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When cylinder deactivation fails on a 5.7L or 6.4L Chrysler engine, the culprit is frequently a cracked or leaking Multiple Displacement Solenoid (MDS). The factory plastic housings degrade over thousands of thermal cycles, causing oil pressure losses, rough idling, and active check engine lights. The Dorman 916-592XD Multiple Displacement Solenoid replaces vulnerable plastic with durable cast aluminum to solve this design weakness once and for all. This review covers the fitment, performance gains, and installation details to help you decide if it is the right fix for your truck or SUV.
Quick Verdict
Rating: 9.2/10 (Highly Recommended Replacement)
Best For: Owners of 2010–2023 Chrysler, Dodge, Ram, or Jeep V8 vehicles experiencing cylinder deactivation codes, rough idling, or reduced highway fuel economy.
Bottom Line: Dorman’s 916-592XD replaces fragile factory plastic with rugged cast aluminum, ensuring superior heat dissipation and permanent oil pressure retention. While installation requires removing the intake manifold, its heavy-duty build makes it a reliable permanent fix.
| Specification | Detail |
|---|---|
| Brand | Dorman (OE FIX Series) |
| Part Number | 916-592XD |
| OEM Cross Reference | 53022298AA, CD001, CDS01, VDS01 |
| Housing Material | Cast Aluminum (Upgraded from factory plastic) |
| Dimensions | 5.75 x 2.28 x 2.28 inches |
| Item Weight | 6.4 ounces |
| Coil Resistance | 20–40 Ohms |
| Included Hardware | Pre-installed High-Temperature O-Rings |
| Fitment Coverage | Chrysler 300, Dodge Charger/Challenger/Durango, Ram 1500–5500, Jeep Grand Cherokee (2010–2023) |
| Primary Function | Direct hydraulic oil control for cylinder deactivation (MDS) |
What Is the Dorman 916-592XD Solenoid?
The Dorman 916-592XD is an aftermarket Multiple Displacement Solenoid designed specifically for Chrysler, Dodge, Ram, and Jeep V8 engines built between 2010 and 2023. In these engines, four solenoids sit beneath the intake manifold to control oil flow to specialized lifters. When activated by the Powertrain Control Module (PCM), the solenoids drop four cylinders to conserve fuel during highway cruising.
Original equipment (OE) solenoids rely on composite plastic housings. Over years of engine heat cycles, that plastic hardens, stress-cracks, and warps. This causes internal oil leaks that prevent the lifters from deactivating properly. Dorman engineered the 916-592XD as part of its OE FIX line, upgrading the body to cast aluminum while keeping identical mounting dimensions and electrical connections.
Who Should Buy It?
Best For
- Owners of 2010–2023 Chrysler, Dodge, Ram, or Jeep vehicles facing MDS diagnostic trouble codes (e.g., P3401, P3425, P3441, P3497).
- Drivers noticing rough engine vibrations when transitioning between 4-cylinder ECO mode and full V8 power.
- DIY mechanics wanting a durable metal upgrade that eliminates future plastic housing fractures.
Skip If
- Your vehicle is equipped with a non-MDS V8 engine or has an active aftermarket PCM tune that completely disables cylinder deactivation.
- Your engine noise is caused by mechanical cam lobe wiping or collapsed lifters rather than solenoid pressure failure.
Design Upgrades and Build Quality
The defining advantage of the Dorman 916-592XD is its cast aluminum housing. Measuring 5.75 x 2.28 x 2.28 inches and weighing 6.4 ounces, the solenoid body handles high under-hood temperatures without expanding or cracking. Metal construction dissipates heat faster than thermal plastics, protecting the internal electromagnetic coil from heat-induced resistance spikes.
Hydraulic sealing is equally critical. The 916-592XD includes premium pre-installed O-rings engineered to resist engine oil additives and high thermal stress. These seals maintain strict oil pressure boundaries between the main oil gallery and the deactivation lifters, preventing pressure bleed-off that triggers false ECU fault codes.
Vehicle Compatibility and Fitment
This solenoid acts as a direct-fit replacement for OEM part numbers 53022298AA, CD001, CDS01, and VDS01. Before ordering, verify your vehicle year, model, and engine trim using a fitment checker or your VIN. Compatibility spans a wide range of Chrysler platforms:
- Chrysler 300: 2010–2023 (5.7L V8)
- Dodge Challenger & Charger: 2010–2023 (5.7L & 6.4L V8)
- Dodge Durango: 2010–2023 (5.7L V8)
- Jeep Grand Cherokee: 2010–2023 (5.7L & 6.4L V8)
- Ram 1500, 2500, 3500, 4500, 5500: 2010–2023 (5.7L & 6.4L V8)
How It Performs in Real Use
Daily Commuting
In routine city driving, a functioning solenoid ensures seamless switches between V8 power during acceleration and 4-cylinder mode while coasting. Replacing a sticking solenoid eliminates the awkward shudder or hesitation often felt during traffic light pull-aways.
Highway Cruising
Highway driving relies heavily on cylinder deactivation to maintain target fuel economy. By holding consistent hydraulic pressure, the Dorman unit keeps deactivated cylinders stable, helping restore lost miles per gallon on long trips.
