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2nd Generation Dodge Non-Powertrain

Discussion of the 1994 to 2002 2nd Generation Dodge Ram Trucks with 5.9L Cummins Turbo Diesel non-power train. This includes interior, air conditioning, heating, lighting, body, suspension, brakes, stereos, etc.

  1. Started by Marcus2000monster,

    Hi all!! My headlights are extremely dim in high and lows! If I didn’t have a light bar I would have already been in the ditch probably! Lol not quite that bad but they are definitely abnormally dim! What should I check test etc ? Thanks

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  2. Started by Rotket,

    Its me again. Ive been restoring the front of the truck so I've run into a lot of questions My current problem (besides my headlights) is that my front bumper is sagging. I bought all new plastics and chrome bumper besides the brackets. My old bumper lined up fine, besides being a rusted mess. The passenger side of my new bumper sags and also it seems my bumper isn't seating all of the way back and not lining up with the fender. Any tips for this?

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  3. Started by ISX,

    ..I will fix the fuel leak in the o-ring of the tank. I power washed it but I couldn't even see what I was doing because it's dark so tomorrow I will get you all the end result. But here are some before pics. If anyone has some pic requests while I am under there let me know.. Probably have the bed off all day tomorrow.

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  4. So after I was T boned Christmas eve and my drivers door pushed in. I finally got my replacement door on after doing the inner and outer rocker and some rust repair. Now my door won't latch tight. I adjusted the striker as far in as it will go, I even changed the latch assembly. But I can not get the door to latch tightly, it just rattles because it acts like the latch is only tripped part way. I'm at my wits end. I've been without my main truck since Christmas because the person who hit me didn't have insurance and my carrier drug their feet getting an adjuster out....

  5. Started by 015point9,

    Being "new" here and reading the multitude of elec problems...any advice on battery jumping?

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  6. I bought my '99 Dodge diesel Ram 2500 new in October '99 and now have about 212,000 miles. The power steering has always been fine but lately has faded out while trying to park or making rapid turns in opposite directions. It doesn't seem to do this when the engine and power steering system is cold. I drive 30 miles to work and it will sometimes do it while parking at the office. At times it only acts up for a moment but at other times the steering stays difficult until the truck is parked and the engine turned off. During all of this the power brakes seem to be OK. The power steering fluid got low a couple of months ago but I simply refilled the pump. A leak was never fo…

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  7. Started by Prowelder,

    Hey gang, Okay a friend of mine just installed a set of used GS gauges I got in on a trade. He has the wires all hooked up and such, grounded to the battery and all. Well his fuel pressure gauge isn't working quite right. When he turns the key on, the other gauges sweep over and back down to zero. Well the FP sweeps up to 30 psi and stays there. Then when he starts the truck it drops to about 26ish psi, then once the truck starts, it goes up to about 33 psi which is the end of the gauge. My question is this: This there a way to test the sensor without just replacing it?? Fuel pressure doesn't drop with heavy throttle either and the truck doesn't appear to have any after…

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  8. Started by JAG1,

    How did you guys deal with the loss of gloss from the weather? Anyone do something creative about this problem?

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  9. Started by wil440,

    I have just finally resealed the Hydroboost on my truck only had the seal kit for most of this year, MOT (our yearly check) is overdue so as it was leaking and that would be a fail I decided nows the time. The reseal went ok, had to cut the rod as it's a staked item, I was going to make a threaded joiner on my lathe but decided against that as the inner bore of the input seals are tiny compared to the rod they have to be fitted over to get to their grooves and didn't want sharp threads incase I had to ever reaseal again, anyway thats all done and rod welded back together. Question is has anyone got a picture of the accumulator looking right in it, speci…

  10. Started by stevens cummins,

    Well guys my keeping a eye on the nv5600 didn't work it failed after only 10k, so my question is what are s one of the common mistakes company's make rebuilding these I'm just sorta curious what they could of screwed up

