2022 Ram 3500 Engine Problems

### **NHTSA Complaint Statement of Facts** **RE: Recall Y43 (NHTSA Campaign 22V-406) – Failure of Recall Remedy** **Summary:** The manufacturer (Stellantis/FCA) is refusing to provide a complete and effective remedy for **Recall Y43**. My 2022 Ram 3500 was manufactured without the **Particulate Matter (PM) Sensor**, a defect officially acknowledged in Recall Y43. This factory omission has caused terminal blockage of the **Diesel Particulate Filter (DPF)**—a specific consequential failure documented in the manufacturer's own recall filing. **Technical Argument:** 1. **Causal Link:** The official Y43 recall notice states: *"The PM sensor... may not have been installed... This could increase vehicle emissions and **block the diesel particulate filter**."* My vehicle currently suffers from the exact "blocked DPF" condition described. 2. **Ineffective Remedy:** Stellantis has offered to install the missing sensor (the Y43 part) but refuses to replace the ruined DPF. Installing a sensor on a filter already terminally blocked due to the sensor's absence is not an "effective remedy" under the **National Traffic and Motor Vehicle Safety Act**. 3. **Warranty Admission:** Per **TSB 09-014-22 (X97)**, the manufacturer has issued a 1-year unlimited mile warranty extension for the DPF specifically for vehicles affected by Y43. Refusing to replace a filter that failed *before* the recall was performed is an attempt to circumvent this warranty obligation. **Safety Risk:** The vehicle is currently in "Limp Mode" with a "Filter Full - Power Reduced" message. This creates an unreasonable safety risk of **stalling or loss of power** while operating on public highways, a condition explicitly mentioned in the Y43 safety report as increasing the risk of an accident. I am seeking an order for the manufacturer to replace the DPF as part of the Y43 recall remedy at no cost to the consumer. The manufacturer’s Case Manager has denied the claim and refused further communication

Valvetrain No Yes Yes No

The contact owns a 2022 Ram 3500. The contact stated that while driving approximately 10-15 MPH, there was an abnormal rattling sound coming from the vehicle. The engine warning light was illuminated. The local dealer was contacted, and it was determined that the grid heater bolt had melted and fallen into the engine. The vehicle was repaired after two months due to the piston being on backorder. The manufacturer was contacted, but no additional assistance was provided. The approximate failure mileage was 35,000. The VIN was not available.

Lifter tick issue on 2019 to 2024 ram 6.7 engines ....lifters failing casuing excessive wear on valve train known issue major costly repair

The contact owns a 2022 Ram 3500. The contact stated that while driving at various speeds, the vehicle hesitated to accelerate while the accelerator pedal was depressed. The check engine warning light was illuminated. The vehicle was taken to a local dealer, where it was diagnosed; however, the cause of the failure was not determined. In addition, the contact stated that the vehicle was taken to the same dealer approximately eight times, and a loaner vehicle was provided; however, after several unknown repairs, the failure reoccurred. The vehicle was previously repaired under warranty. The manufacturer was made aware of the failure. The failure mileage was approximately 2,000.

I own this truck and have had issues with the exhaust regeneration process for about 6 months. I have taken it to the dealer 3 times and they have done diagnostics and replaced the diesel particulate filter, but the issue continues to happen. They have now told me that the system is not reparable and they don't have support from RAM manufacturer to troubleshoot and repair this issue. They have multiple customers with the same issue with the diesel exhaust system not operating properly, hampering the engine performance, damaging the engine and exhaust system, polluting from the exhaust discharge. This is a widely known issue with the 2022 Ram 3500 from other owners, yet RAM refuses to properly address the issue. They advertise their trucks with certain horsepower and output specs, which aren't accurate due to their faulty exhaust systems. Consumers are now completely removing the factoring exhaust systems because they damage the engines and cost thousands of dollars to attempt to repair, which many times never work. This needs to be addressed with RAM and recalls put in place to address the failures with their exhaust systems. My truck has 28,000 miles on it, 3 years old, and is not operable. The dealer has had 3 attempts to repair this and is now turning me away. Please help! Thank you

The contact owns a 2022 Ram 3500. The contact stated that while driving at an undisclosed speed, the engine made abnormal knocking and ticking sounds. The knocking and ticking sounds became louder while accelerating. There was no warning light illuminated. The vehicle was taken to an independent mechanic, who determined that the piston had ingested the grid heater nut. The mechanic replaced the piston, cylinder head assembly, gaskets, rod, gasket intake, Hamilton flat tappet conversion kit, and XDP grid heater. The manufacturer was made aware of the failure. The failure mileage was 88,745.

The # 4 cam bearing seized to the camshaft. Upon further investigation the #4 main bearing was damaged from metal chips that were not removed during the manufacture of the engine. This damage from the manufacturing defect left the engine block damaged beyond repair. So a short block was ordered and installed.

Driving on highway 02/24/2025 approximately 07:15 pm EST at 65 mph, vehicle began Diesel DPF automatic regeneration cycle. Strong smell of "burning trash" and fuel vapor entered cabin with windows up. this happens frequently

Emission system failure. Code P2459 Regeneration Frequency. Overheating of the DPF while stuck in regen cycle causes burning smell and diesel fumes in the cabin while driving. Suspected vehicle on fire. Date of incident 01/25/2025. Vehicle at dealership for repair 01/28/2025. Dealership repair unsuccessful following STAR approved process of elimination. Vehicle returned to dealer 02/18/2025 for same issue. Many customers with 2019-2022 diesel engines having same issue. No known fix according to dealership.

The contact owns a 2022 Ram 3500. The contact stated while driving 40-45 MPH and hauling a 14-ft loaded trailer, the engine made an abnormally loud knocking sound. The check engine warning light was illuminated. The contact was able to pull over to the side of the road. The vehicle failed to restart and was towed to the residence, where a mobile independent mechanic diagnosed that the grid heater nut had melted and entered cylinder #6. The vehicle was then towed to the dealer, where it was diagnosed that the grid heater nut failure had caused catastrophic failure of the pistons, turbo charger, and engine. The dealer determined that the engine assembly needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and informed the contact that the repair could not be covered under warranty due to the mileage on the vehicle. The failure mileage was approximately 112,700.

The contact owns a 2022 Ram 3500. The contact stated while at a stop light, the vehicle would not accelerate, with the check engine warning light illuminated. The vehicle was towed to the dealer and the contact was informed that the hub one assembly kit and snap ring needed to be replaced. The vehicle was not repaired. The manufacturer was contact but provided no assistance. The failure mileage was 200,119.

DEF warning: see dealer. 125 miles until 5mph max speed. Happened 250 miles to nearest dealer during winter storm in SD and NE. Stranded at night, in storm, in freezing conditions, without available help. This is a potentially fatal situation due to failure of new vehicle despite preparation per vehicle manual. DEF tank 2/3 full, DPF gauge at 0. Eventually towed 135 miles to dealer to have DEF code reset. This is dangerous and very common.