Cold Weather Starts
Cold engine oil places extra strain on solenoid seals. The 916-592XD’s upgraded O-rings prevent fluid bypass during morning start-ups, allowing rapid pressure buildup so the PCM registers clean diagnostic signals immediately.
High-Thermal Engine Loads
Towing heavy loads or driving in hot summer weather subjects the engine valley to extreme temperatures. The aluminum housing resists warping, preventing local pressure drops when engine oil temperatures peak.
Installation and Troubleshooting Tips
Replacing an MDS solenoid is a straightforward repair, but accessing the valley requires pulling the intake manifold. Expect to spend 2 to 4 hours on the job depending on your experience level.
Before You Buy: OEM plastic solenoids become extremely brittle with age. When removing old units, their lower housing can snap off inside the engine port. Always inspect the oil passage with a flashlight after extraction to verify no plastic debris remains behind.
Pro Tip: Coat the new solenoid O-rings with fresh engine oil prior to pressing them into place. Because intake manifold removal requires significant labor, replace all four solenoids at the same time to prevent a secondary failure down the road.
When diagnosing solenoid issues, use a digital multimeter to measure resistance across the terminal pins. A healthy coil reads between 20 and 40 Ohms. An open circuit or zero resistance indicates electrical failure inside the solenoid coil.
Skin and Material Safety Notes
While installing automotive solenoids does not involve direct chemical hazards, you will work around engine oil and fuel rails. Disconnect the negative battery terminal before starting to prevent electrical shorting. Wear nitrile gloves and safety glasses when cleaning oil ports, and use dedicated intake gaskets during reassembly to prevent vacuum leaks.
Pros and Cons
Pros
- Upgraded aluminum housing resists heat cycles far better than fragile factory plastic.
- Restores correct hydraulic pressure for smooth cylinder deactivation and improved MPG.
- Includes high-temperature O-rings pre-installed for reliable sealing.
- Matches original electrical connector and mounting bolt dimensions exactly.
- Back-tested under Dorman OE FIX standards to guarantee long-term operation.
Cons
- Access requires removing the intake manifold, making installation labor-intensive.
- Original plastic solenoids may break during extraction, requiring extra care.
- Will not fix mechanical cam or lifter damage if the engine was driven long-term with failed solenoids.
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Is It Worth the Price?
The Dorman 916-592XD represents strong value for any Chrysler V8 owner. Purchasing factory replacement parts often means buying the same plastic-housed design that failed initially. Dorman’s metal upgrade costs roughly the same as a standard replacement while eliminating the primary vulnerability.
Given the labor required to remove the intake manifold, installing a higher-grade aluminum component is a smart investment. It protects your time and money by preventing repeated teardowns caused by brittle plastic failure.
How It Compares to Alternatives
Compared to standard OEM plastic solenoids, the Dorman 916-592XD offers superior structural strength and thermal management. Standard OEM units are prone to hairline fractures around the O-ring grooves over time. Cheap unbranded solenoids often suffer from loose electrical pin fitment and poor internal coil winding. Dorman strikes the ideal balance between OE-level fit and aftermarket structural engineering.
Frequently Asked Questions
How difficult is installation for a DIY mechanic without special tools?
Installation is of moderate difficulty because you must unbolt and lift the intake manifold to reach the top of the engine block. Standard sockets, extension bars, and a torque wrench are all you need. Take care when pulling old units so brittle plastic pieces do not fall into the oil ports.
Are replacement O-rings included with the Dorman 916-592XD solenoid?
Yes, the unit comes with premium high-temperature O-rings pre-installed. Lubricate them with fresh engine oil during assembly to ensure a tight hydraulic seal without pinching the rubber.
Does replacing this solenoid affect engine oil pressure readings?
Yes. A cracked or clogged solenoid permits oil to leak past internal passages, causing localized pressure drops in the cylinder deactivation gallery. Installing a properly sealed solenoid restores correct oil pressure behavior across the system.
Can this solenoid be used on performance-tuned or modified engines?
Yes, as long as the engine retains active MDS programming in the PCM. If an aftermarket tune completely disables cylinder deactivation electronically, the PCM bypasses solenoid operation entirely.
Why is the aluminum housing superior to the factory plastic housing?
Aluminum handles high under-hood heat without drying out, expanding, or becoming brittle. It completely eliminates housing fractures, which are the leading cause of stock solenoid failure.
Should I replace all four MDS solenoids at the same time?
Replacing all four solenoids at once is highly recommended. Because manifold removal requires significant labor, replacing the full set prevents having to perform the same tear-down later when another aged solenoid fails.
What OBD-II trouble codes indicate a failing MDS solenoid?
Common fault codes include P3401 (Cylinder 1 Deactivation Control Circuit), P3425 (Cylinder 4), P3441 (Cylinder 6), and P3497 (MDS System Performance). Testing coil resistance helps confirm electrical failure before replacement.
The Bottom Line
The Dorman 916-592XD solenoid effectively corrects a known weak point in Chrysler, Dodge, Ram, and Jeep V8 engines. By replacing failure-prone plastic housings with solid cast aluminum, it restores reliable cylinder deactivation, eliminates rough transitions, and protects long-term fuel efficiency. If your vehicle shows MDS fault codes, this aluminum upgrade is a dependable, high-value solution.
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