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 ↗2009 Dodge Ram 2500 engine problems
moderate 10 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
10
Recalls
0
Avg fix
$3,100
When does it fail?
Of the 10 engine complaints filed for the 2009 Dodge Ram 2500, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Of the 5 model years of Dodge Ram 2500 we track for engine problems, this one has the fewest owner complaints on file (10).
No new NHTSA engine complaint has been filed on this vehicle in over 12 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
Valve Body. These may cause over drive cycling.
full bulletin at NHTSA ↗NAG1 (5A580) Valve Body As per Warranty Bulletin D-13-22, please use R2108213A$ 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 ↗Flash: MIL Illumination With Transmission And Driveability Improvements This bulletin involves flash reprogramming the Powertrain Control Module (PCM) with new software. The customer may experience a MIL illumination. Upon further investigation the technician may find that any of the following erroneous Diagnostic Trouble Codes (DTCs): ? U0140 - Lost Communication With Body Control Module. 2010 DJ 5.7L (Sales Code EZC) Attempting to clear this DTC will be unsuccessful. ? P050D - Cold Start Rough Idle. ? P2181 - Cooling System Performance has been set. ? P0935 - Line Pressure Sensor Circuit High. All RFE transmissions. P0300 through P0308 - Multiple and Single Cylinder Misfire. This condition
full bulletin at NHTSA ↗RAM: DIESEL EXHAUST FLUID (DEF) GAUGE LEVEL IS ERRATIC AND STICKS FOR LONG PERIOD OF TIME ALONG WITH MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATING AND INFORMATION IS PROVIDED FOR APPROVING PROPER DIESEL EXHAUST FLUID INSIDE TANK AND REPLACING DEF PUMP IF NECESSARY
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2009 Ram 2500 diesel exhibits a chronic DPF problem that surfaces as early as 3,000 miles and recurs throughout the vehicle's life. The DPF warning light jumps straight to 80–100% full with no intermediate warnings at 25% or 50%, leaving owners blindsided. Dealer regeneration runs $150+, while additive-based turbo cleaning adds labor costs. One owner cycled through the clog three times and expects it will keep happening. Dodge has not issued a software upgrade to provide progressive warnings or address root causes.
The turbocharger clogs with soot, especially if owners drive primarily in town without pulling heavy loads or maintaining sustained high RPMs. Dealers clean turbo and DPF together, sometimes waiving diagnostic charges, but the underlying design—which expects constant highway pulls at 2,500+ RPM or trailer work—is impractical for typical owners.
Secondary failures compound the headaches: electrical ground shorts and grid heater failure at 162,000 miles, exhaust odor from loose manifold bolts, black smoke and stalling from failed particulate filters, exhaust fumes leaking into the cabin (unresolved across three dealers), and sporadic severe vibration events. Owners report Chrysler and Dodge providing no concrete fixes or warranty coverage, with manufacturer referrals to NHTSA instead of recalls or TSBs.
Same Dodge Ram 2500 engine reports on nearby years: 2006 · 2007 · 2008
Failure modes owners describe
DPF (Diesel Particulate Filter) clogging and regeneration failure
The DPF fills to 100% or beyond, triggering warning lights and requiring forced regeneration or professional cleaning. One owner reports the filter clogged three separate times and anticipates recurring issues. The 2009 models lack pre-warning intervals (25%/50% thresholds) that newer trucks provide, leaving owners unaware until the filter reaches critical fullness.
When: As early as 3,000 miles; also reported at 43,900 miles and recurring thereafter
Symptoms owners cite: DPF indicator light on dashboard illuminated; DPF warning light reading 80-100% full; Check engine light triggered; Vehicle restricted from operation per owner's manual instructions
Codes mentioned: DPF filter clogged, DPF filter full 100%
Repairs/costs cited: Dealer performed regeneration ($150+), additive cleaning (3 cans, 2-hour machine run), and software upgrade. One narrative estimates DPF + catalytic converter replacement at $5,000-$6,000. One owner had filter clogged three times requiring repeated dealer service.
Recalls/TSBs owners mention: Dealer software upgrade performed; Chrysler acknowledged complaint (#19286219, February 2010) but stated no fix available; Dodge referred owner to NHTSA; no manufacturer pre-warning system upgrade offered despite owner requests
Turbocharger clogging with soot accumulation
Turbocharger becomes clogged with soot, particularly in owners who do not use the diesel engine's automatic deceleration brake or who drive primarily in-town without heavy load pulls or sustained high-RPM highway driving. Error codes flag the turbo as faulty.
