2022 RAM 3500 Fuel system Problems

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

NHTSA ID

11722490

Incident

Sep 1, 2025

***1*** The emissions system on this truck (2022 Ram 3500 with 34,435 miles) has been problematic since I acquired it 5 months ago. It continually attempts to regenerate and rid itself of ash/soot buildup. If it does not successfully regenerate, it will go into a state of reduced power, also known as limp mode. The truck is available for inspection and will be at Lithia CDJR in Corpus Christi tomorrow, 07 Jan 2026. ***2*** Today specifically, the truck flashed a message EXHAUST FILTER NEARING FULL SAFELY DRIVE AT CONSISTENT SPEED TO CLEAR. I got on the highway to achieve this and avoid lights and stop/go traffic. It typically takes around 25 minutes of consistent driving for it to clear. But today, shortly after I reached highway speeds, the truck entered limp mode, displaying EXHAUST FILTER FULL REDUCED POWER SEE DEALER. This was a very alarming incident that created a bottleneck on the highway and presumably for me to nearly be rear ended as it happened at 5:35pm. I was able to safely make it off of the highway, however this incident has put the lives of all motorists on the road around me today in danger. ***3*** The truck has been inspected numerous times by the dealership. The Diesel Particulate Filter was replaced on 01 October 2025 (this was the first time the truck went into limp mode on me). The frequent regenerations continued after the DPF replacement and a sensor was replaced on 29 October 2025. Regens continue at approximately 1 per week. ***4*** This is a known issue amongst the community of RAM truck owners. It's unfortunate that many do not report it because the safety issue could easily set off a chain reaction, especially if this heavy duty truck were to be towing a heavy load as it capable of doing.

NHTSA ID

11709256

Incident

Jan 6, 2026

My pm sensors or particulate matter system malfunction and failed which lead to emissions issues and created my vehicle to drive in limp mode. Limp mode basically slowed downs the vehicle is slow as 5 mph as soon as this light displays at any time while driving on the highway. This put my safety in danger and the public as I transport what dot considers a type hazardous material. The sudden loss of power in the middle of the road has made vehicles around me extremely vulnerable to fatal collisions. I took my vehicle to the dealership where they confirmed this malfunction and problem with my vehicle but no recall has been issued as of yet no warning lamps appeared prior to the failure.

NHTSA ID

11692604

Incident

Sep 8, 2025

My 2022 RAM 3500 has repeated failures of the diesel particulate filter (DPF) system. The truck enters limp mode unexpectedly, including while towing on the interstate, creating a serious safety hazard due to sudden loss of power. Since purchasing the vehicle, I have experienced ongoing issues with the emissions system, specifically related to the DPF. The check engine light comes on frequently, and diagnostic scans consistently show code P2459 (Diesel Particulate Filter Regeneration Frequency Too High). The DPF system has been replaced approximately five times by authorized RAM dealer. Despite these repairs, the same problem continues to occur. The truck will sometimes enter limp mode without warning, drastically reducing engine power. This has happened while towing a camper on the interstate, making it difficult or impossible to maintain safe highway speeds or accelerate when needed. This puts me, my passengers, and other motorists at risk of a crash, particularly when merging or changing lanes in fast-moving traffic. I have already pursued and settled a claim with Stellantis (RAM’s manufacturer) for $10k due to these issues. However, the problem persists, and the root cause has not been resolved. Accepting the settlement was recommended by legal counsel. The failure has occurred on multiple occasions (at least five separate incidents). The vehicle has undergone several service visits and emissions system replacements, but the safety issue continues. Current mileage 42,000. Dates of incidents from most recent: 6/25 (still in shop), 3/25, 9/24, 8/24,7/24,6/24,4/24,1/24,7/23,6/23,11/22. Documentation available upon request. Diesel particulate filter (DPF) system replaced approximately five times. I believe there is a defect in the design or operation of the emissions system that poses a safety risk. Loss of power while driving at highway speeds or towing creates a dangerous situation. I am reporting this in hopes that NHTSA will investigate this recurring issue.

