Diesel Fuel System Problems of Dodge Ram 3500 - part 1

2006 Dodge 3500. Consumer writes in regards to recall notice 14v-795. The consumer submitted invoices, proving the repairs were done, prior to the recall. Also, the outer and inner tie rods, fuel pump and blower motor were replaced.

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2010 Dodge Ram 3500. Consumer writes in regards to diesel fuel heater electrical connector recall notice issues. The consumer was informed there was a waiting list.

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The contact owns a 2010 Dodge Ram 3500. The contact received a notification for NHTSA campaign number: 14v635000 (engine and engine cooling, fuel system, diesel) and stated that the part needed was unavailable to repair the vehicle. The dealer was unable to inform when the part would become available. The manufacturer was notified of the issue. The contact had not experienced a failure.

The contact owns a 2010 Dodge Ram 3500. The contact received a notification for NHTSA campaign number: 14v635000 (engine and engine cooling, fuel system, diesel) and stated that the part needed was unavailable to repair the vehicle. The dealer was unable to inform when the part would become available. The manufacturer was not notified of the issue. The contact had not experienced a failure.

The contact owns a 2012 Dodge Ram 3500. The contact received notification of NHTSA campaign number: 14v635000 (engine and engine cooling, fuel system, diesel); however, the part to do the repair was unavailable. The contact stated that the manufacturer exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure.

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2012 Dodge Ram 3500. Consumer writes in regards to tie rod assembly recall issues. The consumer also experienced loss of power. The consumer stated there were times, where he couldn't obtain a speed greater than 40 mph. Also, he was experiencing poor fuel economy.

The contact owns a 2012 Dodge Ram 3500. The contact received notification of NHTSA campaign numbers: 13v529000 and 14v635000 (steering, engine and engine cooling, fuel system, diesel). The contact brought the vehicle to the dealer for the tie rod replacement; however, the VIN showed that the vehicle never received a recall repair. The parts to repair the electrical connectors of the diesel fuel heater were unavailable and the contact stated the manufacturer exceeded a reasonable amount of time to repair the recall. The manufacturer was made aware of the issues and referred the contact to NHTSA. The contact had not experienced a failure.

While driving on the interstate 35 I noticed smoking coming from my vehicle, as I pulled over the smoke become thick and rolled out from under the hood of my truck. I immediately open the hood to find diesel fuel covering the complete engine compartment and noticed fuel spraying from the number four fuel injection line. I am a mechanic so called Dodge dealer to get new line (part #5086874-ac) for my cummins 5. 9 engine. After talking to the parts man he said this is a common problem and they have redesigned the clamping system on the line. I feel this is a very dangerous situation, when this line leaks it is under high pressure and sprays fuel all over the engine. I feel I was very lucky that the fuel did not ignite and burn up my truck. I would highly recommend owners are notified about the new line so they can replace it before it leaks.

See all problems of the 2004 Dodge Ram 3500 🔎.

Driving home from a trip at 65mph #4 injector line breaks covers complete truck with diesel. I contacted Dodge with safety concern they say they didn't know about the problem and would take it into consideration for future products. This is problem will kill people now if they are not informed of the problems with there truck and they catch on fire. Dodge and cummings has changed the way the replacement fuel lines are made to stop them from breaking but won't let people know ahead of time that there's could break . There is listing after listing in the internet about this problem and Dodge can't keep up with the amount of replacement lines.

See all problems of the 2005 Dodge Ram 3500 🔎.

2006 Ram 3500 with 5. 9 cummins. Nearly the same as all the other reports here. 9pm, major highway, entire family in cars, kids asleep, start smelling raw diesel fumes. Big cloud of mist behind truck, about mile further "check engine" light came on. Nearly made it home, but died suddenly and only place to go was median in 4 lane highway. Huge cloud of steam out of engine compartment smelling like diesel. Several gallons of diesel pumped all over hot engine, exhaust, entire underside of truck, body of truck, highway, major mess. Vehicle just out of warranty. Towed it home after a harrowing ordeal getting a wrecker there and trying to not get hit by cars. Non-dealer mechanic diagnosed what appears to be a very common problem--cracked injector line-- despite only seeing a few complaints here (google "cracked #4 injector line). He agrees, atomized diesel touching a hot turbo could ignite, and we would have had a vehicle fire and become a flaming bomb with the entire family in the car. Dodge and cummins should be ashamed. They have ignored this, and it will take a death or serious injury before they get sued and fix things. Consumers who bailed out Dodge are left hanging with expensive repairs, and their families stranded in the middle of nowhere. Nauseating.

