My truck is old. She is a 2001 Dodge 2500 with a 5.9L 24V Cummins Diesel and a Manual 5 speed. She has been mostly reliable, but her age is starting to show. I bought her in July 2014 and had no issues, until…

 

In September 2018, She had no oil pressure, this was an easy fix, I just had to remove the driver side front tire, unplug the wire from the sensor, unscrew it and screw in a new one. But I did get her towed home.

 

Embarassing

Wasn’t sure what the problem was.

 

Next one in August 2019 was a little more severe, I was driving on the interstate and she started overheating. The belt was shredded and the fan was loose, so I got her towed home again.

 

Made me late for work

Broken Fan Belt

 

Because the hub was broken(caused by the bolts loosening and shearing off), I was not able to unscrew the fan and then remove the hub. I had to take them out together. The only way to fit this was to remove the radiator, so at that point, to quote my Step Dad, “It went from a job to a project”. On these trucks, that’s pretty easy, drain it, remove the hoses, the overflow tank, the windshield washer tank, and a couple bolts.

 

PITA to remove

Hub and Fan Together

 

Now I enjoy being my own mechanic, but it does have its drawbacks. Number one, my mechanic is an idiot sometimes. In this case when I put the fan on the new hub I used too much Loctite and the fan wouldn’t turn. So, I bought another fan hub and was much more careful with the Loctite this time. Got it all put together and took a drive to warm up so I could fill the rest of the antifreeze. Came in the garage and the radiator was leaking, one of the bolts must have hit it when it sheared off. That gave me an excuse to buy a new aluminum radiator, and once again remove the radiator..(I am way too good at removing the radiator) After that install she was back on the road.

 

In December 2019, she started to get a real bad vibration, so I crawled underneath and manipulated the drive shaft (not a euphemism). There was a noticeable clunk.I pulled the driveshaft. This was not easy, it’s a two piece, so it’s awkward and heavy. With my vice and a rented AutoZone press, I changed all the universal joints. One was stuck to the shaft and broke in two. I said “Well there’s your problem.” I grease them every oil change, so I’m not sure what happened.

 

Looked like it had been chewed on

There’s your problem

 

Damn thing is haevy

Rear shaft

 

And it's awkward

Front shaft

 

I got them all replaced and no vibration, all was well, until…

 

Every joint was loose

Before

 

The steering, a known weak point on this generation Dodge, was getting really loose. I also had a front axle seal leak so I figured I would take care of both issues at the same time. To remove the front axle seals you have to remove the ring gear, not too hard.

 

Just getting started

Work in progress

 

Then press out the old seals and press in new ones. Then I tore the old suspension off and put the new parts on. This was a lot of work, but everything went together nicely.

 

Came out nicely

POR 15

 

This was not easy

All stock replacements except the sway bar end links

 

Drives like it did brand new

Lot of work to get here

 

To do an alignment that was good enough to get me to the shop, I aligned the front driver wheel with the rear wheel by sight and turned the tie rod connector to center the steering wheel. Next I turned the other tie rod to align the passenger front with the rear wheel.

 

Took her to the shop and the report said it couldn’t be brought within specs because the steering gearbox was loose. Went for a test drive and while the steering was much better, but there was still 4-6 inches of play before the wheels turned. Bought a new gearbox and put that in.

 

Probably the original one

Time to go

 

OH YEAH!

Redhead Steering Box

 

$400

The last piece for straight steering

 

Much better! Got another alignment done and she drives phenomenally well. She still drives like a heavy duty truck, but she does it in a straight line.

 

I also wanted to do something about my valve cover. It looked a little rough.

 

I did this 5 years ago, didn't hold up very well

Ugly

 

I sanded it with my wire wheel and polished the letters and metal center with 400, 800, 1000, and 2000 grit sandpaper. Then I taped the letters and center section and painted it. I then painted the spot with the Ram head red and sanded the top so it has a little accent color. I am not great at paining, but as a learning project, I’m pretty happy with it.

 

Next time, I will paint it then sand, taping the letters was tedious

I like the red

 

I know I suck at painting

Looks much better

 

Last for this project was a new seat cushion and seat covers.

 

Name is Smoke

He loves to ride in the truck

 

I like it!

Seat covers from Wet Okole

 

I like it a lot

They look so nice.

 

Holy crap! The old girl is so comfortable and rides so nice. It was a lot of time and money, but definitely worth it. Stay tuned, I am currently in the middle of my next project and it has gone a little sideways.