The 2016 RAM 1500 exhibits a pattern of catastrophic failures across both gasoline and diesel engines. EcoDiesel owners report the most severe issues: EGR coolers fracture and leak coolant, causing overheating, engine fires, and melted intake manifolds starting at 40,000 miles. High-pressure fuel pumps seize internally, dumping metal particles throughout the fuel system and leaving owners stranded at highway speeds. Crankshaft position sensor tone wheels lose magnetic material, cutting ignition and power steering mid-drive. Crankshaft bearings fail and detach, with one owner documenting three complete engine failures by 145,000 miles.
The 5.7L HEMI gasoline engine develops exhaust manifold bolt fatigue around 40,000 miles, causing carbon monoxide leaks into the cabin—a hazard no recall addresses despite being documented since 2008. Plastic intake manifolds use sheet metal screws in untapped holes to hold the throttle body; holes strip on first tightening and replacement parts use the same defective design.
The AEM emissions software update deliberately degrades throttle response by 3–4 seconds from cold starts, creating genuine accident risk at intersections and highway merges. Dealers acknowledge this is intentional and unfixable.
Engines routinely consume coolant at alarming rates (4 gallons per year reported), yet dealers say no remedy exists. Stalling failures occur unprompted and often undiagnosed; multiple critical recalls remain parts-constrained for years after issue date, leaving owners driving unsafe vehicles with known defects.
Failure modes owners describe
EGR cooler and intake manifold failure with coolant leaks and fire risk
EGR cooler fractures or fails, leaking coolant into the engine and causing overheating, white/gray smoke from exhaust, and engine fires. Intake manifold melts or warps as a result. Owners report fires starting under the hood with sweet-smelling coolant fumes.
When: 40,000–156,000 miles
Symptoms owners cite: White or gray smoke from exhaust; Sweet-smelling fumes in cab; Loss of power while driving; Check engine light; Low oil pressure warning; Fire or flames under hood; Engine overheating; Coolant in oil
Codes mentioned: P0336, Service throttle control warning, Low oil pressure indicator
Repairs/costs cited: EGR cooler, intake manifold, exhaust particulate sensor, and sometimes engine replacement required. Some owners reported $4,750+ in repairs. Dealers encountered parts shortages and weeks-long delays.
Recalls/TSBs owners mention: NHTSA Campaign 19V757000 (Engine and Engine Cooling), 23V411000 (Engine and Engine Cooling). Recall parts frequently unavailable for extended periods. Some owners reported dealers said no fix available.
High-pressure fuel pump (CP4) failure and fuel system contamination
High-pressure fuel pump seizes internally or fails, causing metal particles to contaminate the entire fuel system. Vehicle loses power suddenly at highway speeds. Pump seizure can fracture the drive gear as a secondary failure. Some owners report pump failure immediately after recall work on the fuel system.
When: 40,000–184,000 miles; often shortly after fuel system recalls
Symptoms owners cite: Loss of power while driving; Vehicle shuts off without warning; Check engine light; Erratic check engine lights; Hard starting; Loud whining sound from engine; Unable to restart after stall
Codes mentioned: Fuel system fault codes, Fuel control sensor warning light
Repairs/costs cited: Complete fuel system replacement, fuel tank removal and cleaning required. Owners reported costs for tank cleaning charged separately even when contamination source was manufacturer defect. Dealers sometimes misdiagnosed as gear failure.
Recalls/TSBs owners mention: NHTSA Campaign 22V406000 (Fuel System, Diesel). Recall parts frequently on backorder; many owners unable to get repairs completed for months or years. Known defect in EcoDiesel vehicles per complaint narratives.
Crankshaft position sensor tone wheel magnetic material loss
Magnetic material attached to the tone wheel degrades or chunks detach, causing loss of crankshaft position signal. Engine cannot synchronize injector pulse and cam timing, resulting in stalling and loss of power. Vehicle may fail to restart. Secondary issues include failure of the crankshaft position sensor itself.
When: 40,000–216,000 miles
Symptoms owners cite: Engine stalling at highway speeds; Loss of power without warning; Engine fails to restart; Loss of power steering and brakes; Check engine light; Throttle positioning sensor fault
Codes mentioned: P0336 (crankshaft position sensor performance), Code PO336-00
Repairs/costs cited: Tone wheel and crankshaft position sensor replacement required. Some owners reported out-of-warranty denials despite matching failure pattern to active recalls.
