2015 Ram 1500 Fuel System Problems

Front strap on fuel tank is broken. It is a danger and being held in place by ratchet straps. It is also sagging.

After few hours of research I found a part number to order replacement fuel filter required for use from Recall 22v-406. After passed onto by FCA and reaching out to Mopar who passed me onto local dealer and research on various forums I found a part number 68632011AA for the fuel filter so I thought. I contacted dealer and was told no filter is available and no date when it will be available, so back to research to find part number CSSMZ462AA-001 in the recall listed, I tried to order online but was told to contact local dealer and they confirmed the number good and placed order. I received the part today to find filter and housing cap. the filter resembles previous filters used but does not have any MOPAR stamp on it says made in China but box is labeled MOPAR and says made in Korea. the date on box is 12/15/2023. Is an aftermarket filter being packaged as OEM filter for a recall?

After having recall 22v-406 completed on November 24,2024 I am nearing time to complete a fuel filter change which after having this recall completed specifies a particular part number requirement and this fuel filter pn 68632011AA is not available anywhere, so now I am at risk for my filter getting clogged and my vehicle stalling and if a gas station gets gasoline put in the diesel tank and it gets put in my truck I cannot use my truck until the systems is drained, clean and filter replaced. Call any MOPAR dealer and ask for that part number and they will tell you not available and no timeline for it to be available.

The contact owns a 2015 Ram 1500. The contact stated that while driving approximately 55 MPH, the vehicle started to hesitate while depressing the accelerator pedal, with the oil and check engine warning lights illuminated. The contact pulled over and attempted to restart the vehicle; however, the vehicle failed to restart. Due to the failure, the contact had the vehicle towed to the residence. The contact used a code reader to diagnose the vehicle and retrieved DTC: P0087 (Fuel Relay Flash System). The system advised the contact to replace the diesel injection pump, fuel pump, and fuel water separator filter. Upon investigation, the contact linked the failure to NHTSA Campaign Number: 22V406000 (Fuel System, Diesel); however, the VIN was not included in the recall. The contact called the dealer and left a message. The manufacturer was not notified of the failure. The failure mileage was approximately 122,000.

Gas tank straps corroded and broke off, causing gas tank to drop down off truck. Repair garage noticed and caught before caused a fire/accident.

The contact owns a 2015 Ram 1500. The contact received notification of NHTSA Campaign Number: 22V406000 (Fuel System, Diesel); however, the part to do the recall repair was not yet available. The contact stated that while driving at various speeds, the vehicle was running rough. The check engine warning light was illuminated. The vehicle was taken to a local dealer, where it was diagnosed with a seized engine. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 103,000.

On Friday, August 15, 2025, while leaving a grocery store, my wife pointed out that a part was hanging under my truck. After checking, I noticed that it was one of the two straps that supports the gas tank. It had dropped 3 inches from its original location and was only supported by one strap (the rear one). I temporarily attached the tank with a strap to secure it. At home, I checked the cause of this damage. I noticed that the area (the spacer on the frame, which has a "T"-shaped notch) where the tank strap is held (the end of the strap is "T"-shaped) is rotten, and the end of the strap has passed through. I didn't check the other attachment, but it could have the same problem because it's the same design. This part of the spacer is welded to the frame tightly and fills with dirt and water, causing corrosion.

The contact owns a 2015 Ram 1500. The contact stated that when the vehicle was taken for the annual State Inspection, the vehicle failed the State Inspection. The contact was informed that the fuel tank strap had excessive corrosion, causing the fuel tank to sag around 4 inches. No warning lights were illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the fuel tank strap bracket. The vehicle was repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 18V160000 (Fuel System, Gasoline), but the VIN was not included. The manufacturer was notified of the failure but provided no assistance. The failure mileage was 96,000.

While driving, I suddenly heard a loud metal on metal grinding noise. After getting off the road, other drivers stopped to report that there was a large "shower of sparks" coming from beneath my vehicle. Upon further inspection, I found that the forward fuel tank strap frame mount had completely corroded through. This resulted in the tank strap dislodging, and the front end of the fuel tank falling to just a few inches from the road. Meanwhile, the tank pushed the metal fuel strap against the vehicle's main drive shift, grinding away at the drive shaft like a metal lathe and creating the large shower of sparks directly next to the fuel tank. This was a known defect in the 2008 to 2012 models of this same truck that was the subject of recall. However, for my 2015 truck it is merely a "service bulletin" for the identical defect.