Diesel, 5. 9 while driving at 50mph the check engine light illuminated and shortly there after the engine stopped running all together. I was able to safely stop the pickup along the shoulder of the roadway. I noticed the smell of diesel fuel and the left side of the engine was covered in diesel. After my pickup was towed home I researched the symptom and discovered I wasn't alone with this issue. It seems the bolt that holds a clamp around the fuel line to the number four cylinder backs out allowing movement or vibration to this fuel line and a leak develops in the high pressure line and diesel fuel to spray into the engine. In addition to the potential fire hazard from the diesel fuel the sudden loss of power is very concerning. I found several posts on forums regarding this same issue. The parts guy at cummins said he has sold as many as 6-7 of these fuel lines per month. I can only imagine how many fuel lines were sold at the Dodge dealerships around the unites states.

See all problems of the 2007 Dodge Ram 3500 🔎.

2007 Dodge Ram 3500. Consumer writes in regards to warranty claim the consumer stated he would like a written explanation as to how the banks ram cold air intake and the banks tech- cooler intercooler system caused the failure, since that was the basis for his denial of warranty coverage. The consumer was informed the failure was due to vehicle modifications. The consumer stated he has been to the dealer several times, due to fuel starvation issues. The vehicle was said to have been repaired. However, 10,000 miles after the 100,000 warranty had expired the consumer began experiencing problems again, which led to the injectors malfunctioning again. The consumer stated it would cost $5,1000 to resolve all six injector issues. The consumer was informed all six needed injectors needed to be replaced in order to have the proper balance of fuel injected into the engine. Updated 03/20/12 updated 03/29/12. The consumer stated on more than one occasion while driving, the vehicle would drastically loose power due to the failed bosch injector. Updated 05/16/12 .

#4 high pressure fuel injector line cracked twice in 4 months. Sprayed diesel fuel all over engine compartment, undercarraige, sides, and up tailgate. Smoke was coming from engine compartment both times. . Read more...

The contact owns a 2011 Dodge Ram 3500. While driving approximately 50 mph, the contact noticed a strong fuel odor. The smell in the vehicle was making the occupants nauseous. The vehicle was taken to the three different dealers for diagnostic tests. The technicians were unable to diagnose a failure. After some time, the vehicle would not start. The contact inspected the vehicle and stated that the diesel fuel was injected into the exhaust and was mixed in with the oil, causing the smell. In addition, the vehicle was included in the recall under NHTSA campaign id number 11v350000 (steering:linkages:tie rod assembly). The dealer refused to repair the vehicle because there was a pending lemon law case filed by the contact. The contact had not experienced a failure with the steering. The vehicle was not repaired. The approximate failure mileage was 1,700.

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Seems to occur when it is damp or raining. Doesn't occur when it is dry. Revs up on its own, even in gear with foot on brake. It has done this at least once. When first cranked up it has reved up wide open. It has done this at least twice. Will accelerate on its own while driving down the road. Has done this several times. When accelerating and you let up on the accelerator a little it acts just like you have taken your foot completely off the accelerator. It has done this several times. After the weather dries up and you crank it a few times the check engine light will go off. The light will stay off until the next time it is damp and it decides to go crazy. Then the check engine light comes back on just as soon as the engine starts to accelerate on its own. I think this is extremely dangerous.

See all problems of the 2003 Dodge Ram 3500 🔎.

I have a 2010 Dodge Ram 3500 (single rear) 6 months old with (4000) miles. I was towing my camper (8000lbs) and the engine started knocking - I was told by the dealership that I purchased bad diesel fuel (kerosene in fuel) and it caused the injector to hydro-lock and flood a cylinder and this is not covered under warranty, and it will cost me ($1000+) to fix this vehicle. The analysis they conducted on the fuel was visual, and this was there final determination. I contacted Chrysler corporate and I was told they could only go by what the tech says and there is nothing they can do for me. I called other dealerships to ask if they have had a run on diesel vehicles with bad fuel and not one of them said they had a problem. I believe I have a bad injector and Chrysler will not analyze them to guarantee I will not have future problems. I turned this over to my insurance company and they are forcing the dealership to do further evaluations. The vehicle is currently at another Chrysler dealership where they are going to have the fuel analyzed and determine what actually caused the failure. I will finalize this complaint when I get the final reports on what exactly caused this failure. . .

2004 Dodge 3500 cummins deisel injectors went out on it, died in the middle of the street, after starting hard for a few weeks. Mechanic replaced injectors, less than 2000 miles on new ones and they went out again. Cummins mechanic says whole engine is bad, there were 4 other trucks at mechanic with same problem.

