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 ↗2007 Dodge Ram 3500 engine problems
severe 23 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
23
Recalls
0
Avg fix
$3,100
3fires
When does it fail?
Of the 23 engine complaints filed for the 2007 Dodge Ram 3500, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Of the 5 model years of Dodge Ram 3500 we track for engine problems, this one carries the most owner complaints on file — 23.
No new NHTSA engine complaint has been filed on this vehicle in over 8 years — the issue may be aging out of the active population.
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.
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 ↗NAG1 (5A580) Valve Body As per Warranty Bulletin D-13-22, please use R2108213A$ valve body for all Warranty (W), Mopar (M) and Mopar Vehicle Protection (F) claims.~ Assembly also includes Filter (52108325AA) and Gasket (52108332AA).~
full bulletin at NHTSA ↗Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications. An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2007 Dodge Ram 3500 diesel has a documented track record of premature DPF and catalytic converter failure. Multiple owners report the converter showing 100% full as early as 1,047 miles, with repeated plugging requiring replacement at $2,200–$6,000 per job. Carbon buildup from this system damages the turbo and EGR valve, forcing additional repairs and causing poor fuel economy (one owner reported 11.5 MPG instead of engineered efficiency). The DPF issue persists despite a recall (08V641000), and one recalled vehicle still caught fire while towing.
Exhaust fumes entering the cabin plague multiple owners, causing sore throats, burning eyes, and headaches—especially in winter with windows closed. The problem recurs after EGR valve, cooler, converter, and sensor replacements, with Chrysler refusing to fix it and claiming the system works as designed.
Fuel system issues include injector failure (all six requiring replacement at $5,100) and fuel line leaks from vibration-backed-out bolts, causing sudden engine shutdown and fuel spray into the engine bay. One owner reports a Cummins parts supplier selling 6–7 fuel lines monthly, suggesting this is widespread.
Engine fires are reported at various mileages, including underhood fires during normal driving. An unresolved recall for a dash silencer pad warned of potential fire risk but couldn't be completed due to parts unavailability.
Less common but serious issues include uncontrolled throttle acceleration (reaching 80 MPH without driver input, stoppable only by turning off the key) and crankshaft seal oil leaks at startup.
Same Dodge Ram 3500 engine reports on nearby years: 2005 · 2008
Failure modes owners describe
Diesel Particulate Filter (DPF) / Catalytic Converter Clogging
DPF and catalytic converters plug prematurely, causing loss of power, stalling, and repeated failures requiring replacement. Multiple owners report the converter reaching 100% full at very low mileage (1,047-21,000 miles). Owners cite excessive carbon buildup and inadequate regeneration.
When: As early as 1,047 miles; repeated failures within 2,000 miles of repair; failures at 12,000–107,000 miles
Symptoms owners cite: Check engine light illumination; Power loss or derating; Sudden stalling while driving; Poor fuel economy (11.5 MPG reported); Black smoke from exhaust; Vehicle unable to restart without computer reset
Repairs/costs cited: DPF replacement: $2,200–$3,000 per replacement; multiple replacements required on same vehicle. Catalytic converter replacement cost over $6,000. Some owners reported needing turbo cleaning (6 labor hours at $80/hr) and turbo replacement ($2,000). One dealer drilled port into turbo as band-aid remedy.
Recalls/TSBs owners mention: Recall 08V641000 issued; however, one owner reports recall failed and vehicle caught fire. One owner reports manufacturer offered to replace or buy back vehicle at 29,000 miles. Computer updates and reprogramming attempted without resolving underlying issue.
Engine Fire / Underhood Fire Hazard
Multiple owners report engine compartment fires, including fire at firewall during towing, fire while driving at 30 MPH, and underhood fire from unknown origin. One owner still had unresolved recall (H34 dash silencer pad) that warns of potential underhood fire.
When: Mileage ranging from 86,000 to unknown; some early in ownership
Symptoms owners cite: Smoke in cabin or from hood; Visible flames at firewall/engine compartment; Fire ignition during normal driving or towing
Repairs/costs cited: Vehicles destroyed by fire. One owner had recall part on backorder at time of report.
Recalls/TSBs owners mention: Recall 08V641000 performed on at least one fire vehicle; manufacturer inspector found 'no material defects.' Chrysler refused warranty coverage on totaled vehicle. Recall H34 (dash silencer pad) could not be completed due to parts unavailability.
Fuel Injector Failure
All six fuel injectors fail, causing fuel starvation, sudden power loss, and inability to restart. Failures recur after warranty expiration despite prior dealer repairs.
When: 10,000 miles after 100,000-mile warranty expired; failure mileage not specified in one complaint
Symptoms owners cite: Fuel starvation; Drastic loss of power while driving; Difficulty restarting engine; Check engine light
Repairs/costs cited: All six injectors require replacement at $5,100. One owner experienced injector malfunction after dealer repair, with recurrence 10,000 miles past warranty expiration.
