🔧 3500 - Ignition Coil Replacement

On your 3500’s 6.4L HEMI, each cylinder has its own ignition coil mounted on the valve cover. Replacing a bad coil can fix a misfire, rough idle, or a flashing check-engine light, and it’s a straightforward bolt-off/bolt-on job.

Difficulty Level: Beginner | Estimated Time: 0.8-1.5 hours

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⚠️ Safety & Precautions

• ⚠️ Let the engine cool before working near exhaust manifolds.
• ⚠️ Disconnect the battery negative cable to avoid accidental shorts.
• ⚠️ Don’t pull on wires—always release connectors by the lock tab.
• ⚠️ If the check-engine light is flashing, avoid driving until repaired (can damage the catalytic converters).

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🔧 Required Tools

You'll need the following tools for this repair:

• 10mm socket
• 1/4" drive ratchet
• 6" socket extension (1/4" drive)
• Torque wrench (in-lb or Nm capable)
• Small flathead screwdriver
• Trim clip removal tool
• Flashlight
• Nitrile gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Ignition coil - Qty: 1 (or Qty: 8 if replacing all)
• Dielectric grease - Qty: 1

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📋 Before You Begin

• Park on level ground, shift to Park, and set the parking brake.
• Open the hood and let the engine cool.
• Use a 10mm socket to disconnect the battery negative terminal and move it aside so it can’t spring back.
• Tip: Replace coils one at a time to avoid mix-ups.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Remove the engine cover (if equipped)

• Use your hands to lift the cover straight up to release the grommets.
• If any plastic push-pins are present, remove them with a trim clip removal tool.

Step 2: Locate the coil you’re replacing

• Each coil sits on top of a spark plug along the valve covers (4 per side).
• Use a flashlight to confirm you’re on the correct cylinder.

Step 3: Unplug the coil electrical connector

• Press the lock tab and pull the connector straight off by hand.
• If the tab is stubborn, gently assist with a small flathead screwdriver (don’t pry hard).
• Tip: Wiggle the connector—don’t yank.

Step 4: Remove the coil mounting bolt

• Use a 10mm socket with a 1/4" drive ratchet and 6" extension to remove the coil bolt.
• Set the bolt aside where it won’t get lost.

Step 5: Remove the ignition coil

• Twist the coil slightly, then pull it straight up to remove it from the spark plug tube.
• If it feels stuck, keep twisting gently and pulling upward—avoid using excessive force.

Step 6: Prep and install the new coil

• Put a small pea-sized amount of dielectric grease inside the new coil boot (the rubber tube). This helps sealing and future removal.
• Push the new coil straight down until it fully seats on the spark plug.

Step 7: Reinstall and torque the coil bolt

• Start the bolt by hand to avoid cross-threading.
• Tighten with a 10mm socket.
• Final tighten using a torque wrench: Torque to 9 Nm (80 in-lbs).

Step 8: Reconnect the electrical connector

• Push the connector on until it clicks/locks.
• Give it a gentle tug to confirm it’s latched.

Step 9: Reinstall the engine cover and reconnect the battery

• Reinstall the engine cover by pressing it down into the grommets by hand.
• Reconnect the battery negative terminal using a 10mm socket and snug it securely.

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✅ After Repair

• Start the engine and let it idle for 30-60 seconds. It should run smooth.
• If the check-engine light was on, it may take a few drive cycles to turn off. If it stays on or runs rough, recheck that the connector is fully clicked in.
• If you replaced one coil due to a misfire, consider replacing the spark plug on that cylinder soon (weak plugs can stress coils).

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💰 DIY vs Shop Cost

Shop Cost: $180-$420 (parts + labor) for 1 coil

DIY Cost: $35-$110 (parts only) for 1 coil

You Save: $145-$310 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.8-1.2 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.