2004 Dodge Durango. The contact was driving 25 mph when the engine stalled. The contact stated that prior to the failure, the oil warning light illuminated. The vehicle was taken to the dealer where the dealer confirmed that the engine rod failed and needed to be replaced. The vehicle was not repaired. The manufacturer was not contacted. The failure and the current mileages were 120,000.

- Jackson, MI, USA

problem #126

Jan 252012


  • 93,000 miles
I have the same problem as many other Dodge Durango owners are experiencing. Mine is a 2004 Dodge Durango with a 5.7 hemi engine. It was always properly maintained and serviced. One morning we went to turn it on and a loud knocking sound came out of the engine. It was a broken rod. Without any symptoms or any warnings whatsoever, a rod decided to break. Incredible to think that a well maintained engine would break for no reason with less than 100K miles on it.

- San Antonio, TX, USA

problem #125

Jan 212012

Durango 8-cyl

  • 151,960 miles
I've owned my 2004 Dodge Durango 5.7 hemi since 2005. With only 151,960 miles - taking excellent care and pride in it, the #7 rod has been bent. Water has somehow gotten into my motor causing all kinds of issues. Within the past year, it has had issues running hot, running poorly when it rains and rough idle on occasion. After sitting for 24 hours, I went out to crank it and it jumped (I thought a small animal had crawled into my motor) and it shut off. I then re-cranked it and it sounds like a sewing machine. I had to have it towed and am now looking at $4000 for another motor. I've have researched the internet and am totally blown away at the others having the issues with the same exact make and model of vehicle. This is something Chrysler should make right. I am a single mother and live week to week, I can not afford to do this, but I have to. Working full time, caring for a 10 year old and now applying for a part-time job is what this extra expense is causing me to do. I think someone should do something - if I win the lottery, you best believe I will. Chrysler do the right thing....this is happening too much and is a defect - no doubt. Toyota did a recall - maybe if I'm ever to buy another vehicle, atleast they would make it right. *kicks soapbox*.

- Lyman, SC, USA

problem #124

Jan 162012

Durango 4WD 8-cyl

  • 90,900 miles


We purchased our car new in May 04. We have had no major issues with the vehicle. Last week I got in the car and tried to start it and it made this loud noise like rocks or marbles in the engine. Then it would not turn over. After a few attempts to start, the engine started but has a very loud knocking noise. The car ran fine 2 days before the failure. We had it towed to a Dodge dealership and they said the camshaft and pistons need to be replaced. But haven't really torn the engine apart to diagnose everything. Total cost to rebuild the bottom half only is $5,000. The service guy told me it was one of the cleanest engines he has seen too. I told them that was too much and they went down to $4,100. But we found another licensed shop to rebuild for less. The shop doing the work has 3 other Durangos at his shop with the same problem. This engine should have lasted a lot longer than 90,900 miles. I checked and lots of people have complained about this same issue. The dealership said that they sold over a million and a half of these vehicles and this is a fluke that it happened to a few of them.

- Argyle, TX, USA

problem #123

Nov 082011

Durango 8-cyl

  • 113,000 miles
I was traveling about 15 mph in my 2004 Dodge Durango with the 5.7 hemi. The check engine light came on and before I could pull over the engine blew. It knocked a whole in the side of the engine and immeadiately stopped. The engine had 113,000 miles on it and maintenanced reguarly. I have read in several forums with several people with the exact same issue. I called Dodge and they informed me that there was nothing they can do. This is an absolute outrage, I am military and living on a fixed budget as it is and can't afford the price of another engine. With all the issues that the 2004 hemi's are having, there has to be an issue with this particular engine. When it would rain my vehicle would stall, so I am not sure if that has anything to do with the engine failing. Several people have had the exact same issue as that as well.

- Van Alstyne, TX, USA

problem #122

Jan 032012


  • 65,000 miles
Went to start the Durango when cold herd a loud knocking noise. I shut the Durango off and checked under the hood to see if anythig was stuck under the car. I had the car towed to a service station and they informed me the engine was no good and needed to be replaced. The car has only 65000 miles on it and the powertrain warentee is out on 8/30/11. I can not pay 6000 dollars for a rebuilt motor at this time and need a car to get back and forth to work.