Recalls/TSBs owners mention: Warranty claim denied; denial attributed to aftermarket modifications (Banks cold air intake and intercooler system) by dealership, though owner disputes causation.
High-Pressure Fuel Line Leak / Failure
Fuel line clamp bolt backs out due to vibration, causing diesel fuel spray into engine and sudden loss of power. Consumer reports Cummins parts supplier selling 6–7 fuel lines per month, suggesting widespread issue.
When: During highway driving at 50 MPH
Symptoms owners cite: Check engine light illumination; Sudden engine shutdown; Diesel fuel smell and visible fuel leak on engine; Fuel spray inside engine compartment
Repairs/costs cited: Fuel line replacement required. Cummins parts supplier reported selling multiple units monthly.
Exhaust Fume Intrusion into Cabin
Diesel exhaust fumes enter passenger cabin, causing health symptoms including sore throat, burning eyes, headaches, and nausea. Occurs at stops, idle, or when HVAC in vent/defrost mode. Problem persists after multiple repair attempts including EGR valve, cooler, catalytic converter, and sensor replacements.
When: Early in ownership; recurs during cold weather when windows must remain closed
Symptoms owners cite: Visible/smellable exhaust fumes in cabin; Sore throat, burning eyes, and nose; Headaches and nausea; Unpleasant taste in mouth; Symptoms triggered at stops, during idle, or in certain HVAC modes
Repairs/costs cited: Multiple repairs attempted: EGR valve replacement, EGR cooler replacement, extended tailpipe installation, catalytic converter replacement, three exhaust temperature sensor replacements, oxygen sensor replacement, particulate filter replacement over four dealer visits without resolution.
Recalls/TSBs owners mention: Chrysler sent letter stating the system operates as designed and no fix will be provided. Dealer blamed fuel quality on one complaint.
EGR Cooler Gasket / DPF Overheating and Cracking
EGR cooler gasket fails and DPF cracks from overheating, allowing fuel fumes to enter vehicle.
When: 40,000 miles
Symptoms owners cite: Fuel fumes emitted into vehicle during driving
Repairs/costs cited: EGR cooler gasket and DPF replacement/repair performed.
Turbo Failure
Turbo requires replacement due to carbon buildup from faulty catalytic/DPF system. One case required turbo replacement at high mileage after extended complaints.
When: 107,000 miles
Symptoms owners cite: Check engine warning light; Vehicle deceleration and stalling at 35 MPH
Repairs/costs cited: Turbo replacement needed; one owner cited $2,000 turbo/exhaust brake replacement cost.
Recalls/TSBs owners mention: Manufacturer contacted but vehicle not repaired under warranty (107,000 miles).
Uncontrolled Throttle / Runaway Engine
Engine accelerator does not respond to driver input and engine runs at full throttle uncontrollably. Only stopping by turning off ignition. Extremely dangerous at highway speed.
When: <UNKNOWN>
Symptoms owners cite: Diesel engine accelerates to full throttle without driver input; Unresponsive throttle control; Vehicle reached 80 MPH before driver could shut off engine
Crankshaft Seal Oil Leak
Front crankshaft seal leaks oil at startup and during warm-up. Owner notes this is a common issue with these engines.
When: <UNKNOWN>
Symptoms owners cite: Oil leak from front of engine; Leak occurs each time engine starts and warms up
Alternator Failure
Alternator fails early in vehicle ownership.
When: 1,100 miles
Symptoms owners cite: Alternator failure requiring replacement
Repairs/costs cited: Alternator replaced under warranty.
Synthesized from 23 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
Oil leak on front of engine. Crank seal problems. This is very common issue with these engines.leaks oil every time you start it and it warms up.
Tl*the contact owns a 2007 Dodge Ram 3500. Immediately after purchasing the vehicle in july of 2007, the contact noticed that the catalytic converter warning indicator illuminated on the instrument panel. After the illumination, the vehicle stalled. The dealer repaired the vehicle and they replaced the diesel particular filter. The dealer showed the contact how to reset the computer in order…
I was driving my truck across country and the power downgraded. I took it to a Dodge service dept and they told me my exhaust catalytic system was 90% plugged and it would cost over $6000 to replace it, but because of the nationwide problem with the catalytic system, there would be at least a 2 week wait to get the parts. I managed to drive it back to my home Dodge service dept. They gave me the…
Had engine trouble with your 2007 Dodge Ram 3500?
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 2007 Dodge Ram 3500?
It's a meaningful issue. 23 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 18 complaints that reported odometer mileage, most engine failures cluster between 12,000 and 86,000 miles, with the median around 35,800. A quarter of owners report trouble before 12,000; a quarter make it past 86,000. 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/2007/Dodge/Ram 3500.
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.