On July 2, 2021 my 2015 ecodiesel was given a software flash due to recall W58. This recall deals with the delamination of the tone wheel/CSPS and makes the vehicle rapidly lose acceleration. Instead of being an actual fix, the software simply put a band aid on the issue, by rerouting the tone wheel and sending to a different sensor. On [XXX] it was raining and when I tried to accelerate while in heavy city traffic, the truck lost acceleration rapidly and flashed service electronic throttle control and went into limp mode. I narrowly avoided being in a collision and limped the truck to a medical center parking lot (Koke Mill Medical in Springfield, IL). The truck wouldn't stay running and it wouldn't restart without great difficulty. I was able to limp it to a repair shop (Ruggless Automotive 3417 Constitution Dr, Springfield IL 62711 (217) 787-5484) I have a scanner and I scanned the truck and got code P0336 crankshaft position sensor. Ruggless Automotive ALSO got that code and got code P26AB (yet another recall issue with the EGR cooler recall VB1) Ruggless advised waiting for parts. Talked to Green Dodge about the issues, they didn't want to fix because out of warranty. I contacted FCA/Stellantis. I was given a case [XXX] and told to take to dealership for diagnostics and if diagnostics showed it was to do with the recall issues, that FCA would pay for repairs. Truck was towed BY ME to dealership July 3rd. Green Dodge called me and said they couldn't do any diagnostics because supposedly the battery was dead/bad/unable to be jump started. They tried to make me purchase a new battery from them or else they wouldn't do the diagnostics I need for FCA. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I am submitting this complaint to report a serious safety defect involving a high-pressure fuel system failure that occurred shortly after recall service was performed by an authorized dealership. The failure created a significant risk of engine compartment fire and potential loss of vehicle control. On March 25, 2025, my vehicle underwent recall service at Hall Ram Dealership for replacement of the high-pressure fuel pump. This repair required removal and reinstallation of the high-pressure fuel supply lines. These lines are torque-to-yield, single-use components that must be replaced once removed to ensure proper sealing under high operating pressures. On April 7, 2025, while driving at highway speed, the high-pressure fuel line connected to the pump suddenly ruptured. This resulted in an uncontrolled release of fuel into the engine compartment, creating an immediate safety hazard. Atomized fuel was exposed to high-temperature engine components, significantly increasing the risk of ignition and fire. The failure also posed a risk of sudden engine power loss. The vehicle required emergency towing. A review of the March 25 service invoice shows no documentation that the high-pressure fuel lines were replaced. This strongly suggests the original single-use lines were reused, contrary to OEM standards and accepted repair procedures. Reuse of these components can lead to sealing failure, fatigue, and rupture under pressure. This incident raises concerns regarding compliance with federal safety regulations, including 49 U.S.C. Chapter 301 and FMVSS No. 301 governing fuel system integrity. A fuel line rupture under normal operating conditions indicates a critical safety defect and possible improper execution of a recall remedy. I request that NHTSA investigate whether authorized repair facilities are properly following required procedures during recall repairs, including replacement of single-use fuel system components.

The contact owns a 2015 Ram 1500. While the contact’s father was driving at highway speeds, the check engine and throttle body warning lights illuminated and the vehicle started losing motive power; however, the vehicle failed to properly accelerate. The vehicle was taken to the local parts supply store who diagnosed that the throttle body had failed and needed to be replaced. The vehicle was not repaired. The contact stated that later driving on the freeway and attempting to pass a semi, the vehicle failed to properly accelerate and started shaking and vibrating abnormally. The vehicle was later restarted but only operated in "LIMP Mode” and failed to accelerate above 40 MPH. The contact stated that had scanner was used to diagnose the vehicle and retrieved information of high-pressure fuel pump failure. The vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The contact was informed that the VIN was not included in the NHTSA Campaign Number: 22V406000 (FUEL SYSTEM, DIESEL). The contact stated that the vehicle had experienced the failure listed in the recall. The failure mileage was 149,000.

The contact owns a 2015 Ram 1500. The contact stated that while the vehicle was parked, upon inspecting the vehicle, the contact became aware that the metal bar frame was rusted, and the fuel tank had detached from the vehicle. A dealer was contacted. The vehicle was not taken to the dealer to be diagnosed. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 18V160000 (FUEL SYSTEM, GASOLINE); however, the VIN was not included in the recall. The manufacturer was notified of the failure but offered no assistance. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 151,000.

The check engine light has been on and the code and a message of fuel sender unit failure is on the message being displayed. The vehicle always shows empty even when filled. I never know if the the car is going to run out of fuel while I'm diving it on the road or highway. I have to keep very good records to estimate how many miles I'll get before needing to refill. I've seen recalls from other car makers for the same problem.

Failing fuel pump

I looked under the truck before a long trip and found a gas tank strap hanging oddly. Upon looking further into discovered the mount has rusted through. Doing some online research I have found this is a fairly common issue.

The contact owns a 2015 Ram 1500. The contact stated while driving approximately 40 MPH, the vehicle shuddered and experienced a loss in motive power. The contact pulled over to the shoulder of the road and restarted the vehicle; however, upon arrival to the destination, there was black smoke coming from the rear exhaust. The vehicle was towed to an independent mechanic where the contact was advised to take the vehicle to a local dealer for a recall repair. The vehicle was towed to a local dealer where the high-pressure fuel pump was replaced; however, metal fragments were found in the fuel injectors were damaged. The contact was informed that unburnt fuel had damaged the DEF sensor and the sensor needed to be replaced. In addition, the contact was informed that the failure was related to Chrysler Recall: Z46; however, the repair was not covered by the warranty. The vehicle was not repaired because the repair was not covered by the manufacturer. The manufacturer was made aware of the failure. The failure mileage was approximately 140,000.

Fuel Tank strap (Front) disconnected from the frame slot it is attached to. The frame slot is completely rusted out. This was a recall on earlier models and amended to include other years including my year (2015). Yet it does not come up as a recall for my vehicle. I've seen online that this is a common problem with the Ram 1500. Vehicle mileage is 50,575.

The contact owns a 2015 Ram 1500. The contact stated while the vehicle was receiving a State Inspection, the mechanic diagnosed the vehicle with a small fuel leak, due to a faulty fuel cap. The fuel cap was replaced, and the failure was remedied. The contact stated that the failure eventually reoccurred, and the fuel cap was replaced a second time. The manufacturer and local dealer were not informed of the failure. The failure mileage was 80,000.

The contact owns a 2015 Ram 1500. The contact stated that the vehicle was repaired under NHTSA Campaign Number: 22V406000 (Fuel System, Diesel); however, the repair failed to prevent the failure. The contact stated that the vehicle was towed back to the local dealer where it was diagnosed and determined that the high-pressure fuel pump replacement had failed, causing metal shavings to enter the fuel line, fuel injectors, and the engine. The vehicle was left at the local dealer for further diagnostic testing. The manufacturer was made aware of the failure by the local dealer and the contact. The failure mileage was approximately 148,321.