2022 RAM 2500 Fuel system Problems

The vehicle has experienced repeated failures related to the diesel emissions system despite multiple repair attempts. The primary symptom is an illuminated check engine light accompanied by diagnostic trouble code P2459 (Diesel Particulate Filter Regeneration Frequency). The vehicle frequently enters regeneration cycles and continues to exhibit the same symptoms after major emissions system repairs. The emissions system components, including the Diesel Particulate Filter (DPF) and related DEF system components, were previously replaced by an authorized dealer. Following those repairs, the same warning light and fault code returned. The vehicle was subsequently inspected by another authorized dealer, which was unable to identify a definitive cause of the recurring condition. The check engine light was cleared, but it returned less than a week later with the same symptoms. The failure creates a safety concern because the vehicle may enter reduced-power or limp-home operating modes without warning, potentially limiting acceleration and the ability to maintain traffic speed. This is especially concerning when merging onto highways, crossing intersections, towing loads, or operating in heavy traffic. The recurring nature of the failure has reduced confidence in the reliability and safe operation of the vehicle. The condition has been reproduced multiple times and has been documented by authorized service facilities. Warning lamps and fault codes have repeatedly reappeared following repairs. The vehicle and emissions system components remain available for inspection upon request.

NHTSA ID

11743315

Incident

Mar 21, 2025

My 2022 Ram 2500 6.4L HEMI has a long crank/hard-start issue every morning. It takes 5–6 attempts to start when the vehicle sits overnight. After starting once, it runs normally the rest of the day. I also had issues where the truck struggled to start after refueling. I replaced the gas cap and EVAP purge valve, which improved the refueling issue, but the long-crank cold start continues. I suspect a fuel pump internal check-valve failure causing fuel pressure to bleed down overnight. This is common on these trucks and is a safety concern because the vehicle may fail to start in emergency situations or stall unexpectedly. No check-engine light is present. The issue is repeatable daily.” Faulty fuel pumps in these specific RAM models can suddenly fail while driving. This failure can lead to a complete loss of engine power without warning, increasing the risk of a crash.

NHTSA ID

11703388

Incident

Oct 1, 2025

Truck will regen every 100 miles, then Truck will come up with regen message then immediately come up with see dealer full dpf. Truck will start shutting down causing a safety hazard for family in truck. Dealer and ram will claim nothing is wrong with truck. And that we need to continuously pay for dpf manual regen $500 per manual regen (happens once a year). Truck has 32,000 miles and is a 2022. Dealer claims they did the recalls.

NHTSA ID

11673942

Incident

Jul 16, 2025

The Mass Air Flow (MAF) sensor on my 2022 Ram 2500 failed, causing multiple system malfunctions. It triggered inaccurate Diesel Particulate Filter (DPF) codes and showed abnormally high idle hours that do not reflect actual vehicle use. This defect is tied to a known issue identified by Stellantis in Technical Service Bulletin #18-002-24, which acknowledges improper MAF sensor calibration or compatibility on vehicles like mine. The bulletin was verbally confirmed by the dealership as applying to my truck. This faulty sensor caused emissions system errors, degraded engine performance, and may impact emissions compliance. There was a persistent check engine light, reduced fuel economy, and the risk of engine derating. The problem was reproduced and confirmed by Encore Chrysler (Mobile, AL), an authorized Ram dealership. Stellantis has agreed to cover the repair under Goodwill, but the issue appears systemic. Safety was potentially compromised by inaccurate sensor data that may cause sudden engine derate or failure during operation. Additionally, the incorrect idle hour readings could affect warranty determinations and long-term diagnostics if not corrected. The check engine light first appeared on May 21, 2024. The vehicle has been out of service since May 22, 2024, and repairs are still pending. The MAF sensor and affected systems are available for inspection upon request. This issue may affect a broader set of Ram 2500 trucks, and given the manufacturer’s internal bulletin, it may merit a recall review.

NHTSA ID

11664846

Incident

May 22, 2025

Significant fuel leak from top of engine, leaking down back of engine and creating puddles on ground. Potential fire hazard due to proximity to turbo and exhaust. No warning lamps or messages. Issue was confirmed at dealer and repaired by replacing multiple fuel injector supply lines.

