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moderate 10 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
No new NHTSA fuel system complaint has been filed on this vehicle in over 11 years — the issue may be aging out of the active population.
Fuel leakage, in the presence of an ignition source, could result in a fire.
The manufacturer has issued service bulletins covering fuel system 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.
Part Description: Injector, Fuel Issue Description: Attention: Be aware that although they may look the same there are different injectors for the 6.7L Cummins Turbo Diesel depending on application and they are not interchangeable! Using the wrong injector may seriously affect engine operation. The proper usages are as follows:~ For DH/D1 (Ram 2500/3500 pickup - with a factory bed) the P/N is: 68027067AA~ For DC/DM (Ram 3500/4500/5500 Chassis Cabs) the P/N is: 68002012AB
full bulletin at NHTSA ↗CHRYSLER GROUP: THERE ARE DIAGNOSTIC ENHANCEMENTS FOR THE FUEL SYSTEM.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
Owners describe recurring fuel injector line failures where the #4 cylinder line cracks and sprays diesel fuel over the engine, hood, firewall, and electrical connections due to vibration loosening the retention bracket. In two separate cases, fuel pooled under the vehicle and on towed trailers; one owner pulled over immediately after smelling diesel and seeing smoke. Fuel injector failures appear across multiple cylinders in the same vehicle, with #5 and #6 injectors failing around 48,000–54,000 miles despite warranty replacement. Loss of power and engine stalling accompany these failures.
The fuel tank vent allows dirt and contaminants into the system, clogging components and stranding one truck at 68,500 miles; the $675 aftermarket "vent up fit kit" suggests Dodge awareness of the defect. Check engine lights cycle repeatedly over months with codes P254A, P2262, P1451, and P2000. Dealers perform carbon clearing, turbo replacement, ECM flashing, emissions recalls, and computer updates—some per TSB—without lasting results. One owner reports a turbo failure at 5,000 miles (warranty) and recurrence at 119,000 miles. One dealership refused warranty coverage on six injector replacements ($4,322.91), claiming water in the diesel; another owner's case worker never contacted them. Exhaust fumes in the cabin via HVAC fresh air intake persisted even after a $1,068.84 EGR valve replacement.
Same Dodge Ram 2500 fuel system reports on nearby years: 2005
The #4 cylinder fuel injector line from the common rail cracks and sprays fuel over the engine, hood, firewall insulation, and electrical connections. The retention bracket becomes loose due to vibration, which leads to the line cracking. Owners report fuel pooling under the truck and smoke from the engine compartment.
When: 64,000 miles in one case; appears across multiple model years (2006–2007)
Symptoms owners cite: Fuel spraying from #4 injector line; Smoke emitting from engine compartment; Fuel pooling under vehicle; Fuel all over engine, under truck, and on towed trailer; Diesel fuel smell while driving
Repairs/costs cited: Line replacement required; one owner reported fuel tank drop, flush, and system cleaning with 'vent up fit kit' ($675) totaling $1,175 plus $130.90 for 34 gallons of fuel
Recalls/TSBs owners mention: No TSB issued despite awareness of problem per owner report; 'vent up fit kit' availability suggests knowledge of fuel system contamination issues
Individual fuel injectors (#5 and #6 in one case) fail, causing loss of engine power and check engine light illumination. Injectors are replaced during warranty, but failures recur on other cylinders shortly after.
When: 48,000–54,000 miles for reported failure and recurrence
Symptoms owners cite: Check engine light illumination; Loss of power to vehicle while driving (~50 mph); Engine stalling without warning
Repairs/costs cited: Fuel injector replacement (reported for #5 and #6 injectors); repairs conducted under warranty but recurrence occurred
Fuel tank vent allows dirt and contaminants to enter the fuel system, clogging multiple components. The original equipment vent was inadequate, requiring replacement with an aftermarket 'vent up fit kit.'
When: 68,500 miles when stranded
Symptoms owners cite: Vehicle left owner stranded; Fuel system blockage
Repairs/costs cited: Fuel tank drop, system flush, disposal of 34 gallons of fuel, installation of aftermarket 'vent up fit kit' ($675); total repair cost $1,175 plus fuel cost $130.90
Recalls/TSBs owners mention: Aftermarket 'vent up fit kit' available, suggesting Dodge knowledge of the defect; owner questions why not issued as recall
Check engine light cycles on and off repeatedly over months, with codes P254A, P2262, P1451, and P2000 appearing. Dealer performs multiple attempts to resolve via carbon clearing, turbo assembly replacement, ECM flashing, and computer updates with no lasting fix. Multiple shop visits and TSB procedures fail to resolve the issue.
When: Two weeks after delivery (07/12/07) through at least 08/25/08; another case reports 119,000 miles with repeated turbo failures
Symptoms owners cite: Check engine light cycling on and off repeatedly; Turbo assembly failure
Codes mentioned: P254A, P2262, P1451, P2000
Repairs/costs cited: Turbo assembly replacement, carbon clearing procedure, ECM flash per TSB, emissions recall, sensor replacement, ECM reprogramming, computer updates; one owner reports turbo failure at 5,000 miles (under warranty) and again at 119,000 miles
Recalls/TSBs owners mention: ECM flash per TSB; emissions recall performed; multiple computer updates attempted; no permanent resolution; owner also mentions computer crash at 119,000 miles
Exhaust fumes enter the cab through the heater-A/C fresh air intake intermittently. Does not occur when recirculation mode is used. Independent and dealer shops unable to identify cause in initial visits. One dealer identified small EGR valve leak; replacement at $1,068.84 did not resolve the issue. Owner suspects diesel particulate filter operation or smog system malfunction.
When: Intermittent issue; EGR valve replaced
Symptoms owners cite: Exhaust fumes entering cab via fresh air intake; Intermittent occurrence; No occurrence in recirculation mode
Repairs/costs cited: EGR valve/cooler assembly replacement ($1,068.84); did not resolve problem
Recalls/TSBs owners mention: No resolution from multiple dealer shops or independent shop
Synthesized from 10 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
Exhaust fumes entering the cab via the heater-a/c fresh air intake. Does not do this when the "recirculation" mode is used. I've had an independent shop and three different Dodge dealer shops check for the problem. The first three shops could find nothing wrong. The last shop said there was a small leak in the EGR valve assembly. I had dealership shop (lithia Dodge of roseburg,or) replace the…
It's a documented issue but not catastrophic. 10 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
Based on the 10 complaints filed, fuel system issues most often appear around 51,769 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
Independent shops typically charge around $1,200 for fuel system 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.
Yes — 1 active recall(s) cover fuel system issues on this vehicle. Recall fixes are always free regardless of mileage or warranty status. Use the VIN decoder at the top of the page to check if your specific vehicle is affected.