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2020 RAM 3500

Owner reports · Recalls · Investigations

More warning signs than most 3500 years

Owner complaints for the 2020 RAM 3500 are substantially higher than the model-year median of 52.5.

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When problems were reported

Mileage at the reported incident

44 reports with mileage · 72 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Fuel/propulsion System. Review the 33 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 27 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Diesel. Review the 23 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

6 crash reports7 fire reports2 injury reports

Electrical System complaints

9 reports
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Mileage unknown · May 7, 2025
Electrical SystemService Brakes

Abs module has failed twice since truck purchased.

NHTSA ODI #11659464

Mileage unknown · Dec 8, 2023
Electrical System

Check engine light turned on in my 2020 dodge ram 3500, I took the truck back to the dealership. According to them the Grid Heater Relay needs to be replaced & the truck could have caught on fire if we would have kept driving like that. I have done some research and saw that there has been a recall on that same part for the 2021…

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Check engine light turned on in my 2020 dodge ram 3500, I took the truck back to the dealership. According to them the Grid Heater Relay needs to be replaced & the truck could have caught on fire if we would have kept driving like that. I have done some research and saw that there has been a recall on that same part for the 2021-2023. Could it be possible the 2020 were defective also, this is a major safety concern and should be looked into. I also don’t believe the customer should be responsible for paying for this issue to be fixed when it was my family’s safety that was jeopardized.

NHTSA ODI #11559100

Mileage unknown · Dec 6, 2023
Electrical SystemEngineFire

On 12/4/23, at 6:37 am PST, we initiated remote start via the key fob. At 6:40 am pst, a flash and fire erupted from under the hood of the truck. We immediately worked to control the fire using extinguishers and garden hoses until the fire department arrived a few minutes later. They worked to put the fire out that engulfed the …

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On 12/4/23, at 6:37 am PST, we initiated remote start via the key fob. At 6:40 am pst, a flash and fire erupted from under the hood of the truck. We immediately worked to control the fire using extinguishers and garden hoses until the fire department arrived a few minutes later. They worked to put the fire out that engulfed the engine compartment and then worked to get the hood open to finish putting the fire out. The fire didn’t fully go out until the battery cables were cut.

NHTSA ODI #11558743

Mileage unknown · Jul 8, 2023
Electrical SystemEngineFuel/propulsion System

While driving Down a paved roadway on 6/30/23 @ 5pm doing approximately 20 miles per hour the vehicle died and the dash lite up with every single message possible such as 4WD inactive, oil change due, fuel filter service required and etc. Attempted to restart the vehicle for about 25 minutes when another citizen noticed we were…

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While driving Down a paved roadway on 6/30/23 @ 5pm doing approximately 20 miles per hour the vehicle died and the dash lite up with every single message possible such as 4WD inactive, oil change due, fuel filter service required and etc. Attempted to restart the vehicle for about 25 minutes when another citizen noticed we were having issues with the vehicle so they stopped to assist us. The citizen towed my vehicle to location we were staying at for the weekend and upon arrival to the location I disconnected both battery terminals to allow the computer modules to drain/reset. After allowing the batteries to be disconnected for several hours I hooked them back up and tried starting the vehicle and was unsuccessful getting it to restart. I disconnected the batteries again for the night and returned the next morning to hook them up. after hooking the batteries back up, I was able to get the vehicle started and moved it around at the place we were staying at and allowed it remain running for about 20 minutes before I shut it off. Went and did other projects and about 5 hours later returned to the pickup to see to see if it would start since we were heading back the next morning and it started so I figured it would get us home on Sunday July 2nd. On July 2nd @ 11:30am started the pickup to leave and everything seemed normal. We drove about 5miles from the location we were staying at and were approaching an intersecting highway OR58. I proceeded out onto OR58 westbound and as we got about 1 mile down the road when the pickup died and every message was being displayed again. As we sat way off the shoulder of OR58 incident response pulled up behind us to make sure everything was ok. I told the incident responder that we were good and I was working on contacting RAM for a tow. About 15 minutes had passed and IR person walked away then the pickup started. I was able to drive the pickup about 2 more miles down the road when it died again and had to be towed.

