Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Dodge Durango owners, lightly cleaned up (personal details are redacted by NHTSA).
1. Recall failed to repair air bag failure. Currently - airbags are not functional (dash warning light). 2. At approximately 72,000 miles - vehicle began to show signs of rust through at both rear quarter panels and both rocker panels. By 85000 miles - complete body rust through failure was irreparable - vehicle was maintained exceptionally clean. 3. At 100000 miles - noted by way of mechanic that the engine was 'sludged up' to the point that the valve train was starved of lubrication and subsequently - the engine has encountered what appears to be a total catastrophic failure. Valves, lash adjuster, piston rod or bearings May all be destroyed directly due to poor design and low quality components from FCA. There are hundreds (thousands) of similar complaints across multiple media regarding this 'familiar' Dodge engine breakdown. …
Approximately 10 months ago noted severe rust through beginning on both driver and passenger side rocker panels and rear quarter panels/wheel wells. Estimate at that time for full repair was over $4000 due to extent of rust. Rust affects rocker panels, driver compartment floor at door entry points and both driver and passenger quarter panels. Dealership body shot personnel noted that 'these Durango's and dakotas all rust out bad - and it happens fast'. Very telling. The vehicle has been fully maintained throughout ownership and has been garaged continually. We do live in the 'rust-belt' area - but we are in no way pleased with the condition of this vehicle. To date - the rust is expanding to most lower body parts exposed to weather and the speed at which its - literally - disintegrating is ridiculous. The repair now will cost nearly $6000 and we simply do not feel it is worth doing. …
Tl contact owns a 2004 Dodge Durango. The contact stated that while driving approximately 70 MPH, she noticed a burning odor and smoke started pouring into the vehicle. She mentioned that the failure happened as a result of the rain leaking into the computer panel and wires. The contact stated that before the failure occurred, the vehicle was inspected for recall 07V092000 (electrical system: instrument panel) and the mechanic stated that it was not necessary to applied the remedy since it did not qualify. The vehicle was taken to the dealer who stated that the vehicle needed new spark plugs. The remedy did not repair the failure and the contact had to take the vehicle back to dealer who was unable to diagnose the failure. A reservoir was installed which repaired the failure temporarily. …
Tl* the contact owns a 2004 Dodge Durango. Whenever it rained or snowed, water leaked into the inside of the vehicle through the hood. The water entered the motor and caused the vehicle to stall and the engine to shut off without warning. The check engine indicator illuminated. The contact took the vehicle to a certified mechanic who diagnosed that the water was leaking into the motor and the pistons, which caused them to fail. As a result, the motor needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was 200,000.
I was getting gas and as I pulled out of the gas station I was getting a load ticking noise. To find out later my 5.7 himi lifter and cam shafts needs to be replaced. I get a regular oil change and filter change. I am not sure why this is happening but I did see that this is normal and 5.7 himis Dodge durangos and not understanding why it hasn't been recalled. I'm a mother of 3 little ones and I'm terrified we can get stranded if my engine decides to go out due to this issue.
Noticed over the past few years water when it rains that it is accumulating on top of the engine. Noticed the engine felt like it had a miss fire on a cylinder. Seal from windshield cowl is no longer making a positive seal and water is dripping down onto the top of the engine and also into the spark plugs. Using you tube there have been numerous complaints of this issue which in turn has resulted in what is called hyro-loc of the engine which is causing push rods to break and causing the engine to completely fail, as in my case pushing a rod thru the block of the engine spilling oil out on to the street. Shutting down the engine loosing all power to steer and control vehicle. …
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 intake 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. …
Cowl screen has water leaking on the engine when it rains. It caused my truck to drive shaky and then cut off. I almost got into an accident. It stalled out in the middle of me driving on a busy highway. Why isn't there any recalls for this, I have seen numerous complaints about it but nothing is getting done. I guess it would take for some people to lose their life behind the wheel before it get fixed. I always thought Dodge was the best vehicle but I am now second guessing myself and will never buy another Dodge vehicle again if this problem isn't fixed. It is very unsafe to be riding with your kids while its raining and tour vehicle cuts off on a busy highway with no warner.if you really care about your customers lives you will seriously likeinto getting this problem resolved. Until then I would recommend Chevy vehicle for my family friends and everyone I know. …
Vehicle was running fine until storm came through dumping continuous rain on vehicle. I went to move the vehicle later that day and noticed standing water on drivers side floorboard/carpet. It was soaked! I went to start the engine it didn't respond initially so I turned ignition backwards (off direction) and tried to restart. At that moment it started very rough and made a loud noise from the engine and continually does so whenever it is started now. I can't and don't drive it. Looking closer under the hood apparently water is getting inside the engine compartment when it rains. The black material lining under the hood was soaked also. On the engine there were water droplets and most components of the engine had dried water marks/streaks throughout the compartment.
Car has completely rusted out below the gas cap as what has become a common problem with this vehicle. I have been quoted in excess of $4000 to fix this given the severity of the damage and labor required to fix this. It appears a common problem on this year since I have personally seen 11 exact same vehicles years with the same rust problem. This coupled with the same rust issue arising on the hatchback which was said due to a faulty drain hole being taped over by dealer/manufacturer which nothing could be done. The overall vehicle body is a perfect shape outside the rust problems below the gas cap and the rust throughout the hatchback. Given the commonality of this problem it appears to have been a manufacturing defect.
Body complaints in other Durango years
Frequently asked questions
How common are body problems on the 2004 Dodge Durango?
NHTSA has 35 complaints about the body & structure of the 2004 Dodge Durango, 3% of the model year's 1,115 complaints. The component named most often is body (18 mentions).
Is there a recall for 2004 Dodge Durango body problems?
No. NHTSA lists no body & structure recall for the 2004 Dodge Durango, though it has 8 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Dodge Durango body problems start?
Half of the complaints with a recorded mileage happened before about 89,000 miles, and 18% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to body & structure problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.