The lift/transfer pump of the fuel system failed while driving on the freeway. (separate from the main fuel pump ). After talking to my mechanic and researching online, I found that apparently the original system was such a terrible design, and the problem I had so common, that Dodge doesn't even make a replacement part for it anymore. Instead, they sell you a kit which requires about 5-6 hours of labor to totally re-do the system (plus $500 parts). Customer service? forget about it. If you finally get through to talking to your "case manager" all you'll hear "it's no longer covered by the warranty" the problem manifested itself by my truck stalling out in the fast lane on the freeway during rush hour- not a lot of fun trying to steer/brake a 6000+ pound truck with no power steering or brakes! how could this not be a safety recall issue?.

I was driving my 2006 Dodge Ram 3500 5. 9 cummins turbo diesel pickup at approximately 60 m. P. H. When I started smelling diesel fuel fumes. I looked in my outside rear view mirrors and could see what appeared to be a mist spraying behind the vehicle. I began to look for a safe place to pull off the road as I was pulling a trailer behind me. Just before I pulled off the road, the check engine light came on. When I stopped, I could see a mist coming from the engine compartment. I opened the hood and noticed there was diesel fuel sprayed under the engine compartment and also underneath the vehicle. There was fuel dripping from underneath the engine compartment where it sprayed heavily. Upon looking further, I noticed there was a broken fuel line that caused raw fuel to be sprayed in the engine compartment including directly onto the engine and underneath the vehicle onto the exhaust system. It appears this is a common problem and is usually the #4 fuel line. I feel this is a fire hazard and could be very dangerous to the driver and/or passengers and other vehicles on the road.

I have the 6. 7 cummins diesel engine. While stopped and with the air conditioning on and while the truck is performing the regeneration process raw fuel and exhaust fumes enter the cab of the truck forcing me to roll my windows down. This has caused me to get lightheaded if I don't roll my window down in time. This happens about once every two weeks to me(each time the above conditions are met). Putting the air conditioning on recirculate will help. However recirculate will not work for the heater or window defroster which further impairs my ability to drive. I spoke to the dealer and they called Dodge. Dodge said that this is normal. This is not normal and is a serious health and safety issue.

The contact owns a 2002 Dodge Ram 3500. The contact stated the vehicle stalled without warning. The contact was able to restart the vehicle. He then further inspected the failure and found that the fuel pump within the fuel tank had failed. As a result, the fuel injectors also failed. The vehicle was not inspected or repaired. The manufacturer would not provide any assistance. The failure mileage was approximately 63,700 and the current mileage was approximately 64,400.

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Failure of 2003 Dodge Ram 3500 with ho diesel engine and manual 6 speed transmission - engine turns over but fails to start. Been to crown in nitro and courts in hurricane a total of 7 times. Dealerships fail to fix. Have spent approx. $2500 and still not fixed. Can stall at intersection or railroad crossing causing grave injury or death; need help to get problem fixed by recall process. All Chrysler-Dodge says "I apologize". Chrysler-Dodge knows of problem b/c will fix on as need basis if under warranty; told by crown, nitro that we were lucky fuel pump lasted as long has it had when replaced (we had to pay) over a year ago. Has caused compounded problems with injectors. Mostly likely has caused high pressure pump then injectors to fail as these parts use the lubricating properties of diesel fuel as the lubricant for these parts.

The next Toyota is in your lap four times now my Dodge truck with a cummings diesel motor has had a fuel line burst and spray fuel all over a hot motor and exhaust pipes. The last time, this resulted in a fire on the underside of the truck that I put out with a fire extinguisher. Dodge claims they know nothing about this problem, yet the cummings diesel forums on the internet have thousands of posts on this problem. . Read more...

Fuel line ruptured while driving on the interstate at 75 mph. Check engine light came on, but because it was dark driver was unaware of fuel leak until smoke was observed coming from engine. Diesel fuel was spraying all over engine and was leaking down exhaust. Smoke was rolling out of vehicle. Police and fire dept. Responded due to fuel leak. Repair was covered under warranty, except for towing. Parts were replaced by dealer.

I have a 2004 Dodge Ram 3500. I have had 4 #2 injection lines break on it since 10 Nov 2009. I have called both Dodge and cummins on the issue. Cummins said to call Dodge, and Dodge said it was "noted" and they would look into it. The problem that I have with it is that when it breaks it sprays desiel fuel onto the turbo charger. That reches temperatures that exceed the lower flamability rate of desiel fuel. But lucklily it has not caught fire yet. But 4 lines in six months seems to be excessive. I have seen a trend while trying to locate the part. Almost all of the parts dealers knows which injection line is broken before I tell them. So it has to be a common problem. And this particular injection is usually on back order. I think it is a severe saftey issue. And I would like to see it gget fixed or addresed before anyone gets burned up in a vehicle due to the fuel ignition.