NHTSA ODI #11531042

16,000 miles · Nov 28, 2022
Electrical System

The contact owns a 2020 Ram 3500. The contact stated that she locked the vehicle with the key fob, and the auto start system started the vehicle. The vehicle was not taken to the dealer. The manufacturer was contacted and suggested that the manufacturer of the battery be contacted. The manufacturer provided no additional assista…

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The contact owns a 2020 Ram 3500. The contact stated that she locked the vehicle with the key fob, and the auto start system started the vehicle. The vehicle was not taken to the dealer. The manufacturer was contacted and suggested that the manufacturer of the battery be contacted. The manufacturer provided no additional assistance. The failure mileage was 16,000.

NHTSA ODI #11495206

135,000 miles · Oct 4, 2022
Electrical SystemEngine And Engine Cooling

The contact owns a 2020 Ram 3500. The contact stated that after his son started the vehicle, there was a metal-on-metal sound coming from the engine. The contact stated that his son was not aware of any warning lights being illuminated. The contact had not taken the vehicle to a local dealer or independent mechanic. The vehicle …

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The contact owns a 2020 Ram 3500. The contact stated that after his son started the vehicle, there was a metal-on-metal sound coming from the engine. The contact stated that his son was not aware of any warning lights being illuminated. The contact had not taken the vehicle to a local dealer or independent mechanic. The vehicle was towed to an independent mechanic but was not diagnosed or repaired. The manufacturer had not been informed of the failure. The contact researched online and related the failure to NHTSA Campaign Number: 20V511000 (Engine and Engine Cooling, Electrical System). The failure mileage was approximately 135,000.

NHTSA ODI #11487812

213,000 miles · Jan 11, 2022
Electrical SystemEngine And Engine CoolingFire

The contact owns a 2020 RAM 3500. The contact stated that while driving at 15 MPH, the oil warning light was illuminated, and the vehicle made abnormal sounds. Additionally, there was smoke coming from under the hood of the vehicle. The contact pulled over and refilled the oil reservoir; however, the failure recurred with oil le…

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The contact owns a 2020 RAM 3500. The contact stated that while driving at 15 MPH, the oil warning light was illuminated, and the vehicle made abnormal sounds. Additionally, there was smoke coming from under the hood of the vehicle. The contact pulled over and refilled the oil reservoir; however, the failure recurred with oil leaking from the vehicle. The vehicle was towed to the dealer and diagnosed with engine damage and connecting rod failure, which punctured the engine block. The engine needed to be replaced. The vehicle was not repaired and remained at the dealer. The manufacturer was not made aware of the failure. Upon investigation, the contact related the failure to NHTSA Campaign Number: 20V511000 (Engine and Engine Cooling, Electrical System) however, the VIN was not included in the recall. The failure mileage was approximately 213,000. The oil light did not come on until after the engine had started knocking rapidly. The engine oil also ran out quickly as well. Consumer immediately refilled the oil and drove for 5 minutes and the engine stopped knocking for a few seconds before there was louder knocking, smoke and spewing oil. Consumer had previously reported to the customer care FCA group 2 times last August about metal shavings on the fuel filter. The fuel pump continued to produce metal shavings in the filter every time the filter was change.

NHTSA ODI #11447086

Mileage unknown · Dec 30, 2021
Electrical SystemStructureCrash

This Laramie trim level truck has an electronic drop tailgate with a button to drop the tailgate on the overhead console and one on the key fob. The tailgate on my truck was closed during my pre-trip and entering the vehicle. I had a trailer hooked to the receiver hitch and drove ten miles before realizing the tailgate was now i…

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This Laramie trim level truck has an electronic drop tailgate with a button to drop the tailgate on the overhead console and one on the key fob. The tailgate on my truck was closed during my pre-trip and entering the vehicle. I had a trailer hooked to the receiver hitch and drove ten miles before realizing the tailgate was now in the down position and caused significant damage to the tailgate because the tailgate made contact with the trailer. With the electronic release tailgate on this particular year truck there is not a warning message alerting the driver that the tailgate is ajar. There is such an alert on newer models (2021-2022) I went to a local dealership to check. I’m sure the tailgate drop button somehow was pressed on the key fob while in my pocket entering the truck. But I did not receive any alert on the instrument cluster or even hear the tailgate open because the tailgate has a soft open feature. I see this being a serious safety concern to possibly lose cargo and cause a more serious accident.

