NHTSA Complaint #11627026 — 2019 RAM 2500

The truck was initially brought in on April 10, 2024, for a continuous regeneration issue with the DPF filter, showing codes P242F and P1451. The dealership diagnosed it as requiring a new EGR valve and possibly a DPF filter assembly, under the VB6 emissions recall and extended warranty (XQ1). After replacing the EGR valve, the Y-78 HPFP safety recall was completed. Upon completion, the technician noted multiple fuel-related DTCs, lack of power, and metal debris at the fuel control actuator caused by a failed CP4 pump. At this time, the dealership was unaware of the XQ1 warranty, so instead of replacing the DPF filter, they force regenerated it. Upon picking up the truck, the check engine light came on (April 26, 2024). After reporting it, the dealership stated the DPF filter needed replacement, and on May 26, 2024, it was replaced under XQ1. However, after picking up the truck again, the check engine light came back on, and diagnostics revealed misfires across all six cylinders (codes P0300–P0306) and abnormally high fuel pressure at the wire harness—issues that weren't present before the EGR valve or HPFP recall repairs. The truck has since remained at the dealership, with multiple unsuccessful attempts to fix the issue by replacing the fuel lifter, wire harness, fuel filter, and a second Y-78 recall replacement due to "faulty parts" from the first attempt. The dealership charged a diagnostic fee and suggested replacing rocker arms and push rods, but this did not resolve the problem. The dealership has since recommended replacing the PCM module but then retracted the recommendation and is now requesting a new diagnostic fee to tear down the engine, remove cylinder heads, and inspect for debris, as the misfires and high fuel pressure have persisted since April 26. The safety concern is that the truck behaves as though it is starving for fuel when the engine light reappears, with stored codes showing misfires and high fuel pressure, related to Y-78.