When: At 43,900 miles
Symptoms owners cite: Check engine light illuminated; Turbocharger error code present
Codes mentioned: Turbocharger error code
Repairs/costs cited: Dealer ordered additive-based turbo cleaning; performed 3 cleaning cycles with 3 cans of cleaner on a machine, taking 2 hours. Dealer waived labor charges ($150-$200 estimated based on other diesel turbo cleanings) citing interconnection with DPF issue.
Recalls/TSBs owners mention: Dealer service manager stated Dodge has no plans for a software upgrade to warn owners of turbocharger soot levels
Engine grid heater failure with electrical issues
Engine grid heater malfunction occurs alongside electrical ground shorts and low voltage to the intake air heater relay. Check engine light remains illuminated, and secondary electrical symptoms emerge.
When: At 162,000 miles
Symptoms owners cite: Check engine warning light illuminated; Headlights flashing off and on; Battery failed to remain charged
Codes mentioned: Electrical ground short, Low voltage to intake air heater relay, Engine grid heater faulty
Repairs/costs cited: Engine grid heater diagnosed as needing replacement; vehicle not yet repaired at time of complaint
Recalls/TSBs owners mention: Manufacturer and dealer notified; no assistance offered; VIN not covered under Extended Warranty
Abnormal exhaust odor and exhaust manifold bolt failure
Abnormal odor detected from exhaust at engine start-up, with check engine light illuminated. Dealer diagnosis points to loose or failing exhaust manifold bolts.
When: At 140,000 miles
Symptoms owners cite: Abnormal odor from exhaust at start-up; Check engine warning light illuminated
Repairs/costs cited: Dealer diagnosed exhaust manifold bolts as needing replacement; vehicle not repaired at time of complaint
Black smoke emission and exhaust stall
Black smoke erupts from the exhaust while driving at highway speed, causing engine stall and unknown warning light illumination. Mechanic diagnosis attributes failure to particulate filter exhaust system requiring replacement.
When: At 79,000 miles
Symptoms owners cite: Black smoke emitted from exhaust; Vehicle stalled; Unknown warning light illuminated
Repairs/costs cited: Independent mechanic diagnosed particulate filter exhaust system as needing replacement; vehicle not repaired
Exhaust fume leakage into cabin and undiagnosed ventilation issue
Exhaust fumes enter the passenger cabin through the ventilation system while vehicle is stopped. Three authorized dealers attempted diagnosis and repair of exhaust system and EGR gasket without resolving the problem. Root cause remains unidentified.
When: At 10,000 miles
Symptoms owners cite: Exhaust fumes emitting through interior vents
Repairs/costs cited: Various repairs attempted on exhaust system and EGR gasket at multiple dealers; failure persisted
Recalls/TSBs owners mention: Manufacturer made aware and referred contact to NHTSA
Severe engine vibration
Vehicle experienced severe shaking and vibration 2–3 times greater in intensity than typical road-surface-induced vibrations, causing driver concern over vehicle control and stability. No external loose parts found. Incident resolved on its own.
When: <UNKNOWN>
Symptoms owners cite: Violent shaking and vibration of entire truck; Concern over vehicle staying upright
Synthesized from 10 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
A few weeks ago my check engine light came on. Advance auto parts said an error code for the turbo charger was present. I have 43900 miles on the engine. Dealer told me it was not critical and I made an appt. Before bringing it back, a new code stated DPF filter full 100%. Brought it to the dealer and was told the DPF needed regeneration and would cost $150+. New trucks give warnings of…
The whole truck began shaking so violently, I thought I may loose control, or the truck would not stay upright. The shaking continued until I stopped on the shoulder. A careful inspection revealed no evidence of loose parts. I drove another 30 minutes (5 on freeway, 25 on surface roads) without another incident. Baffling. I have driven this diesel truck in many conditions and on many…
Had engine trouble with your 2009 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 2009 Dodge Ram 2500?
It's a documented issue but not catastrophic. 10 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Across the 9 complaints that reported odometer mileage, most engine failures cluster between 10,000 and 79,000 miles, with the median around 43,900. A quarter of owners report trouble before 10,000; a quarter make it past 79,000. 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/2009/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.