At engine oil change, serviceman noticed fuel tank hanging by aft fuel hanger strap only. First failure of the fuel tank hanger strap assembly. Had the tank completely failed on the road, the 35 gallons of diesel fuel could have caused a burned up vehicle and or injury/ loss of life.

See all problems of the 1997 Dodge Ram 3500 🔎.

Fuel gauge reads half full and it is empty. I have put in 6 fuel sending units and it will last 6 to 9 months and the gauge will slowly start to show fuel in tank and it is empty. This is a very common problem with all diesels. Last time I was ran out of fuel in the fast lane of I-75 in florida. Cars wound up in the median and shoulder cause my truck was dead in the fast lane. Gauge read a little over half a tank of fuel. This is going to get someone killed.

See all problems of the 2001 Dodge Ram 3500 🔎.

# 4 fuel line on Dodge cummins 5. 9 l diesels cracks forcing 5-6 GLS. Of fuel in 5 miles onto engine. By me giving the auto dealers parts counter the type of engine (5. 9 l diesel) and that it was a fuel line problem he already knew which line it was.

When purchased at the dealers driveway, idle dropped extremely low then surged, salesman said that was normal for diesels, drove from that dealership to home with same problems almost at every stop, took to dealership again, they changed fuel filter, no change, then changed fuel pump, no change, then said they think it might be injectors or fuel rails, I had enough asked for the keys they still made me pay $600 plus to remove the vehicle even though they couldn't find the problem, shortly after that I started getting alot of blow by from number 6 cylinder, the pcm stopped functioning normally so I had to replace that, shortly after that I had to replace the turbo charger. Recently I was driving it and it started smoking extremely bad and just quit, I opened the hood and there was oil everywhere, had to have it towed home where it still sits as of this day. I have heard so many bad things about this vehicle between the years of 2006 and 2007, I think it only fair the dealer should stand up for their product.

2007 Dodge diesel 3500 truck fuel filter system doesn't work will not stop any thing and kills injectors.

The contact owns a 2008 Dodge Ram 3500. While driving 60 mph, the contact was informed by other motorists that his vehicle was on fire. He then noticed flames in the cabin and the bed, in addition to the fuel tank. He pulled over and called the fire department. The highway patrol also arrived at the scene. The vehicle left a trail of fire on the highway due to the fuel leak. The vehicle was towed to a salvage yard. The insurance company was notified and stated that there was a shortage between the fuel pump and the fuel tank. The dealer wanted to investigate; however, they will not inform the contact or the insurance company what caused the fire. The passenger sustained minor burns to his hands, arms, and hair. A police report was filed. The failure and current mileages were 19,000.

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Dodge truck died,wouldn't start, when trying to start gas was leaking all over the engine, towed to aamco, fuel filter housing was leaking, mopar part was discontinued because Chrysler was aware of the problem, new part cost $1606 to replace,. . This should have been a recall because of the safety hazard. . . Chrysler said it wasn't an issue and refused to reimburse the cost of the part. . . . Aamco said that Chrysler had a lot of problems with this part so why wasn't it recalled. . . All it would have taken was a spark to set the truck on fire.

See all problems of the 1999 Dodge Ram 3500 🔎.

Started noticing truck hard to start, then it dies at idle, in traffic etc, it happens about anywhere from 4 times a day to 4 times a week just depends, told that the truck transfer pump is a dealer item only at about 400. 00 over the coast of internet pricing for the kit, wouldn't this be a recall? I have searched an found numerous other complains on this same problem , but since Dodge discontinued the exterior transfer pump then it was a design flaw and should be a recall I had my truck die on my 2 times today in traffic moving 70 miles an hour with kids in the back seat and an 18 wheeler behind me , the truck has no other problems but I don't think Dodge should be allowed to change the design with out having a recall.

Vehicle died on road with no warning. Dodge won't replace the fuel injectors under my warranty because I had sediment in my gas tank.

2002 Dodge diesel turbo charged: while pulling up a hill in 95 degree outside temperature, towing a 5th wheel trailer, and acts like the turbo charger cut out while the engine continues to run without power. This does not happen in cooler temperature or while not towing. This is a danger that can lead to a very serious accident.