1991 Dodge W350

1991 Dodge W350

The 1991 Dodge W350 is a heavy-duty pickup truck that offers a variety of engine and transmission options. The 5.9L V8 engine is the most popular choice, paired with a 4-speed automatic or 5-speed manual transmission. Other engine options include the 7.4L V8 and the Cummins 5.9L inline-6 diesel engine.

People like the Dodge W350 for its powerful engines, towing capacity, and rugged construction. However, the truck is also known for having several common issues.

Engine

5.9L V8

• Intake manifold gasket failure
  • Description/Symptoms: Coolant or oil leak from the intake manifold, loss of coolant, overheating
  • Solution: Replace the intake manifold gasket
  • Estimated Cost to Fix: $500 - $1,000
• Cracked cylinder heads
  • Description/Symptoms: Coolant leak from the cylinder heads, overheating, loss of power
  • Solution: Replace the cylinder heads
  • Estimated Cost to Fix: $2,000 - $3,000
• Valve train noise
  • Description/Symptoms: Noisy lifters or rocker arms
  • Solution: Adjust or replace the valve train components
  • Estimated Cost to Fix: $500 - $1,000

7.4L V8

• No major issues found

Cummins 5.9L Inline-6 Diesel

• Turbocharger failure
  • Description/Symptoms: Loss of power, black smoke from the exhaust
  • Solution: Replace the turbocharger
  • Estimated Cost to Fix: $1,500 - $2,500
• Fuel injector failure
  • Description/Symptoms: Hard starting, rough idle, loss of power
  • Solution: Replace the fuel injectors
  • Estimated Cost to Fix: $500 - $1,000

Transmission

4-Speed Automatic

• Slipping gears
  • Description/Symptoms: Transmission slips out of gear, especially under load
  • Solution: Overhaul or replace the transmission
  • Estimated Cost to Fix: $2,000 - $3,000

5-Speed Manual

• Grinding gears
  • Description/Symptoms: Gears grind when shifting, especially when cold
  • Solution: Replace the synchronizers or transmission gears
  • Estimated Cost to Fix: $500 - $1,000

Suspension

• Leaf spring failure
  • Description/Symptoms: Broken or sagging leaf springs, rough ride
  • Solution: Replace the leaf springs
  • Estimated Cost to Fix: $500 - $1,000

Electrical

• Alternator failure
  • Description/Symptoms: Battery not charging, dim lights
  • Solution: Replace the alternator
  • Estimated Cost to Fix: $500 - $1,000
• Starter failure
  • Description/Symptoms: Engine won’t start, clicking sound when turning the key
  • Solution: Replace the starter
  • Estimated Cost to Fix: $300 - $500

Exterior

• Rust
  • Description/Symptoms: Rust spots on the body, especially around the wheel wells
  • Solution: Repair the rust or replace the affected panels
  • Estimated Cost to Fix: $500 - $2,000+

Interior

• Dashboard cracking
  • Description/Symptoms: Cracks in the dashboard
  • Solution: Replace or repair the dashboard
  • Estimated Cost to Fix: $200 - $500
• Air conditioning failure
  • Description/Symptoms: AC not blowing cold air
  • Solution: Diagnose and repair the AC system
  • Estimated Cost to Fix: $500 - $1,000+

Summary

The 1991 Dodge W350 is a capable heavy-duty pickup truck with powerful engines and a rugged construction. However, it is also known for having several common issues, including intake manifold gasket failure, cylinder head cracking, and turbocharger failure. These issues can be expensive to repair, so it is important to be aware of them before purchasing a used W350.