NHTSA ODI #11445680

70,000 miles · Jun 25, 2021
Electrical System

The contact owns a 2020 RAM 3500. The contact stated while attempting to start the vehicle, he depressed the START/STOP button several times however, the vehicle failed to start. After waiting for approximately 45 minutes the vehicle started. The contact also stated the vehicle failed to recognize the key fob inside the cabin of…

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The contact owns a 2020 RAM 3500. The contact stated while attempting to start the vehicle, he depressed the START/STOP button several times however, the vehicle failed to start. After waiting for approximately 45 minutes the vehicle started. The contact also stated the vehicle failed to recognize the key fob inside the cabin of the vehicle. The contact called the local dealer and made them aware of the failure. The vehicle was not diagnosed nor repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 70,000.

NHTSA ODI #11422268

Official recalls

11

22V904000 · Structure:body:tailgate:hinge And Attachments

Dec 8, 2022

Chrysler (FCA US, LLC) is recalling certain 2019-2022 Ram 1500, 2500, and 3500 pickup trucks. The tailgate may not latch properly due to misaligned tailgate strikers, which could result in the tailgate opening while driving.

Consequence & remedy

Consequence: An unintended tailgate opening while driving may result in a loss of unsecured cargo, possibly creating a road hazard and increasing the risk of a crash.

Remedy: Dealers will inspect the tailgate striker alignment to the box latch and adjust, if necessary, free of charge. Owner notification letters were mailed December 22, 2022. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC's number for this recall is ZB8.

22V835000 · Power Train:automatic Transmission

Nov 10, 2022

FCA US, LLC (Chrysler) is recalling certain 2020-2023 Ram 2500 and 2020-2022 Ram 3500 vehicles. A build-up of pressure and heat inside the transmission may result in a transmission fluid leak from the dipstick tube.

Consequence & remedy

Consequence: Leaking transmission fluid may contact an ignition source within the engine compartment, increasing the risk of a fire.

Remedy: Dealers will replace the transmission dipstick and transmission vent assembly, free of charge. Owner notification letters were mailed December 29, 2022. Owners may contact FCA US, LLC customer service at 1-800-853-1403. Chrysler's number for this recall is ZA3.

22V140000 · Electronic Stability Control (esc); Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

Mar 10, 2022

Chrysler (FCA US, LLC) is recalling certain 2019-2022 Ram 2500 and 2021-2022 Dodge Durango vehicles, and 2019-2022 3500 cab chassis with GVWR less than 10,000 lbs. The ABS control module software may prevent the electronic stability control (ESC) malfunction indicator light from illuminating during certain conditions. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 126, "Electronic Stability Control Systems."

Consequence & remedy

Consequence: An ESC malfunction indicator light that fails to illuminate during an electronic stability control problem can increase the risk of a crash.

Remedy: Dealers will update the ABS control module software, free of charge. Owner notification letters were mailed March 29, 2022. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC's number for this recall is Z20.

Additional source detail variants (2)

Electronic Stability Control (esc)

Chrysler (FCA US, LLC) is recalling certain 2019-2022 Ram 2500 and 2021-2022 Dodge Durango vehicles, and 2019-2022 3500 cab chassis with GVWR less than 10,000 lbs. The ABS control module software may prevent the electronic stability control (ESC) malfunction indicator light from illuminating during certain conditions. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 126, "Electronic Stability Control Systems."

Consequence: An ESC malfunction indicator light that fails to illuminate during an electronic stability control problem can increase the risk of a crash.

Remedy: Dealers will update the ABS control module software, free of charge. Owner notification letters were mailed March 29, 2022. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC's number for this recall is Z20.

Service Brakes, Hydraulic:antilock/traction Control/electronic Limited Slip:control Unit/module

Chrysler (FCA US, LLC) is recalling certain 2019-2022 Ram 2500 and 2021-2022 Dodge Durango vehicles, and 2019-2022 3500 cab chassis with GVWR less than 10,000 lbs. The ABS control module software may prevent the electronic stability control (ESC) malfunction indicator light from illuminating during certain conditions. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard number 126, "Electronic Stability Control Systems."

Consequence: An ESC malfunction indicator light that fails to illuminate during an electronic stability control problem can increase the risk of a crash.

Remedy: Dealers will update the ABS control module software, free of charge. Owner notification letters were mailed March 29, 2022. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC's number for this recall is Z20.

22V035000 · Visibility:windshield Wiper/washer:linkages

Jan 27, 2022

Chrysler (FCA US, LLC) is recalling certain 2019-2020 Ram 2500 and Ram 3500 vehicles, Ram 3500 Cab Chassis, 4500 Cab Chassis, 5500 Cab Chassis and 3500 Cab Chassis with a gross vehicle weight rating (GVWR) of less than 10,000 lbs. The windshield wiper arms may loosen, possibly causing the wipers to function improperly and reduce the driver's visibility in certain weather conditions.

