Manifold/header/muffler/tail Pipe problems of the 2004 Dodge Durango

The problem happens to every hemi vehicle. As it age. Exhaust manifold will start to leak. Making a ticking sound.

Went to go start Durango & heard a loud boom, & now it seems to be knocking & not drivable now, after do research online we cam across that on these models (2004 Dodge Durango 5. 7 hemi magnums) it seems too leak water into where the engine is due to hood manifold is designed horribly & water leaks on wires, spark, plugs, engine etc. Etc. We've noticed when we drove in the rain or even going through a carwash that the Durango would sputter as if it was going to die & it has a couple times & took about 15 mins to start again, after this event has happened we thank god that it happened at home & not on the interstate around other vehicles because this is a serious safely issue that needs to be addressed & now we are out of a vehicle at the moment and we are still currently making payments on this vehicle for another year and a half at-least.

Bought the car used in 2014. Always had misfire/rough running problems in heavy rain or a car wash. In may 2019, driving in the rain, the engine failed catastrophically. Research on line and my own repairs discovered a flaw in the first generation cowl grill. It allowed water to flood the top of the engine. A leak in the intake manifold gaskets allowed the water to enter the engine, causing it to hydrolock. It broke a connecting rod. It did however still run, but was very noisy. The intake leak was not noticed in any other conditions, nor was the check engine lamp on prior to this event. The engine did not use oil or make any other noises prior to this event. It has about 175000 miles.

The windshield wiper cowl became defective and let water into the engine compartment, specifically the fuel intake manifold. After about 5 years of random water related stalls (rain,dew,car washes) which could never be replicated by numerous mechanics and therefore not properly diagnosed, water eventually found its way into a piston chamber. While on the freeway in san francisco on March 31,2017, hydrolock ensued and caused the number four piston rod to snap and break through the engine block destroying the engine. I was at the Dodge dealership in colma a few weeks prior for an unrelated airbag recall fix and spoke to the a service supervisor about the water related stalling issue. He basically told me to go somewhere else because they only use oe parts and even if they could figure out the problem (no guarantee), they probably couldn't get original parts. He acted like he was doing me a favor! I feel as the Dodge and the dealership is negligent. I have found out subsequently that this issue is widely know amongst parts suppliers (specifically used and rebuilt engine suppliers) and has a high rate of incidence according to various internet forums. I have lodged a formal notice/complaint with Dodge as have many, many others. I got three quotes for replacing the engine, all were over $6000. The vehicle proved to not be wiorth that cost to fix. I have subsequently donated it to a local charity. This problem definitely deserves a recall, and customers such as myself who have incurred financial losses should be compensated. Thanks.

Gas and body issues: when you go to fill up the gas sprays out. I have a vert strong smell of gas and the lower finder by the wheel well has rusted badly. Motor: whenever there is heavy rain, my car will stop running. Most recently when I turn on the ac or heater the car stalls. I also just recently had to change out a manifold which caused another set of problems. I owned a Durango before this one and loved it. This one has changed my mind and I will never own another.

It was a rainy day on Friday oct. 2, 2015. That morning my vehicle started fine, it wasn't until I came out of work that evening when I went to start it the engine made a loud sound and it wouldn't start. I tried a few times until suddenly it turned on and it was making a knocking noise. I then called my mechanic and explained the situation and he told me to bring it to the shop so they can put it on a lift to take a look underneath. As I drove away the sound was unbearable and the faster I drove the louder it got, suddenly I heard a loud explosion and the vehicle stopped. It felt like the engine fell out, there was a lot of smoke and oil everywhere. I got the vehicle towed to the my mechanics shop for further diagnosing when they told me the engine blew out. The next day I got a call after they took the engine apart and told me the block had a hole because the piston blew through it. They told me it would cost more money to rebuild my original engine than buying a used one, I opted out on the used one. As I was home I went online and did some research when I come to find out that many people had the same problem happen to them with the same vehicle on a rainy day or when they took their car through a car wash. So as I did more research it turns out the wiper cowl which at some point Chrysler came out with an upgrade tends to leak water on top of the intake manifold which is another bad design, then sucks in water into the engine eventually causing it to hydro lock. I bought my vehicle brand new in 2004 and now I'm disappointed they never issued a recall to fix this problem. I just paid over $4000 to repair it and god knows how long until this used engine goes out with the same problem. I filed a complaint with Dodge and spoke to someone yesterday for them to tell me that my vehicle is out of warranty . Please help me with this matter.

