IllustrationHigh pressure fuel pump recall failed and put my life in danger ⚠️ Terrible experience not only for me but it put in danger a Semi truck driver and others almost got killed
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.
About this comparison →How this year compares
Owner complaints by model year
Compare all 3500 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
210–25K
1125–50K
250–75K
275–100K
4100–150K
4150K+
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
Fuel/propulsion System complaints
33 reportsCodes: P2002, P242F, P2463, P1451 Failures: DPF, Charge air cooler leak, PM sensors, EGR internally cracked, Catalytic Convertor, Pink tinged oil, strong diesel odor in oil - post failures. Erratic def gauge readings, unstable idling, clunking downshift when exhaust brake decelerates, warm up stumbling. Power reduced, see deale…
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Codes: P2002, P242F, P2463, P1451 Failures: DPF, Charge air cooler leak, PM sensors, EGR internally cracked, Catalytic Convertor, Pink tinged oil, strong diesel odor in oil - post failures. Erratic def gauge readings, unstable idling, clunking downshift when exhaust brake decelerates, warm up stumbling. Power reduced, see dealer (over and over and over and over). Limp Mode (5 MPH). Permanent ticks/taps from front left motor, front passenger wheel well, passenger side mid-truck. Extremely loose gear shifter plus an occasional “Vehicle Not in Part” message on the dash display. Manufacturers Service Center (local and ONLY Ram dealership) has reproduced the issue. Independent Diesel Mechanic shop also reproduced. Service center and Independent shop both inspected. The safety issues of a 5 MPH limp mode and risk of sudden engine stalls while driving in traffic, especially on an interstate should be fairly self explanatory… As is a constant “Power Reduced See Dealer” problem, when your truck is used to do what it’s designed to do… Tow large loads. As is an extremely loose gear shifter that doesn’t always properly register as “in Park”. The date listed below is simply the date of the very first occurrence. It’s not a representation of every date after. The most recent date was just last week.
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.
My check engine light went on, along with the DEF warning, early June 13th,2023. The DEF warning stated I had 150 miles to get the Track to a Dealer. After Dealer evaluation, I was told the truck had DEF contamination, from ,Diesel Fuel. I asked how this could happen? I was not given an explanation. To me this is a DEF Pump fail…
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My check engine light went on, along with the DEF warning, early June 13th,2023. The DEF warning stated I had 150 miles to get the Track to a Dealer. After Dealer evaluation, I was told the truck had DEF contamination, from ,Diesel Fuel. I asked how this could happen? I was not given an explanation. To me this is a DEF Pump failure. The DEF Pump did not have enough PSI to inject DEF into the Diesel Fuel, so the Diesel Fuel back flowed into the DEF system. Additional facts, my Truck warranty expired 5/15/2023. My truck has less than 36,000 miles. I had the High Pressure Fuel pump, Recalled fixed in May 2023. I was told this repair did not lead to this issue. The Repair bill is over $3700 for this repair.
My high pressure fuel pump went out while I was towing the 43 ft enclosed trailer causing the engine to shut down. I was able to get it home and onto a car hauling trailer took it to a dealership and confirmed the high pressure fuel pump was the culprit they informed me that they would not perform the safety recall because of a …
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My high pressure fuel pump went out while I was towing the 43 ft enclosed trailer causing the engine to shut down. I was able to get it home and onto a car hauling trailer took it to a dealership and confirmed the high pressure fuel pump was the culprit they informed me that they would not perform the safety recall because of a modification to the vehicle which has no bearing on the safety issues at hand I contacted FCA they encouraged me to take it to a different dealership which I did. I had to pay a tow truck to haul it to another dealership in which they told me they would do the recall however when they put my VIN number in their system my pickup had been blacklisted by the parent company Chrysler saying do not work on this vehicle for safety recalls. I at this point got quotes to have it done and it was extremely expensive to friend advised me to look into the law so I contacted a lawyer and they told me to file a complaint with NHTSA.
As of today, manufacturer/dealers have failed to comply with repairs based on national recalls. On several appointments, the parts are never received. Manufacturer and dealers are not complying with mandated recalls. Please take action!