  11. Started by Glenn Perry,

    Steering Gear bottom domed cover seems to have cracked and leaks fluid. Truck is 175kms steering gear showed very little wear any reason why this might have happened. Can I get another cover and just replace it or are they matched? Thanks

  12. Started by dieselautopower,

    New High Idle Switch has been developed. Thank you Mopar1973Man for your help in this project. If you order one from DAP please put Mopar1973Man in the highlighted field and DAP will credit/donate funds Mopar1973Man to help with his cancer treatments and other miscellaneous costs. https://www.dieselautopower.com/quadzilla-power-high-idle-switch.html Product description Quadzilla Power High Idle Switch Faster warm up Improved Economy in cold weather Reduce cylinder wash during extended idling The Quadzilla Power High Idle Switch will manually engage the 24 valve Cummins Hig…

  13. Started by woodtrucker,

    After my new paint job is complete, sometime early spring, I'm going to move on to the dash replacement. I've decided I am going to replace dash versus a dash cover glued on. Since I am going that route, the heater core will be accessible. Should I go ahead and replace it too even if it's not leaking? Wasn't sure how widespread the leaky heater core problem is. I have 108k miles.

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  14. Started by Heavyd1980,

    Ok guys so far I have seen truck after truck (12v) get better mileage than a 24v so what else is there to consider when looking to buy a cummins powered truck??? Lets see what everyones opinion is on this subject since I could have used some of this info when I was looking. Thanks.

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  15. Started by rotohead,

    I've been fighting a abs/brake light issue for awhile now. When I first start the truck all is fine until I drive for about 5 miles or so, apply the brakes and both lights come on. I can clear the lights by restarting the truck and drive another 5-6 miles and the same thing. First brake press the pedal seems to travel slightly further then the second or third, etc. Here's what I've done to try to fix it. Replaced the rear diff sensor, replaced brake master cylinder (twice), replaced combination/differential valve, replaced the brake switch under the dash, had the abs module repaired by shop in Austin, TX. I've bench bled the BMC's four or five times now, also rigged up lo…

  16. Started by scummins,

    Does anyone know where the Joint Connector No. 3 is located on the truck? It has a few wires going to it including 4wd, horn and a few others. I am trying to trace a wiring problem with my 4wd and need to be able to follow the wire to this connection.

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  17. Started by joecool911,

    Since a water pump failure the pad/insulator got soaked and sagged. Pulled away from the buttons or tabs. Anyone experience replacing it? Looks like I can get a new one for about $80. Wondering about larger tabs to keep it up better. Sent from my iPhone using Tapatalk - now Free

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  18. Started by Dave3500,

    Well my Volt gauge is saying that I'm no longer getting 14 volts. Took it to an auto parts store to get a diagnosis &said it was the alternator. So I went to the good folks at Geno's Garage to hook me up with an alternator rebuild kit for my Denso. shipped to my door was a little over 40 bucks, as opposed to 150 or more. Should be here any day.Never rebuilt one, I'll let you know how it turns out. I'll pass on a piece of advice that one guy that checked my charging system offered, was to charge the batteries one at a time not in series. Just take off the negative cables. Don't want to replace these babies, one is 800 cold cranking amps & the other is 1,000 I slow …

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  19. Started by Exalted85,

    So I'm dealing with a new issue. The truck is having some hesitation starting..and for some reason the alternator isn't kicking in for about a minute. Sometimes the voltage will drop off even after the alt has kicked in. I did the w-t mod..but I haven't put a new line from the pdc to the passenger side battery..I know this isn't supposed to be necessary, but could it affect anything like what I'm describing? This issue didn't pop up after the mod..It's been about a month. The only other thing that I can think of..is my gf used my truck to jump her car a couple times in the morning..I've never jumped anything before, and I wasn't present when she …

  20. Started by portlandareae28,

    Alright, I guess if I am going to spend some time on the truck this weekend maybe I should open this can of worms.. None of the courtesy lights in the truck work. When I acquired the truck the previous owner said they were all fine until Best Buy put in the stereo. Something they did screwed up the lights. Is this something anyone has heard of, or has an idea of where to start? Thank You

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