Bought this vehicle 3 months ago with just 52000 miles and running in good condition. During the weekend of 25th of September 2015 it rained and upon trying to turn on the vehicle to go to work on Monday as usual, the motor/engine was hydrolocked. Water had seeped into the cylinders and the motor suffered failure and broke rods. I had installed the newly redesigned cowl vent grille that was supposed to prevent this ,but it didn't work. Dodge company is very well aware of their bad engineering but won't recall the vehicles and protect their customers. I just lost over 9000. 00 dollars in investment, including taxes for 700. 00 + getting the vehicle registration, inspected, tags, etc. The vehicle wasn't in motion when this happened. It was parked. Not even their redesigned cowl vent grille prevents hydrolock, water from leaking into the intake manifold, from happening.

I have had this SUV for just a few months the day I mad my first payment it went into the shop to be fixed. At first it was apparently my #5 piston shot thru the block with only 120,000 mile on it. Than after spending the $3,700 to get that fixed it was still smoking and having issues. Next thing I know it is now the intake manifold whitch was another $700. 00 and it was 84 in back order when I seen that I pulled it up online were I read that thousans and thousands of people have had this same problem with the first year of the hemi motor in the Durango. I have three small children and I support my kids and husband due to his spine surgerys. I feel if there has been this many parts go bad that it should have a recall with it. I cant afford to keep putting money in something that is still not going to drive properly with my children in it. It has shut off while driving the SUV. It is not safe for my kids to be in im afraid they will be hurt or killed if it happens again. Dodge needs to do the right thing and have thiss recalled as soon as they can. The vechile turned off while on a street thank god it was not on the free way.

Tl- the contact owns a 2004 Dodge Durango. The contact stated that the vehicle was smoking excessively within a week of purchasing the vehicle. The contact mentioned that the previous owner replaced the motor and the dealer also replaced the contacts motor and the failure recurred. The contact indicated that the dealer replaced the motor and the failure recurred so they stated that the intake manifold needed to be replaced but the part was on back order. The dealer stated that 94 other consumers were waiting for the part before she could receive the part and was placed on the list as number 95. The manufacturer was notified of the failure and was unable to supply the part. The vehicle was not repaired and the contact was waiting for weeks to receive a repair while continuing to experience the failure. The approximate failure mileage was not available. Dyd.

One random day. . As I started my Durango, it started making a fast clicking sound from the engine. Seems to driver and idle fine,but it isn't a normal sound since I have had this Durango a while and never heard it till now. To find out its on the passenger side. . Been told its the exhaust manifold. Takes a few mins,but goes away about 90%. The colder it is outside the worst and louder the noise is. I searched online about this and looks like I am not the only one and supriseing its not a recall. I was told by a shop I have a broken stud bolt and will cost. 1200-2000. I don't have that kinda money. So is there a way I could get help getting this fixed? because it is possible it could mess up the piston on that side of the loos manifold. Also received a letter that I have a recall for the driver airbag inflator. . Waiting for my dealer to call me back for a appointment.

Was driving and my engine was making knocking noises, but no check engine light, and then as I accelerated, my engine made a loud bang and my check engine light came on. Smoke was flying out my tail pipe and my car started to shake.