Consequence & remedy

Consequence: Reduced visibility increases the risk of a crash.

Remedy: Dealers will tighten the wiper nuts, free of charge. Owner notification letters were mailed February 15, 2022. This recall is an expansion of recall number 20V-208. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC's number for this recall is Z08.

21V880000 · Fuel System, Diesel:delivery:fuel Pump

Nov 12, 2021

Chrysler (FCA US, LLC) is recalling certain 2019-2020 Ram 2500, 3500 pickup trucks, and Ram 3500, 4500, and 5500 cab chassis vehicles equipped with Cummins 6.7L Turbo Diesel engines. The High Pressure Fuel Pump (HPFP) may fail, resulting in a sudden engine stall without warning.

Consequence & remedy

Consequence: An engine stall increases the risk of a crash.

Remedy: Dealers will replace the HPFP, update the Powertrain Control Module (PCM) software, and inspect and replace additional fuel system components as necessary, free of charge. Interim owner notification letters to inform owners of the safety recall were mailed on January 4, 2022. Owner notification letters were mailed on May 17, 2022. Phase 2 owner notification letters are expected to be mailed on March 2, 2023. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC's number for this recall is Y78.

21V439000 · Engine And Engine Cooling:engine:oil/lubrication

Jun 10, 2021

Chrysler (FCA US, LLC) is recalling certain 2019-2020 Ram 3500, 4500, and 5500 cab chassis vehicles equipped with a Cummins 6.7L High Output engine. The engine calibration software may not warn about low oil volume.

Consequence & remedy

Consequence: Low oil can damage the engine, causing an oil leak or a punctured engine block, increasing the risk of a fire.

Remedy: Dealers will update the engine calibration software, free of charge. Owner notification letters were mailed June 25, 2021. Owners may contact FCA US LLC customer service at 1-800-853-1403. FCA US LLC's number for this recall is Y21.

21V398000 · Wheels:lugs/nuts/bolts/studs

May 27, 2021

Chrysler (FCA US, LLC) is recalling certain 2012-2021 RAM 3500, 3500 Cab Chassis, 4500 Cab Chassis, and 5500 Cab Chassis vehicles. Incorrect information in the Service and Owner's Manuals may cause the flanged lug nuts to be over-tightened, which could result in a broken wheel stud and possible wheel separation.

Consequence & remedy

Consequence: Wheel separation can cause a vehicle crash.

Remedy: Dealers will update the torque specification in the owner's manual and other published service documents. Dealers will also inspect the vehicle's wheel studs, replacing them if necessary, free of charge. Owner notification letters were mailed on November 30, 2021. Campaign Y36 owner notification letters were mailed on November 30, 2021. Campaign Y26 owner notification letters were mailed on December 1, 2021. Owners may contact FCA US customer service at 1-800-853-1403. FCA US's numbers for this recall are Y26 and Y36.

20V191000 · Back Over Prevention: Sensing System: Camera

Sep 10, 2020

Chrysler (FCA US LLC) is recalling certain 2020 Jeep Gladiator and Jeep Cherokee, 2019-2020 Ram 1500 Pickup, Ram 2500 Pickup, Ram 3500 Pickup, Chrysler Pacifica, Dodge Durango, Jeep Grand Cherokee, Jeep Wrangler, and Jeep Renegade and 2019 Dodge Challenger vehicles equipped with 8.4" or 12" radio displays. A software error can cause the rearview camera image to remain displayed after the vehicle has been shifted out of reverse. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 111, "Rearview Mirrors."

Consequence & remedy

Consequence: The lingering rearview image can distract the driver, increasing the risk of a crash.

Remedy: Chrysler has notified owners, and dealers will update the radio display software, free of charge. Optionally, owners can choose to remotely update their software via an Over-The-Air (OTA) update available as of May 1, 2020. The recall began April 27, 2020. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is W30-W37.

20V511000 · Electrical System:software; Engine And Engine Cooling:engine:oil/lubrication

Aug 27, 2020

Chrysler (FCA US LLC) is recalling certain 2019-2020 Ram 3500, 4500 and 5500 cab chassis built with a Cummins 6.7L High Output engine. Inadequate warmup protection can cause a lack of oil film on the engine connecting rod bearings while the engine is reaching operating temperature. This can result in engine damage and connecting rod failure, which could potentially puncture the engine block.