NHTSA ID

11667995

Incident

Nov 17, 2022

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

NHTSA ID

11645431

Incident

Feb 24, 2025

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.

NHTSA ID

11643337

Incident

Jan 25, 2025

On 9 September, while driving, I got an emergency dashboard notice that stated Throttle System Malfunction contact dealer. It went out and then another immediately flashed that stated Exhaust System Malfunction contact dealer. The vehicle lost power within seconds after the second notice. I coasted to a stop on the side of the road. Once stopped, smoke quickly started coming out of the engine compartment and then flames. I contacted 911, an engine arrived but the truck was fully engaged and completely burnt.

NHTSA ID

11624859

Incident

Sep 9, 2024

The engine stopped while driving with no warning and provided no opportunity to exit the travel lane of the road. No warning lights were illuminated on the dashboard and all gauges appeared normal leading up to the event. This event is extremely frustrating, but I am thankful that it didn't happen on the interstate as there is no telling what the outcome may have been......... Leading up to the event, I had been driving on the interstate around 70mph for about 180 miles since the last restart. I exited the interstate and made it about 3/4 miles on a secondary road and the engine died without warning and the truck came to a quick stop in the lane of travel. No abnormal sounds were observed, just a sudden unwelcome deacceleration that did not provide enough time to exit the lane of travel. It was like stepping on the brakes. I attempted to restart the truck and the starter would not crank the engine and briefly pulled enough voltage to kill all the electronics. I attempted starting it again with a jump box attached and met the same result. The computers freaking out from the low voltage during the starting attempts wouldn't allow me to put the truck in neutral to move it out of the lane of travel. A police officer called for the tow truck on rotation since I was stuck in a live travel lane. The truck was towed to the Dealer on 8/19/2024 after the service department had closed and still would not turn over when removed from the tow truck. There were no signs of any fluids leaking from the truck after the event........ The next day the Service Advisor called and advised there were only 3 codes stored related to low voltage. Truck is waiting for a tech to become available to further investigate.

NHTSA ID

11609700

Incident

Aug 19, 2024

The Deisel Exhaust Fluid (DEF), SUPPLY LINE (part #57008975AA) has been replaced on my truck 4 times in 113 k miles. It now needs replaced again. The last 2 times were less than 5000 miles each. It is a plastic line that runs from the DEF tank and passes nearby the exhaust filter which is very hot. A RAM dealer in Georgia told me they have sold/replaced many of these lines. When cracked, they leak DEF in large volumes on the ground which then becomes contaminated.

NHTSA ID

11595715

Incident

Jun 19, 2024

The dealer and manufacture have not been able to fix emissions issue. It has cause severe fuel saturation in oil and has cause severe motor damage. No one cares and they brush it off as no big deal.

NHTSA ID

11584318

Incident

Apr 19, 2024

HIGH PRESSURE FUEL PUMP WENT OUT. I KNOW THEY HAD A RECALL ON THIS BEFORE. TRUCK IS DOWN AND IT WILL COST TO MUCH TO REPLACE FUEL SYSTEM

NHTSA ID

11569445

Incident

Jan 22, 2024

Transmission K1 snap ring failure. Left me stranded on busy road unable to move truck.Dealer has diagnost it. No warnings, just failed.

NHTSA ID

11533176

Incident

Jun 28, 2023

hello, on the truck, a review was opened, they took the truck to the dealership, they didn’t even give us anything in return, since they were in california themselves from new york for another 2 weeks, they waited in line, they said to replace the transmission and something light to do, more than a month has passed, the costs will grow hotel trailer work we don’t know what to do, they don’t pick up the phone by the truck, they take 80 thousand each and the attitude is terrible

NHTSA ID

11521839

Incident

Mar 7, 2023

Diesel Particulate Filter (DPF) Sensor never installed, digital gauge has never read anything but 0%. This can cause issues with regeneration of the DPF that will result in Limp mode.

NHTSA ID

11477076

Incident

Aug 2, 2022