GEAR MOTOR, Transfer Case The gear motor assembly is shipped in AWD/2WD position. The transfer case needs to be positioned in AWD/2WD position to properly assemble gear motor to T-Case. Please reference Star Online publication S2121000003 for further details. Do not have the transfer case in in another position other than AWD/2WD and rotate the motor to align the bolt holes as this could result in damage to the gear motor.
full bulletin at NHTSA ↗2006 Dodge Ram 2500 engine problems
severe 15 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
15
Recalls
0
Avg fix
$3,100
1crash
1fire
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
GEAR MOTOR, Transfer Case The gear motor assembly is shipped in AWD/2WD position. The transfer case needs to be positioned in AWD/2WD position to properly assemble gear motor to T-Case. Please reference Star Online publication S2121000003 for further details. Do not have the transfer case in in another position other than AWD/2WD and rotate the motor to align the bolt holes as this could result in damage to the gear motor.
full bulletin at NHTSA ↗Cummins Equipped Vehicles ONLY - The replacement oil pan gasket can be a four piece gasket rather than a single piece gasket. This applies to Cummins 5.9L and 6.7L engines only.
full bulletin at NHTSA ↗Service - Four Piece Oil Pan Gasket All Cummins Equipped Vehicles ONLY - The replacement oil pan gasket can be a four piece gasket rather than a single piece gasket. This applies to Cummins 5.9L and 6.7L engines only. Installation: 1. Clean the oil pan T-joints.~ 2. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar® Silicone Rubber Adhesive Sealant or equivalent. 3. Apply a 2-mm [0.063-in] bead of Mopar Engine Sealant RTV Silicone Rubber Adhesive, to the oil pan flange.~ 4. The four piece gasket will need to be assembled to make a complete oil pan gasket. 5. Lay the oil pan gasket(s) onto the oil pan flange.~ 6. Ensure the oil pan gask
full bulletin at NHTSA ↗Valve Body. These may cause over drive cycling.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Number 4 fuel injector line rupture is the dominant pattern in this cluster. Five owners report fuel line failure at the injector tube or coupling, typically while highway driving at 65–78 mph. The ruptures spray 2–3 gallons of diesel fuel into the engine compartment, saturating the firewall insulation. Owners describe white smoke, strong fuel smell, loss of power, and loss of power steering/brakes as the fuel ignites or dissipates. One owner notes the firewall was soaked and emphasizes fire risk. No recalls or service bulletins are mentioned; Chrysler customer service reportedly declined action on an expired warranty claim and did not acknowledge a safety concern.
Beyond the fuel line issue, owners report engine stalling at various speeds (low-speed stop-and-go and highway), sometimes accompanied by warning light illumination. One owner documents a long crank time (10–15 seconds) at startup that persisted after a dealer software update. Another reports abnormal acceleration at 78 mph that required shutting off and restarting the vehicle, resulting in a crash. Two owners describe power loss during highway driving. One notes metal particles in engine oil at 8,000 miles, prompting dealer concern about motor seizure. A hydro-lock failure from water ingestion and three serpentine belt breaks round out the reported issues, though these appear isolated.
Same Dodge Ram 2500 engine reports on nearby years: 2005 · 2007 · 2008 · 2009
Failure modes owners describe
Number 4 fuel injector tube rupture
Diesel fuel line ruptures at the number 4 injector tube or coupling seam, spraying 2–3 gallons of fuel into the engine compartment. Owners report this occurs only on the number 4 line among six injector lines and cite multiple internet forum reports of the same defect on 2006 Cummins diesel Ram trucks.
When: Highway driving at 65–78 mph; one owner also reports it occurred early in ownership
Symptoms owners cite: Check engine light illumination; Engine shutdown; White smoke from engine compartment and undercarriage; Strong fuel smell; Loss of power steering and power brakes; Visible fuel spray and pooling under engine and firewall; Firewall insulation saturated with diesel fuel
Repairs/costs cited: Dealer replaced number 4 injector tube; owners note this requires significant disassembly and cost recovery is difficult
Recalls/TSBs owners mention: Chrysler customer service declined to address the issue on an expired warranty; no recall or service bulletin mentioned
Engine stalling at various speeds
Vehicle stalls unexpectedly while driving or idling. Owners report stalling at stop signs and traffic lights, during 25 mph travel, and at highway speeds (65 mph). Vehicle typically restarts immediately.
When: 42,500–65,000 miles; also reported at 155,000 miles
Symptoms owners cite: Engine stall without warning; Warning lights illuminate during stall episodes; Loss of power during highway driving; Repeated stalling (multiple occurrences)
Repairs/costs cited: One dealer flushed throttle body with no resolution; dealers and independent mechanics cited power distribution center and integrated power module issues but could not fully resolve the problem on repeat visits
Recalls/TSBs owners mention: Manufacturer offered no assistance; noted as recurrent unresolved issue across multiple dealer visits
Extended engine crank time
Intermittent long start time on Cummins diesel engine. Occurs approximately one-third of the time. Dealer applied a computer software update that did not resolve the issue.
When: After 400 miles of ownership
Symptoms owners cite: Crank time of 10–15 seconds (normal is under 5 seconds typical)
Repairs/costs cited: Dealer installed software update; problem persisted
Recalls/TSBs owners mention: Dodge acknowledged the problem in June 2006 but had no fix available; owner alleges Dodge should have disclosed the issue before sale
Abnormal acceleration episode
Vehicle abnormally accelerates during highway driving at 78 mph. Owner turned vehicle off, shifted to neutral, and restarted to recover normal operation. Failure recurred three times, and on the fourth occurrence the vehicle was involved in a crash.
When: 144,000 miles
Symptoms owners cite: Sudden abnormal acceleration at highway speed; Required manual shutdown and restart to recover
Repairs/costs cited: Vehicle was not taken to dealer for diagnosis; front fender damaged in resulting crash
Recalls/TSBs owners mention: Manufacturer advised diagnostic testing at dealer; no further action mentioned
Metal particles in engine oil
Fresh oil change revealed large metal particles in oil at 8,000 miles. Dealer flagged as safety concern and stated motor could seize.
When: 8,000 miles; second oil change
Symptoms owners cite: Visible metal particles in fresh oil
Repairs/costs cited: Dealer held vehicle for safety reasons and scheduled diagnostic and repair work
Serpentine belt breakage
Belt broke three times in driveway within a 4-month period.
When: November 2007, January 2008, February 2008
Symptoms owners cite: Belt failure requiring replacement
Repairs/costs cited: Three replacements in four months
Synthesized from 15 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had engine trouble with your 2006 Dodge Ram 2500?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2006 Dodge Ram 2500?
It's a meaningful issue. 15 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 13 complaints that reported odometer mileage, most engine failures cluster between 21,000 and 114,400 miles, with the median around 65,000. A quarter of owners report trouble before 21,000; a quarter make it past 114,400. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2006/Dodge/Ram 2500.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.