Love my 2003 Dodge Ram 2500

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Stoffregen Motors

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Feb 27, 2025
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Location
Cool, CA
Ram Year
2003
Engine
5.9 Cummins
Hi, new member here from Cool, CA. Yes, the town is named Cool and is said to be named after a gold rush era parishioner, but I think it's a lie. I think they named it after a bunch of hippies...

Anyway, my truck is a 2003 Dodge Ram 2500 4x4 crew cab with a fedral cummins and auto trans. I've owned it since about 2010 and I will never sell it. It is the perfect blend of modern convenience and old tech. I mean, what new trucks have only three knobs on the dash anymore? Oh yeah, and a floor shift t-case.

It gets pretty good maintenance, but it also gets beat up from time to time. We tow an enclosed race car trailer with it, use it to explore mountain dirt roads, use it to haul the dirt bikes and whenever we get a good snowfall, it's my overgrown snow toy. With only 200,000 miles, it's in great shape. I have gone through the trans, with a couple different shift kits, a billet converter, upgraded PS pump, red head steering box with lower brace and updated tie rod/drag link/panhard bar, one ton springs, heavy duty brakes and a "boost box" on the boost controller. It goes through balljoints about every 10k miles, I've replaced the lift pump four times and the entire accessory drive too (with all OEM components). It eats up serpentine belts, or at least, they get squeaky after a thousand miles or so, but whatever.

I do have one nagging problem right now - a driveline vibration starting at about 65 MPH and going to about 75 MPH. I took the front driveshaft out and the vibration went away, so I rebuilt the shaft and put it back in, same problem. I have heard that it's possible for the chaindrive in the t-case to break one link and the vibration comes from the link flailing around. Anybody ever heard of that before? I plan to tear into the t-case soon, so I guess I'll let you know.

Anyway, here's a couple pics.
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quickster2

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SE Michigan
Ram Year
2015 Ram Laramie 2500 4 X 4
Engine
6.4L
Nice truck! I had a 2003 Laramie 2500 V10 for 12 years until I sold it to a friend and bought my current truck. With proper maintenance it should last a good long time.
 
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Stoffregen Motors

Stoffregen Motors

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Location
Cool, CA
Ram Year
2003
Engine
5.9 Cummins
Nice truck! I had a 2003 Laramie 2500 V10 for 12 years until I sold it to a friend and bought my current truck. With proper maintenance it should last a good long time.
I simply don't want a new truck, and luckily I made a good choice when I bought this one 15 years ago. I'll be happy with it until it dies, and then I'll either rebuild it or use the chassis and drivetrain for something else, like a three door suburban.
 
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Stoffregen Motors

Stoffregen Motors

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2003
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Thanks!

So what do you guys think about the t-case causing the vibration? I've read a couple thread posts about the broken link in the chain problem, but in all my years I've never seen that. It could definitely cause the vibration though, so it's worth looking into.

Have any of you guys ever heard about this? Or seen it first hand?
 

quickster2

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2015 Ram Laramie 2500 4 X 4
Engine
6.4L
I would drain the case and see if there is any metal shavings in it. I'm assuming a link would cause some damage. I've not heard of this issue though.
 

biner

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Mar 8, 2019
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Location
BC
Ram Year
2006
Engine
Hemi 5.7
I had a similar issue when I replaced all the front driveshaft U-joints. Vibration in that speed range with the front axle in, no vibration with axle out. Turned out the driveshaft was slightly out of balance after u-joint replacement. Took it to a local driveline shop, and they rebalanced it, and runs smooth as glass afterwards. It’ll cost you around $100, so not expensive to try.

I doubt you have one broken link in the tcase chain, not a common failure mode, especially if you’ve been on top of fluid changes.

Nice truck, mine is an 06 2500 Hemi with 200K miles, and it’s the best truck I’ve ever owned.
 

Blue Truck

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May 31, 2015
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Location
Skagit County WA
Ram Year
2003
Engine
No Spark Plugs
Fellow '03 owner here, but mine's the base model, and I love it! Manual transmission, manual transfer case, manual windows, manual locks, and rubber floor mats suit my love for simplicity. It does have A/C, cruise, and a tilt wheel, which are the functional options I want & use. Nobody has built/sold anything like these in the U.S. for a long time!

