1996 Dodge B3500

Introduction

The 1996 Dodge B3500 is a full-size van available with two engine options: a 5.2L V8 and a 5.9L V8. Transmission options include a 4-speed automatic and a 5-speed manual. Despite its popularity for its spacious interior and powerful engine, the B3500 has been plagued by several issues over the years.

Engine

5.2L V8

• Intake Manifold Gasket Failure
  • Description/Symptoms: Coolant or oil leaking from the intake manifold, overheating, rough idling
  • Solution: Replace intake manifold gasket
  • Estimated Cost to Fix: $500 - $1000+
  • Recalls: None Found
• Valve Cover Gasket Leakage
  • Description/Symptoms: Oil leaking from the valve covers
  • Solution: Replace valve cover gaskets
  • Estimated Cost to Fix: $200 - $400+
• Timing Chain Failure
  • Description/Symptoms: Engine rattling, loss of power, no start
  • Solution: Replace timing chain and related components
  • Estimated Cost to Fix: $1500 - $3000+

5.9L V8

• Intake Manifold Gasket Failure
  • Description/Symptoms: Coolant or oil leaking from the intake manifold, overheating, rough idling
  • Solution: Replace intake manifold gasket
  • Estimated Cost to Fix: $500 - $1000+
  • Recalls: None Found
• Cylinder Head Cracking
  • Description/Symptoms: Coolant leaking from the cylinder heads, overheating, loss of power
  • Solution: Replace cylinder heads
  • Estimated Cost to Fix: $2000 - $4000+
  • Recalls: None Found
• Connecting Rod Bearing Failure
  • Description/Symptoms: Knocking or tapping noise from the engine, loss of oil pressure, engine failure
  • Solution: Replace connecting rods and bearings
  • Estimated Cost to Fix: $3000 - $5000+

Transmission

4-Speed Automatic

• Delayed Engagement and Shifting Problems
  • Description/Symptoms: Transmission slipping, delayed engagement of gears
  • Solution: Replace or rebuild transmission
  • Estimated Cost to Fix: $1000 - $2500+
  • Recalls: None Found

5-Speed Manual

• Grinding Gears
  • Description/Symptoms: Difficulty shifting gears, grinding noise
  • Solution: Replace or rebuild transmission
  • Estimated Cost to Fix: $1000 - $2500+
  • Recalls: None Found

Suspension

• Front Suspension Wear
  • Description/Symptoms: Excessive bounce, vibration, suspension noise
  • Solution: Replace worn suspension components (e.g., ball joints, bushings, shock absorbers)
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Rear Leaf Spring Failure
  • Description/Symptoms: Sagging rear end, rough ride
  • Solution: Replace leaf springs
  • Estimated Cost to Fix: $500 - $1000+
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Dead battery, flickering lights, no power
  • Solution: Replace alternator
  • Estimated Cost to Fix: $500 - $800+
  • Recalls: None Found
• Starter Motor Failure
  • Description/Symptoms: Engine won’t start, clicking sound
  • Solution: Replace starter motor
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found
• Battery Drain
  • Description/Symptoms: Battery going dead overnight, electrical components not working
  • Solution: Diagnose and repair faulty electrical components or replace battery
  • Estimated Cost to Fix: $100 - $500+

Exterior

• Rust
  • Description/Symptoms: Corrosion on the body, frame, or undercarriage
  • Solution: Repair or prevent rust using anti-rust treatment
  • Estimated Cost to Fix: $500 - $2000+

Interior

• HVAC System Failure
  • Description/Symptoms: No heat or cold air, blower motor not working
  • Solution: Diagnose and repair faulty HVAC components
  • Estimated Cost to Fix: $100 - $1000+
• Door Lock Failure
  • Description/Symptoms: Doors not locking or unlocking, key not turning
  • Solution: Replace door lock actuators or mechanisms
  • Estimated Cost to Fix: $100 - $500+

Summary

The 1996 Dodge B3500 has a wide range of issues affecting its engine, transmission, suspension, electrical, and interior systems. While some issues are minor and inexpensive to repair, others can be severe and costly. Potential buyers should be aware of these issues before purchasing a used B3500 and factor in the potential repair expenses.