Ram 1500 Fuel System problems by year

$15,035.42. This is the same failure the safety recall was supposed to fix. The high-pressure fuel pump on this truck was replaced under Recall Z46 (NHTSA campaign 22V-406) on July 12, 2024, repair order 577727, at about 47,604 miles. The replacement pump failed in the recall's own documented failure mode - introducing debris into the fuel system and causing fuel starvation and loss of drive power - after 18,849 miles and about 27 months. The truck is unrepaired and the failed pump is intact and available for inspection. I have asked FCA to cover the repair as a repeat failure of the recall remedy.

pulled the fuel filter housing and is claiming that the system is currently clean and working as designed. However, because I have undeniable, timestamped media evidence of severe metal contamination inside the fuel loop at the exact moment of failure, I am filing this complaint because a federally mandated safety recall component has failed, and the current dealership diagnostics are contradicting the physical evidence of the breakdown.

road. Because the vehicle was unsafe to leave as-is, I had to rig a temporary strap harness under the truck to hold the tank up just enough to carefully limp the vehicle home. This sudden structural failure presents a massive fire and road hazard. Upon contacting my local Ram/Chrysler dealership, I was informed that there is no active recall covering my specific vehicle. However, after researching the issue on automotive forums and Facebook owner groups, I discovered this is a widespread and well-documented defect among Ram 1500 owners. While some older models received a formal recall (Recall U04) for this exact issue, many owners of newer models like mine are being left without assistance, forcing them to pay out-of-pocket at independent mechanics or attempt DIY repairs on a critical safety component. I urge the NHTSA to investigate this ongoing defect for 2016 models. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

contact stated that the vehicle was previously repaired under NHTSA Campaign Number: 22V406000 (Fuel System, Diesel) in May 2024. The dealer was contacted and made aware of the failure. The manufacturer was contacted, and a case was filed. In addition, the contact stated that several cases were filed. The contact was advised to contact the dealer for assistance. The failure mileage was approximately 168,000.

has not inspected the truck. The red throttle warning light came on and the truck stored a P016F fuel pressure code at the time of the failure. A MAP sensor code had appeared earlier and cleared, but I'm not aware of other warning signs before the failure.

I can provide photos of the rotted out area as well as strap that is rotting as well. A known issue like this should not have a time line and should be replaced at no cost. Original in service date for the vehicle was February 18, 2014

the vehicle was moved to the side of the road and parked just east of [[redacted]] on [[redacted]]. Passenger and eyewitness [[redacted]] experienced the entire incident and also observed the fuel tank beneath the vehicle and the broken straps. The vehicle could crank but would not start; and the fuel lines and electrical supply were both damaged. The check-engine light illuminated, as well as the fuel low and fuel sensor fail messages occurred during and after the incident. AAA towed the vehicle directly to Byers Chrysler Jeep Dodge Ram on [redacted]. Dealer repair order [redacted] was opened [redacted], and the vehicle was physically inspected on [redacted]. The dealer documented: "VERIFIED CUSTOMER CONCERN. CHECKED AND FOUND REAR FUEL TANK STRAP MOUNT IS RUSTED OUT. NOTHING TO HOLD TANK IN VEHICLE." The dealer further documented that the vehicle "NEEDS FRAME OR REPAIRED FOR REAR FUEL TANK STRAP." No recall repairs could be made; therefore the disabled vehicle was returned. The concern is that failure of the fuel-tank retention system caused the fuel tank to drop onto the roadway while the vehicle was moving. The dealer subsequently found that the rear fuel-tank strap mounting area was rusted out and that there was "NOTHING TO HOLD TANK IN VEHICLE." I request that NHTSA investigate whether corrosion at the fuel-tank strap/frame attachment area can progress to the point that the fuel tank can no longer be safely retained. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Peterson CDJR performed Safety Recall Z46 (NHTSA 22V-406) Procedure A, replacing only the high-pressure fuel pump. September 2026 (RO #45520): Vehicle presented with an illuminated check engine light. Peterson CDJR diagnosed a faulty fuel pressure sensor and replaced the fuel rail and sensor for $2,809.45. September 2026 (RO #46751): Following a 55-mile test drive, Peterson CDJR technician verified the diesel fuel from the fuel tank tested completely clean. Inspection of the newly installed fuel rail sensor documented internal metallic debris actively circulating through the fuel system. September-October 2026: Peterson CDJR opened STAR Case #102997574. DealerCONNECT records and the technician notes from RO #45520 state that the entire fuel system requires replacement. Dealer requested authorization for Recall Z46 Procedure B (complete fuel system replacement kit CSSMZ46DAA). October 5, 2026: Stellantis corporate documented via DealerCONNECT that the fuel system requires replacement, but stated they will not authorize the repair under warranty because the recall was previously closed. Inspections by Manufacturer / Others: Inspected by Peterson CDJR certified technicians and documented in STAR Case #102997574. Reviewed via DealerCONNECT by Stellantis corporate, who confirmed fuel system failure but refused remedy coverage under open Corporate Case #98257662. I have not had followup from my Stellantis case manager. Dealer is responsive.

entire fuel system and requiring a complete $9,080 replacement of the fuel loop. This is a complete failure of a federal safety recall remedy, duplicating the exact highway stalling hazard the recall was issued to fix. Stellantis/FCA must investigate why these replacement remedy pumps are continuing to fail and creating dangerous conditions for drivers.

stopped and in park. I popped the hood and looked around the engine compartment. I saw no fluids leaking and no steam or smoke coming from the engine. I then attempted to restart the vehicle and it did absolutely nothing. Vehicle was towed to a RAM dealership, [[redacted]] CRJD in [[redacted]]. The did a cursory inspection ad determined that the engine was seized up but gave no indication as to the cause. Recommendation was to replace engine at a cost of nearly 18K dollars. Upon conducting further investigation on my own, I discovered that the Z46 recall of the HPFP, described with total accuracy what I experienced on the highway that day. The recall was performed on my vehicle on [redacted]. It is fully my belief that the fuel pump that was replace through the recall has now failed in the same manner as described in the recall and was the cause of the complete engine failure. I have notified the dealership of my findings and opinions, and they are unwilling to investigate further without direction from the manufacturer. Notified Service Manager, [[redacted]]. ([redacted]) 1302 hours On [redacted] (1310 hours) I notified the RAM Recall Team, [[redacted]], of the situation. He advised that it was to be escalated to case/claim and that I would be contacted by a case file agent. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)