- Wilmington, MA, USA

problem #121

Jan 072012


  • 122,000 miles
Slowing for a stop sign at about 15 mph rod broke and went through block. Complete engine failure. At 120,000 miles this is ridiculous. No noise or any warning, always changed oil. Daughter has Honda with 200K on it and still runs great. What is with Chrysler"? remember the old Fiat== fix it again [xxx]?? if Dodge thinks they will sell me another car I don't think so!! and now the dealer is trying to put me in a new one! will give me a song for mine. It's broke. And finding a motor is not fun either. Seems the junk yards can't keep them. Sell as soon as they get them. It's to bad they won't do anything about this. How many complaints for the same problem before the government says enough is enough?" looking to put a lot of money in to this car and then I;M dumping it. Probably a Nissan or a Toyota. Sorry America I don't have any more money to throw in to America metal. Information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Antioch, IL, USA

problem #120

Jan 112012


  • 102,890 miles
Started car in the morning and a loud knocking started.

- Port Jefferson Station, NY, USA

problem #119

Dec 242011


  • 122,723 miles
The 5.7 Dodge Durango motor is a ticking time bomb they run smoothly then with out any warning blow up. I only had 122723 miles on it when it blew it ran great till the road came out through the block. What is it going to take for you to make Chrysler make a recall on this some one to get killed while driving down the high way cause I'm glad I was with my wife or that case could of been sooner than U expected. Chrysler needs to be held reliable for there huge engine mistake in this middle year before they kill some one going from 65 - 0 on the high way is totally un safe come on government step up to the plate if this was so back yard company you would of shut them down by now do what's right and force them to have a recall before some one gets hurt bad or dies. Kids ride in these vehicles if we would do something like cover up a problem we would be persecuted for criminal neglect and endangering the welfare of a child. And that's exactly what Chrysler motor Corp is doing endangering the welfare of our children and family's so step up ad force the to fix the problem.

- Watsontown, PA, USA

problem #118

Jan 012012

Durango 4WD 8-cyl

  • Automatic transmission
  • 75,874 miles
The contact owns a 2004 Dodge Durango limited. The contact was driving 35 mph when the vehicle decreased in speed. The vehicle was taken to a private mechanic where the mechanic confirmed that a connecting rod had detached and punctured a hole in the engine block. The engine would need to be replaced. The manufacturer was made aware of the failure. The failure and the current mileage was 75,874. Updated 01/18/13

- Waltham, MA, USA

problem #117

Dec 282011

Durango 4WD 8-cyl

  • 119,000 miles
My well maintained garage kept 2004 5.7L Durango with 119,000 miles with absolutely no warning failed to start one morning after sitting for about 3 days. It made a loud noise. I had it towed to the dealer and was told that it had seized and I would need a new engine. The cost would be $7200. The only problem I had previously was that it would stall during extreme rain storms but it occurred infrequently and only under extreme conditions. The dealer had supposedly fixed the problem with this a few months earlier. I bought this vehicle brand new in 2004 and had always maintained it exactly as recommended.

- Graham, NC, USA

problem #116

Oct 112011


  • 93,000 miles
At 93000 miles wheel indicator light stays on replaced tire at normal time to change, but light does not go out. Also having other inside problems, engine is making bad noises, wipers don't work half the time, air conditioner not blowing cool air even having it filled with freeon, center panel over heats. Air bag light come on and off while driving with no one else in truck.

- Elmore, AL, USA

problem #115

Dec 232011


  • 84,116 miles
Started my vehicle and heard a horrible grinding metal sound. Towed it to a mechanic who said that a rod had blown a two inch hole in my engine block. There were pieces of metal in a pile of oil under my vehicle when it was towed and 2 large chunks found upon inspection of vehicle. There was no warning. No problems prior. Vehicle ran fine the day before. No lights ever came on the dash either, no check engine...etc. Upon researching this issue- I have found numerous similar stories. Hoping a class action suit will be investigated.

- Sicklerville, NJ, USA

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