Consequence & remedy

Consequence: A damaged engine block may leak oil, which can contact hot engine or exhaust components, increasing the risk of a fire.

Remedy: Chrysler will notify owners, and dealers will flash the engine calibration software to enhance the engine warm up protection, free of charge. The recall began September 10, 2020. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is W57.

Additional source detail variants (2)

Engine And Engine Cooling:engine:oil/lubrication

Chrysler (FCA US LLC) is recalling certain 2019-2020 Ram 3500, 4500 and 5500 cab chassis built with a Cummins 6.7L High Output engine. Inadequate warmup protection can cause a lack of oil film on the engine connecting rod bearings while the engine is reaching operating temperature. This can result in engine damage and connecting rod failure, which could potentially puncture the engine block.

Consequence: A damaged engine block may leak oil, which can contact hot engine or exhaust components, increasing the risk of a fire.

Remedy: Chrysler will notify owners, and dealers will flash the engine calibration software to enhance the engine warm up protection, free of charge. The recall began September 10, 2020. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is W57.

Electrical System:software

Chrysler (FCA US LLC) is recalling certain 2019-2020 Ram 3500, 4500 and 5500 cab chassis built with a Cummins 6.7L High Output engine. Inadequate warmup protection can cause a lack of oil film on the engine connecting rod bearings while the engine is reaching operating temperature. This can result in engine damage and connecting rod failure, which could potentially puncture the engine block.

Consequence: A damaged engine block may leak oil, which can contact hot engine or exhaust components, increasing the risk of a fire.

Remedy: Chrysler will notify owners, and dealers will flash the engine calibration software to enhance the engine warm up protection, free of charge. The recall began September 10, 2020. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is W57.

20V207000 · Structure

Apr 9, 2020

Chrysler (FCA US LLC) is recalling certain 2019-2020 Ram 2500 and Ram 3500 Pick-up trucks equipped with an accessory bed step. In certain side loading conditions, the bed step may unexpectedly fail while in use.

Consequence & remedy

Consequence: A bed step that unexpectedly fails while in use increases the risk of injury to the user.

Remedy: Chrysler will notify owners, and dealers will replace the bed step support brace, free of charge. The recall began on July 9, 2020 (RAM 2500) and began on October 6, 2020 (Ram 3500). Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's numbers for this recall are W24 and W44.

20V043000 · Power Train:automatic Transmission

Jan 24, 2020

Chrysler (FCA US LLC) is recalling certain 2019-2020 Ram 2500 and 3500 Pickup vehicles equipped with six-speed automatic (68RFE) transmissions. A build up of pressure and heat inside the transmission may result in a transmission fluid leak from the dipstick tube.

Consequence & remedy

Consequence: The leaking transmission fluid may contact the turbocharger or another ignition source within the engine compartment, increasing the risk of a fire.

Remedy: Chrysler will notify owners, and dealers will replace the transmission valve body separator plate and reprogram the powertrain control module. The recall began March 2, 2020. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is W03.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

2

EA23001 · High Pressure Fuel Pump Failure

Opened Mar 17, 2023 · No close date supplied

Status: open (inferred from source dates) · Fuel System, Diesel:delivery:fuel Pump

