NHTSA Complaint #11714891 — 2021 RAM 1500

I am submitting this complaint to report a significant and unusual mechanical failure involving my 2021 Ram truck. The vehicle experienced a failure of the heater core assembly, which resulted in engine coolant leaking directly into the passenger compartment. This failure caused coolant odor and fluid intrusion inside the cabin and required extensive disassembly of the dashboard and HVAC system to repair. The total cost of repairs exceeded $5,300, which I believe is disproportionate and unexpected for a vehicle of this age and mileage. Two separate repair visits were required as it was found after the heater core was replaced the actuator on the driver’s side was damaged by the ongoing leak and required repair. The vehicle has been properly maintained and serviced according to manufacturer recommendations. While this incident did not result in an immediate crash or injury, the nature of the failure raises safety and health concerns, including: •Driver distraction due to coolant fumes and loss of defrost capability •Exposure of occupants to engine coolant within the enclosed passenger compartment •Sudden loss of cabin heating and windshield defogging capability in cold weather Given the age of the vehicle and the severity of the failure, this does not appear to be normal wear and tear. I am concerned that this may represent a design, material, or manufacturing defect that could affect other vehicles of the same model year. The odor was present for many months prior to the failure; however, the local dealership could not examine the issue at the time of a prior oil change due to lack of time on that visit. I am submitting this report to document the issue, assist in identifying potential patterns, and ensure appropriate review by the manufacturer and regulatory authorities. Repair invoices and supporting documentation are included.