2020 RAM 4500

The Office of Defects Investigation (ODI) opened PE21-021 on October 14, 2021, to investigate incidents alleging a stall/loss of motive power as a result of high-pressure fuel pump failures in certain model year (MY) 2019-2020 Ram 2500, 3500, 4500, and 5500 heavy duty trucks equipped with 6.7L Cummins turbodiesel engines. During the investigation, ODI sought to determine if the related defect allegation was limited in scope to the recalled population. After review of information request response materials from both FCA and BMW, NHTSA determined that sufficient information to identify a comprehensive recall population could not be produced by FCA and BMW.During the investigation FCA filed recalls 22V406, 22E048, 22V767, and 22E087 which include vehicles not identified in the initial subject population by ODI. ODI also received recall 21V586, involving loss of motive power due to failed CP4 fuel pumps on certain BMW manufactured vehicles. An information request letter response received from BMW indicated that failed pumps on their vehicles were caused by an interaction between pump internal components and US market diesel fuel, leading to increased slip and eventual particle-generating wear surface. Additional work will be done to identify whether a similar root cause is associated with the FCA recalled population and if similar wear dynamics occur on pumps supplied to vehicle manufacturers other than those included in the recalled population.ODI has upgraded this investigation to an EA in order to 1) determine engineering specifications of internal pump components that are correlated with pump failure leading to loss of motive power or other safety related hazards, 2) identify vehicle populations equipped with alleged defective pump variants, 3) assess if vehicles equipped with alleged defective pump variants result in an unreasonable risk to motor vehicle safety and 4) gather and review any other relevant information related to high pressure fuel pump failure associated with the subject populations of recalls 21V586, 21V880, 21E094, 22V406, 22E048, 22V767, and 22E087.Review of the above information will allow NHTSA to confirm root cause and recall remedy viability, and identify and evaluate vehicle populations equipped with pump components that may pose an unreasonable risk to motor vehicle safety.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID using the following complaint identification numbers: 11257550, 11351441, 11361603, 11361616, 11365300, 11365426, 11365858, 11366401, 11372337, 11373793, 11374797, 11376793, 11377871, 11378173, 11384377, 11386063, 11387018, 11399710, 11402550, 11415339, 11418868, 11418870, 11427075, 11434276, 11436807, 11437226, 11437249, 11437273, 11437292, 11437294, 11437394, 11437399, 11437403, 11437405, 11437423, 11437528, 11437565, 11437579, 11437580, 11437590, 11437679, 11437744, 11437781, 11437842, 11437993, 11438006, 11438008, 11438121, 11438138, 11438155, 11438392, 11438629, 11439359, 11439879, 11440397, 11443030, 11446542, 11448163, 11453556, 11458918, 11460558, 11469337

The Office of Defects Investigation (ODI) opened PE21-021 on October 14, 2021 to investigate allegations of stall/loss of motive power as a result of high pressure fuel pump failures in certain model year (MY) 2019-2020 RAM 2500, 3500, 4500, and 5500 heavy duty trucks equipped with 6.7L Cummins turbodiesel engines.On November 12, 2021, FCA filed vehicle recall 21V-880 and equipment recall 21E-094 on the subject population, identifying an `internally failed component? of the high pressure fuel pump equipped on the 6.7L Cummins Turbodiesel engine that introduced debris into the fuel system potentially causing fuel starvation and consequently an unexpected loss of motive power. Discussions with FCA identified the high pressure fuel pump equipped on these vehicles as the Bosch-supplied CP4. On December 16, 2021, Bosch filed recall 21E-101, stating the pump failure was a consequence of a manufacturer application-specific fuel system design.NHTSA subsequently identified recall 21V-586 involving loss of motive power due to failed CP4 fuel pumps on certain BMW vehicles.As a result of having received multiple recalls related to a common component, from two separate vehicle manufacturers, NHTSA?s focus shifted to determine if the related defect allegation was limited in scope to the recalled population. In early 2022, information request letters were sent to FCA and BMW to determine the root cause and consequentially identify the proper scope of potentially defective vehicles. After ODI received their information request response, FCA filed recalls 22V-406, 22E-048, 22V-767, and 22E-087. During review of information request response materials, NHTSA determined that sufficient information to identify a comprehensive recall population could not be produced by FCA or BMW. On March 17, 2023, this Preliminary Evaluation was upgraded to an Engineering Analysis (EA23-001), expanding the scope to include the Tier-one supplier and any manufacturer who equipped or installed similar high pressure fuel pumps subject to the failures observed in the recall population.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID using the following complaint identification numbers: 11351441, 11361603, 11361616, 11365300, 11365426, 11365858, 11366401, 11372337, 11373793, 11374797, 11376793, 11378173, 11384377, 11386063, 11387018, 11399710, 11402550, 11415339, 11418868, 11418870, 11427075, 11434276, 11436807, 11437226, 11437249, 11437273, 11437292, 11437294, 11437394, 11437399, 11437403, 11437405, 11437423, 11437528, 11437565, 11437579, 11437580, 11437590, 11437679, 11437744, 11437781, 11437842, 11437993, 11438006, 11438008, 11438121, 11438138, 11438155, 11438392, 11438629, 11439359, 11439879, 11440397, 11443030, 11448163, 11458918, 11460558

The contact owns a 2020 Ram 4500. The contact stated that while driving approximately 65 MPH during a rainstorm, the windshield wipers were activated; however, the windshield wipers failed to engage as needed. The contact attempted to activate the windshield wipers several times, but the windshield wipers stopped operating. The contact pulled over and waited out the rainstorm. The rain had not stopped, and the contact drove to a filling station, checked the electrical fuse for the windshield wipers, and then replaced the fuse. The contact stated that the wipers started to function, but only at the highest speed. The contact attempted to slow the windshield wipers, but when the wiper speed control was set to a slower speed, the wiper blades stopped working in the middle of the windshield. The contact drove to the residence with the windshield wipers functioning at high speed. The contact had taken the vehicle to a local dealer but had not yet received a diagnostic report. The vehicle was not repaired. The manufacturer was informed of the failure and referred the contact to the NHTSA Hotline to report the failure. The contact researched online and related the failure to NHTSA Campaign Number: 22V035000 (Visibility); however, the VIN was not included. The failure mileage was approximately 50,000.

NHTSA ID

11691170

Incident

Sep 22, 2025

Mileage

50,000 mi

The contact owns a 2020 Ram 4500. The contact received notification of NHTSA Campaign Number: 21V880000 (Fuel System, Diesel) and 22V035000 (Visibility) however, the parts to do the recall repairs were not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repairs. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

NHTSA ID

11466951

Incident

Nov 12, 2021

Truck turned off while driving and died. Would not turn back on. Was towing a 40ft gooseneck trailer with a load on it. Truck was stopped blocking multiple lanes of traffic. Truck and trailer had to be towed to nearest dealership where they found the CP4 fuel pump had failed and the entire fuel system needed to be replaced.

NHTSA ID

11437842

Incident

Nov 11, 2020

SENSOR - TURBOCHARGER SPEED

SENSOR - TURBOCHARGER SPEED

CORE – HEATER

CORE – HEATER

SWITCH – HEADLAMP

SWITCH – HEADLAMP