The Office of Defects Investigation (ODI) opened PE21-021 on October 14, 2021, to investigate incidents alleging a stall/loss of motive power as a result of high-pressure fuel pump failures in certain model year (MY) 2019-2020 Ram 2500, 3500, 4500, and 5500 heavy duty trucks equipped with 6.7L Cummins turbodiesel engines. During the investigation, ODI sought to determine if the related defect allegation was limited in scope to the recalled population. After review of information request response materials from both FCA and BMW, NHTSA determined that sufficient information to identify a comprehensive recall population could not be produced by FCA and BMW.During the investigation FCA filed recalls 22V406, 22E048, 22V767, and 22E087 which include vehicles not identified in the initial subject population by ODI. ODI also received recall 21V586, involving loss of motive power due to failed CP4 fuel pumps on certain BMW manufactured vehicles. An information request letter response received from BMW indicated that failed pumps on their vehicles were caused by an interaction between pump internal components and US market diesel fuel, leading to increased slip and eventual particle-generating wear surface. Additional work will be done to identify whether a similar root cause is associated with the FCA recalled population and if similar wear dynamics occur on pumps supplied to vehicle manufacturers other than those included in the recalled population.ODI has upgraded this investigation to an EA in order to 1) determine engineering specifications of internal pump components that are correlated with pump failure leading to loss of motive power or other safety related hazards, 2) identify vehicle populations equipped with alleged defective pump variants, 3) assess if vehicles equipped with alleged defective pump variants result in an unreasonable risk to motor vehicle safety and 4) gather and review any other relevant information related to high pressure fuel pump failure associated with the subject populations of recalls 21V586, 21V880, 21E094, 22V406, 22E048, 22V767, and 22E087.Review of the above information will allow NHTSA to confirm root cause and recall remedy viability, and identify and evaluate vehicle populations equipped with pump components that may pose an unreasonable risk to motor vehicle safety.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID using the following complaint identification numbers: 11257550, 11351441, 11361603, 11361616, 11365300, 11365426, 11365858, 11366401, 11372337, 11373793, 11374797, 11376793, 11377871, 11378173, 11384377, 11386063, 11387018, 11399710, 11402550, 11415339, 11418868, 11418870, 11427075, 11434276, 11436807, 11437226, 11437249, 11437273, 11437292, 11437294, 11437394, 11437399, 11437403, 11437405, 11437423, 11437528, 11437565, 11437579, 11437580, 11437590, 11437679, 11437744, 11437781, 11437842, 11437993, 11438006, 11438008, 11438121, 11438138, 11438155, 11438392, 11438629, 11439359, 11439879, 11440397, 11443030, 11446542, 11448163, 11453556, 11458918, 11460558, 11469337

PE21021 · High Pressure Fuel Pump Failure

Opened Oct 14, 2021 · Closed Apr 14, 2023

Status: closed (inferred from source dates) · Fuel System, Diesel:delivery:fuel Pump

The Office of Defects Investigation (ODI) opened PE21-021 on October 14, 2021 to investigate allegations of stall/loss of motive power as a result of high pressure fuel pump failures in certain model year (MY) 2019-2020 RAM 2500, 3500, 4500, and 5500 heavy duty trucks equipped with 6.7L Cummins turbodiesel engines.On November 12, 2021, FCA filed vehicle recall 21V-880 and equipment recall 21E-094 on the subject population, identifying an `internally failed component? of the high pressure fuel pump equipped on the 6.7L Cummins Turbodiesel engine that introduced debris into the fuel system potentially causing fuel starvation and consequently an unexpected loss of motive power. Discussions with FCA identified the high pressure fuel pump equipped on these vehicles as the Bosch-supplied CP4. On December 16, 2021, Bosch filed recall 21E-101, stating the pump failure was a consequence of a manufacturer application-specific fuel system design.NHTSA subsequently identified recall 21V-586 involving loss of motive power due to failed CP4 fuel pumps on certain BMW vehicles.As a result of having received multiple recalls related to a common component, from two separate vehicle manufacturers, NHTSA?s focus shifted to determine if the related defect allegation was limited in scope to the recalled population. In early 2022, information request letters were sent to FCA and BMW to determine the root cause and consequentially identify the proper scope of potentially defective vehicles. After ODI received their information request response, FCA filed recalls 22V-406, 22E-048, 22V-767, and 22E-087. During review of information request response materials, NHTSA determined that sufficient information to identify a comprehensive recall population could not be produced by FCA or BMW. On March 17, 2023, this Preliminary Evaluation was upgraded to an Engineering Analysis (EA23-001), expanding the scope to include the Tier-one supplier and any manufacturer who equipped or installed similar high pressure fuel pumps subject to the failures observed in the recall population.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID using the following complaint identification numbers: 11351441, 11361603, 11361616, 11365300, 11365426, 11365858, 11366401, 11372337, 11373793, 11374797, 11376793, 11378173, 11384377, 11386063, 11387018, 11399710, 11402550, 11415339, 11418868, 11418870, 11427075, 11434276, 11436807, 11437226, 11437249, 11437273, 11437292, 11437294, 11437394, 11437399, 11437403, 11437405, 11437423, 11437528, 11437565, 11437579, 11437580, 11437590, 11437679, 11437744, 11437781, 11437842, 11437993, 11438006, 11438008, 11438121, 11438138, 11438155, 11438392, 11438629, 11439359, 11439879, 11440397, 11443030, 11448163, 11458918, 11460558