NHTSA ID

11616556

Incident

Sep 13, 2024

the forward fuel filter canister is constructed of plastic.i have found several blog sites complaining of the canister cracking and leaking fuel down the side o the engine.i replaced the filter in my truck several months ago and last week I noticed a heavy flow of fuel coming from under the diesel motor.the dealer said I did the damage when I changed the filter[a very simple job that any room temperature IQ mechanic could perform}now they want to charge me hundreds to replace it. I found a company that has already made a better part to replace the cheap plastic canister with a billet aluminum fixture.i don't think its right to push off their poor quality parts on consumers and then make them pay to fix it.check out Cummins Forum and Black Market Performance for the improved replacement parts.

NHTSA ID

11592767

Incident

May 24, 2024

The contact owns a 2022 Ram 2500. The contact stated that while driving at an undisclosed speed, the "Service DEF Now." Message and check engine warning light was illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the diesel exhaust fluid (DEF). The vehicle was repaired, but the failure reoccurred. The vehicle was taken back to the dealer, who was unable to diagnose the failure but informed the contact that all diagnostic trouble codes were cleared. Later, the contact stated that while driving at an undisclosed speed, the vehicle displayed the message "Unable to Exceed 5 MPH." After which, the vehicle lost significant motive power. The vehicle was again taken back to the dealer, who was unable to diagnose the failure. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 17,000.

NHTSA ID

11580995

Incident

Mar 26, 2024

Mileage

17,000 mi

My 2022 Ram 2500 with only 9,900 miles failed to start requiring it be towed to the dealership. The dealer reported the fuel injector harness had failed and replaced it but then it started throwing other codes. The technician determined there was metal shavings in high pressure fuel pump (HPFP) so they contacted Ram engineers and started a STAR case. After two months and countless "pictures" taken and sent the the Ram engineers, they claim it was contaminated fuel which caused the metal shavings to be found in the HPFP. The engineers stated that there were no metal shavings found in the return filter so the metal shaving came from "contaminated fuel." This logic is impossible because for metal shavings to make it from the fuel tank to the HPFP and be visible they must travel through two fuel filter, one of which filters down to 5 microns. The dealership acknowledged the engineers logic didn't make sense to them either. The return filter showed some debris but if metal shavings can pass through a 5 micron paper filter than it would also pass through the metal screen found on the return line inside the tank. Ram is refusing to honor their warranty and trying to stick me with the bill even after they already are aware of a faulty fuel pump in their trucks.

NHTSA ID

11546544

Incident

Jul 22, 2023

DEF sensor malfunctions, threatening to limit vehicle to 5 mph or stop completely. This is because DEF fluid freezes in cold weather. Sensor reads that DEF tank is empty, even when it is full. Contacted local dealer who confirmed the issue and noted that it is a prevalent problem and he has a backlog of trucks with the same issue. I consider this a safety issue, as I could be stranded on the road in winter conditions or not have access to my vehicle in case of emergency. Google search shows that this is a significant issue affecting many people. Dealer said that the only solution is to put the vehicle in a heated garage for several days to defrost the DEF and allow the sensor to reset. They currently have a backlog of several weeks. And then what happens when you get it back? You hope it doesn't refreeze and strand you on the road somewhere?

NHTSA ID

11455502

Incident

Mar 7, 2022

This is a 2022 Ram 2500 Long Horn with teh 6.7L Cummings Diesel. I have owned it for 30 days and it has 1475 miles on the odometer. The Service DEF System came on and after talking with the local dealership, the DEF sensor and or DEF pump has failed due to the DEF freezing. They have explained that this is a know issue and has affected the 2019 to present model year. After doing extensive research on neumorous blogs, it is a much larger problem than the dealer is letting on. It appears to be created by a design change that took place in 2019 and is caused by the DEF fluid itself freezing in the tank damaging the DEF sensor. DEF freezes at -12 so those of us living in areas where it may hit -12 are all affected by this situation and in reality, have spend 60k plus on a vehicle that we cannot operate. Either the DEF needs to be redesigned to not freeze or Ram needs to redesign, or go back to what they had that worked, the DEF system. This is not only an emmisions issue it is also a saftey issue. If the DEF system does not work, the vehicle does not meet the current emmisions standards. If the vehicle goes into limp in mode, you have strandad customers along side the road becomming a safety hazard and if the limp in mode happens at highway speeds, who knows the effectis on the vehicle as it slows down and creats a hazzard on the highway. Please work with RAM to remedy this situation so those of us with a 61k + boat anchor can use their trucks as they intended to when they spent their hard earned money to do so.

NHTSA ID

11454623

Incident

Feb 28, 2022