NHTSA Complaint #11660700 — 2021 RAM 1500

I am reporting a recurring safety issue involving exhaust fumes entering the cabin of my 2021 Ram 1500 Big Horn, particularly during cold starts or remote starts while idling. Despite multiple attempts to have this issue repaired through authorized dealerships, the problem has not been resolved. On the first visit, dealership technicians discovered two cracked exhaust manifolds, which were replaced. On a second visit, they found and tightened bolts further. On the third visit, they claimed there was no longer a problem, but no physical diagnostic tests (such as pressure, bubble, or smoke testing) were conducted. Still concerned for my family’s safety, I paid for an independent diagnostic inspection. The certified mechanic confirmed an exhaust leak at the junction between the exhaust manifold and collector pipe, citing either improper installation or flawed sealing from previous repairs. The technician verified this using a stethoscope and noted a strong odor inside the cabin via the HVAC system. This issue poses a potential carbon monoxide exposure risk to occupants, especially during colder conditions when the vehicle is idling and windows are closed. RAM case management (case #92878431) has been involved, but there has been poor communication and no clear resolution. I am concerned this is a manufacturing or design defect and that it could affect other owners. I am requesting that NHTSA investigate this issue due to the serious health and safety risks associated with exhaust fume exposure.