Can't imagine ever wanting something different, as I also use my truck regularly for truck-y things.
 

YooperEE5

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Location
Michigan
Ram Year
2019
Engine
5.7 Hemi
That's a nice 2003 you have. I had one for 16 years but finally sold it about a year ago.
Since I live in the rust belt the road salt does a number on the body and frame....
The interior was still in very good condition - it was an SLT with factory leather seats!

Not sure about the vibration at 65-75 mph as we don't have any roads within over 150 miles where we can drive that fast.

Pretty sure all the u-joints were replaced on my 2500; many under warranty.

I do miss that truck but my 2019 Ram Laramie 1500 has been a fabulous replacement!
 

Grettberg

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Oct 30, 2021
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Location
Living Room
Ram Year
2004
Engine
5.7 Hemi
I have an 04. Luv my truck and will never get rid of too. Just turned 123k miles.

I like your headlights. What kind are they? Were they easy to install and how do you like? Sorry for all the questions.
 

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Stoffregen Motors

Stoffregen Motors

Senior Member
Joined
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Posts
104
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Location
Cool, CA
Ram Year
2003
Engine
5.9 Cummins
I have an 04. Luv my truck and will never get rid of too. Just turned 123k miles.

I like your headlights. What kind are they? Were they easy to install and how do you like? Sorry for all the questions.
I do not remember the brand name of the headlights, but no matter, when I looked to see if they were still available a year ago, they were not. The high beams a really very bright, but the low beams suck. The bulbs in the low beams are H1 and I've considered upgrading to a HID H1 conversion, but I think I've come up with another solution. I'm going to install another pair of headlights. Yes, the air duct holes in the bumper will fit a 5.5" round headlight, and Holley just came out with 5.5" LEDs that look great and are very bright. So I will have two sets of headlights. Maybe not entirely "legal", but around here it gets so dark at night, and if it's raining, forget it.
 
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Stoffregen Motors

Stoffregen Motors

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Location
Cool, CA
Ram Year
2003
Engine
5.9 Cummins
Thanks for all the suggestions on the driveline. The reason I think it's something other than the driveshaft is that it happened all at once. One day, no vibration, next day, vibration.

I should clarify that I had my driveline shop rebuild the shaft and balance it. I use them a lot and I trust them. He even told me it was fine and didn't need anything, but I had him go through it and balance it anyway. So yeah, pretty sure it's not the front shaft.

The front output on the t-case does have a slight bit of wobble (at the flange), but not more than I've seen on other cases. I haven't ruled that out, but as I said, I do plan on rebuilding the t-case, and that bearing will get replaced. along with the chain and rear output bearing and seals. Gotta love the simplicity of a chain case.

I forgot to mention in the initial introduction the trans overheating issues I went through last year. Basically when towing heavy through the mountains, it would puke fluid. I resolved it by adding a deep oil pan from AFE, plus a heavy duty shift solenoid from a GM transmission (ATS Diesel) and a new transducer as well. Plus, I don't down shift manually anymore. When I want to get to a lower gear, I just mash the pedal now. I figured by shifting manually into second or first, the torque converter was unlocking and creating heat. So, problem solved. Hasn't puked fluid since those mods.

Here's the link to that shift solenoid, if anyone cares - https://atsdiesel.com/products/ats-...1996-2007-5-9l-cummins?variant=45906653708564
 
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Stoffregen Motors

Stoffregen Motors

Senior Member
Joined
Feb 27, 2025
Posts
104
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Location
Cool, CA
Ram Year
2003
Engine
5.9 Cummins
One last thing - I did find picture evidence of a t-case that had a chain link failure (on the web) and it was so bad that it ground the case and the case cracked in half. So I know the problem exists in the wild.

I normally believe about 15% of what I read on the web anymore, but there were a few mentions of the problem. Enough for me to want to look into it.
 

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