My 2004 Dodge Durango limited with the hemi 5. 7 has an erratic idle at stops whenever it rains. Later in the week I went on the highway at 45 mph the engine stalled during a rain storm. I only have 125,000 miles on the vehicle. I researched this online and found it was most likely the plastic wiper cowl below the windshield allowing water to flow over the top of the engine, which collects on the intake manifold and might slowly make it's way in to the block and hydrolock the engine. Seriously I thought. I went out the next day and opened the hood and placed the garden hose over the center of the windshield with the wipers on and ran the water on low, and also in the off position. Sure enough a lot of water flows in to the driver side wiper hole where it rotates and spreads out over the back two cylinders of the center of the engine. I found there is possibly an upgrade wiper cowl that may prevent some of the water flow buy not all of it. So now I am concerned with this circumstanced even after I get the new cowl that water will still be damaging or destroying my engine one day from water flowing through the cowl over the top of the engine once again. This would cost me $5000-$6000 for engine replacement, just because of a poor design, and no recall or solution from Dodge to take care of this water issue.

The contact owns a 2004 Dodge Durango. The contact stated that the vehicle stalled when driving through a car wash and rainy conditions. Prior to stalling, the vehicle would shake violently. The cowl screen was repaired by the dealer, but the failure recurred. The vehicle was taken back to the dealer who discovered that the injector o-ring, plug wires, and gaskets around the intake manifold needed to be replaced. The manufacturer was notified. The approximate failure mileage was 140,000.

Apparently this is a problem that Dodge has been aware of since 2004. The design of the vehicle allows rain water to be directed down the front windshield and into the engine compartment where it is then sucked through the intake manifold causing the pistons to hydro-lock. In turn the piston rods bend and/or break causing the engine to blow up. This happened to my vehicle when I started it on may 18, 2014. There were pieces of my engine block on the driveway. Thankfully I wasn't driving at the time or I could have had a serious accident.

The engine hydro-locked breaking 2 rods and blowing a hole through the engine block. Caused the vehicle to lose all power and my wife drove off of the road. Luckily she did not hit anything or get injured. The vehicle needed an engine replacement. The local Dodge dealership was familiar with the issue as it turns out to be very common with this year vehicle. The windshield dam that directs rain water away from the engine is poorly designed and it allows water to flow right onto the motor. Over time the water rusts and rots the intake manifold bolts eventually allowing the water to flow into the engine causing hydro-lock. This is an issue that Chrysler should have taken responsibility for but instead they have not. My wife could have been killed and it cost me $6,000 to replace the motor.

Moisture entered into the cylinders via that air intake manifold due to a water seal design defect in the area of the windshield wiper arms. When the vehicle is parked, rain water coming down the front windshield will flow directly under the cowl and onto the engine block. This water intrusion causes undue stress on the pistons, rods, and crankshaft eventually causing a rod to break and puncture the engine block. If this happens at highway speeds, the results could be deadly. The other known scenario is after the car is parked for a period of time (exposed to rain), the cylinder will fill with water, causing a hydro-lock condition and the vehicle will not start. The engine usually is found to also have a bent or fractured rod at this point. This is a known problem by Dodge / Chrysler and they refuse to do anything about it. See the numerous complaints on edmunds. Com blogs and on youtube regarding this topic.

Drove vehicle on 12-22-13 everything running fine went to drive on 12-23-13 and started truck just to hear a loud bang and thump checked out by mechanic and it has a busted connecting rod and engine block is shot and cant even rebuild this is a real problem that needs to be addressed quickly before any more hard working americans have to dump $7k dollars in their vehicle because some one wants to cover up a real problem. Dodge recommended replacing the intake manifold as well when do the repairs. If you know anything about engines the intake manifold shouldn't have to be done because of a rod failure. Upon doing research there seems to be another issue with the windshield cowl that leaks down directly to the manifold that may crack because is faulty which in turn allows water to drain on top of the engine. Well even though there is thousands of complaints on here and with Dodge nothing has been done. A v8 engine should not fail between 60-80,000 miles if properly maintained like ours was. Oil changes religiously and all maintenance done to dealership specs. If this rod would have failed while driving at highway speeds it could have easily caused death or injury. Why hasn't anyone looked at this problem. There is obviously a trend here if thousands of people's engines are failing at such low mileage.