Y78 Recall. The recall for the CP4 pump has been issued. Ive been on the dealership waitlist since the recall became available.My truck began to have rough idling and surging which it never had before. I called the dealer to ask a timeframe for when the recall would be completed, they advised me that they were no longer receivin…
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Y78 Recall. The recall for the CP4 pump has been issued. Ive been on the dealership waitlist since the recall became available.My truck began to have rough idling and surging which it never had before. I called the dealer to ask a timeframe for when the recall would be completed, they advised me that they were no longer receiving pumps for the recall and had not received any in a few months. The lady in service advised me if I was that concerned for pump failure to try and source a pump conversion kit myself and submit for reimbursement afterwards (which I did). I submitted copies of receipts from both the retailer I ordered from as well as credit card statements showing proof of purchase which FCA required per their email. However, FCA has denied my request for reimbursement of parts. I have been in communication with them via email trying to get a explanation of why I was denied. They stated that I do not meet criteria for reimbursement even though I have submitted all required documents that they ask for. They are unable to provide explanation aside from their automated generic response saying I do not meet criteria. I have tried calling their provided customer care number to speak to a representative but have been unable to talk to anyone other than an automated system.
0N 4/4/2022 while traveling on interstate 64 E in WV ,towing an R V camper , no warning signals on the dash screen, my truck started losing power and went completely dead,just missed by a tractor trailer rear ending me, as I rolled off to the side of the road. Iwas towed to the nearest Dodge dealership. When I arrived at the dea…
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0N 4/4/2022 while traveling on interstate 64 E in WV ,towing an R V camper , no warning signals on the dash screen, my truck started losing power and went completely dead,just missed by a tractor trailer rear ending me, as I rolled off to the side of the road. Iwas towed to the nearest Dodge dealership. When I arrived at the dealership a mechanic came and open the hood, he found diesel leaking and a metal rod of the camshaft sitting on top of the engine, which he stated shot through the engine block. Warranty company doesn't want to tear down engine after I gave approval to investigate issue. This is my work truck and source of income. Four weeks later, I am not getting help from dealership that sold me the truck and warranty. Warranty company is trying to use loop hole to get out of paying. I found similar complaints, reported to the NHTSA, engines falling apart while driving down the road. I had to pay for my truck to tow from WV to Charlotte NC to my driveway. I have a case# with the Dodge Customer Care Department and they are just informing me that the truck has recalls, but parts are not avaible at this time.
While towing 5th wheel vehicle check engine light came on I was out of state in arizona vehicl then started to stall I canceled my trip checking all fluids headed back to California as I was nowhere near a dealership made a appointment at ram dealer when I got there light went out I talked with technician he said would have to l…
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While towing 5th wheel vehicle check engine light came on I was out of state in arizona vehicl then started to stall I canceled my trip checking all fluids headed back to California as I was nowhere near a dealership made a appointment at ram dealer when I got there light went out I talked with technician he said would have to leave it for 3 weeks before they could look at vehicle needless to say I took it home then in early Feb about 3 weeks after the first incident the check engine light came on again made appointment which was 3 weeks away just to check it in shop and a week before they even looked at the issue they found a cracked hose on inter cooler dealer stated vehicle ok well again on March 4 2022 vehicle again has check engine light on I took to auto store to check code same as before vehicle regeneration frequency it Regenerates ever 100 miles runs poorly uses excessive fuel hesitates when pedal depressed and long cranking time so now I have to be without a vehicle again
DEF reservoir got low and light came on indicating about 300 miles until truck goes into limp mode 5 MPH. Added 1 gallon of DEF and the guage showed to be in the safe zone. The computer system never registered that fluid was added and truck went into limp mode on the way home. When in limp mode you are unable to move vehicle …
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DEF reservoir got low and light came on indicating about 300 miles until truck goes into limp mode 5 MPH. Added 1 gallon of DEF and the guage showed to be in the safe zone. The computer system never registered that fluid was added and truck went into limp mode on the way home. When in limp mode you are unable to move vehicle off the roadway in a safe manner or even drive on any roadway without major risk of getting hit. Truck has to be towed to a dealership to have the computer reset. EXTREMELY DANGEROUS. Ironic that first responder and government vehicles with this same engine ect are omitted from the limp mode function due to safety concerns but not the general public.
Official recalls
1122V904000 · 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
2EA23001 · 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