When starting it made load knocking noise. Had it towed to local auto repair shop they said that the engine had thrown a rod through the block. They found that rain water was coming through the cowl below the windshield onto the engine intake manifold. Water standing on the intake manifold seeped into the engine and allowed cylinder to hydraulically lock.

After a snow storm and the snow melted, when I attempted to start it, the starter was grinding. The engine was hydrolocked and broke the connecting rod for #3 cylinder. Subsequent investigation turned up a tech bulletin (not mandatory recall) to replace cowl at the base of the windshield due to water leakage onto the top of the engine which can cause misfiring. I never received notice of this tech bulletin or the potential catastrophic consequences of not implementing it. There was no indication the defective cowl could cause total engine failure in the tech bulletin. The melting snow seeped into the #3 cylinder, possibly from a failed intake manifold seal or warped intale manifold (yet to be determined), and caused hydrolock. I found evidence of a small amount of water in the oil pan which leaked from #3 cylinder. I also found water under the intake manifold near the #3 cylinder. This is a safety issue because a broken connecting rod usually punches a hole in the block causing oil to spill on the road! this was a 5. 7l hemi. The engine needed to be completely rebuilt.

The contact owns a 2004 Dodge Durango. The contact stated that while attempting to start the vehicle, the vehicle emitted a loud noise and failed to start. The contact also stated that the engine was destroyed because water came down the windshield and entered the engine. The water was able to reach the engine because the gaskets on the intake manifold were defective. The vehicle was taken to the dealer, who stated that a hydro-lock occurred when the engine was started and water was sucked in. The VIN was unavailable. The vehicle was not able to be driven. The failure and current mileages were 90,000.

Bolts in exhaust manifold are too small causing the bolts to breakoff and creating a loud ticking noise in engine motor.

I have a 2004 Dodge Durango with the 5. 7 hemi engine with only 78,000 mile ,the car was running fine one day . Very quiet and smooth . I went to start it a day or two later ,and there was a clanking sound out of the engine,very loud, I thought it might be bad gas, after letting it run a bit ,all of a sudden the noise stopped . But now theres heavy blue smoke pouring out the tail pipe. Being a retired mechanic I know this is a very bad oil issue. I have been reading online other people having trouble with this 5. 7 engine. I can only imagine what could happen at highway speeds with this engine self destruting.

I pulled out of my apartment and began to accelerate up an incline. I heard a loud thump, all of the lights on the dash flashed and the car died right there approximately 60 yards from my door. After having it towed all over the place, I was informed that my engine had seized. I was very confused because I am always adamant about maintaining the vehicle and all of the regular work had been done. Dodge would do nothing because the vehicle's warranty had expired. Because I still owed money, I was forced to pay over $6,000 getting a replacement engine. Separate incident 08/17/2013 started vehicle after work. Got to work fine with no indications of trouble, engine was shaking violently, thick smoke sputtering from tail pipe. Reading engine codes saying fuel injector open. Spent 200 getting injection system checked with no success. Mechanic saying that the computer system is bad in the vehicle which is likely to cost upwards of $1000 from Dodge. Bottom line, this product is a complete disgrace, and I feel like the thousands of people affected by this terrible product should be compensated. I have almost had to pay for this car all over again with the time and money I have had to invest in repairs.

The rh side of the exhaust manifold continuously has an exhaust leak!.

The contact owns a 2004 Dodge Durango. The contact took the vehicle to the dealer for a routine oil change. Several days later, she took the vehicle to another dealer and was informed that both of the bolts in the exhaust manifold failed. The repair would cost $1,100. The vehicle has not been repaired. The manufacturer would not assist. The failure and current mileages were 63,732. Updated 09/15/08 the bolts on the manifold had broken off. Updated 09/18/08.

I recently noticed that the SUV was made a loud ticking sound at startup, getting a little softer as the motor heated up. Returning the vehicle to the purchased dealership,which was inspected for a fee, and found the cause to be the aluminum screws on the left side of the manifold which broke, causing the loud exhaust. I then paid $225. 00 to have the two screws drilled out of the engine, and had the screws replaced along with a manifold gasket.