Recalls/TSBs owners mention: NHTSA Campaign 20V475000 (W58), 23V411000 (66A). Some VINs not included in recall despite identical failure signatures. Owners reported manufacturer refused coverage when VIN not on recall list.
Crankshaft bearing failure and engine seizure
Crankshaft bearings detach or fail, damaging the entire engine. Loud cranking or thumping sound precedes engine seizure. One owner reported three engine failures in 90,000 miles; another reported metal in oil pan from crank failure.
When: 44,000–112,000+ miles; multiple failures possible within vehicle lifetime
Symptoms owners cite: Loud thumping or rocking sound from engine; Engine seizure while driving; Loss of power steering and brakes; Abnormal grinding noise; Metal debris in oil pan
Repairs/costs cited: Engine replacement necessary. One owner reported three engine replacements by 144,806 miles on a 2016 EcoDiesel. Dealers denied buyback requests.
Recalls/TSBs owners mention: NHTSA Campaign 23V411000 mentioned. One owner reported warranty denial due to mileage (44,000 miles, out of typical warranty). FCA refused multiple buyback requests despite three engine failures.
AEM (Approved Emissions Modification) software update causing throttle response lag and drivability issues
After AEM software reflash per emissions recall, vehicle exhibits severe throttle lag of 3–4 seconds when accelerating from stop or cold idle, especially at low speeds. Fuel economy drops 15–18%, overall power decreases noticeably, and idle quality suffers. Danger during highway merges and intersections.
When: Immediately to months after AEM software update (2019–2025)
Symptoms owners cite: 3–4 second throttle response delay from stop; Poor low-end acceleration; Sluggish acceleration; Reduced fuel economy (15–18% drop reported); Rough idle that slowly creeps down and dies; Need to idle 10–15 minutes before stable running; Hesitation and sputtering after accelerator input
Repairs/costs cited: AEM software update (ECM reflash) performed at dealership. Owners report no fix applied despite complaints to dealers and FCA. Dealers acknowledge awareness but state no remedy available.
Recalls/TSBs owners mention: Part of EcoDiesel emissions settlement. Advertised as having no performance impact, but owners report significant degradation. Dealers confirmed manufacturer aware of throttle lag complaints but no fix issued. VA7 update mentioned as performance restoration option but not available to all owners.
Excessive coolant consumption and loss
Engine consumes coolant at abnormally high rate, requiring top-ups every 1–4 weeks. One owner added 4 gallons in one year. Coolant leaks detected but may not be easily visible. Related to EGR cooler leaks and internal coolant path failures.
When: Throughout vehicle ownership; noted as early as 4 years old in complaints
Symptoms owners cite: Low coolant reservoir; Sweet-smelling fumes; Heater malfunction (heat quits); Coolant leak smell; Frequent need to add antifreeze
Repairs/costs cited: Dealers provided free antifreeze as temporary measure but no permanent repair. Owners reported dealer stated RAM aware but no fix available.
Recalls/TSBs owners mention: Dealer acknowledged manufacturer aware of excessive coolant consumption but stated no fix available. Free antifreeze provided as workaround.
Intake manifold design defect—throttle body fastener failure
Plastic intake manifold uses sheet metal screws in untapped plastic holes to secure throttle body. Screw holes strip easily, allowing throttle body to loosen. Replacement OEM manifold uses same poor design. Owners resort to high-temp RTV sealant to keep throttle body attached.
When: Typically noted when vehicle is used; becomes apparent after first tightening attempt
Symptoms owners cite: Rough idle; Throttle body loose or rattling; Difficulty accelerating
Repairs/costs cited: Attempted tightening of throttle body bolts per torque specs stripped holes. High-temp RTV sealant applied as field repair. Replacement OEM manifold exhibited same design flaw.
Recalls/TSBs owners mention: No recall issued. Design incorporated across Chrysler V-8 vehicles in multiple model years. Dealership unable to source replacement part with improved design.
Exhaust manifold bolt fatigue and exhaust leak hazard
Exhaust manifold bolts fatigue and fracture around 40,000 miles, causing exhaust leak. Leaked exhaust gases can be drawn into passenger cabin through intake air behind hood, creating carbon monoxide inhalation risk. Also causes emissions violations and fuel economy penalties. Widespread issue affecting 5.7L HEMI engines from 2008 onwards.
When: Typically 40,000+ miles
Symptoms owners cite: Exhaust leak noise; Carbon monoxide or exhaust smell in cabin; Performance loss; Check engine light (emissions-related)
Repairs/costs cited: Broken bolts replaced, new bolts installed. Repair cost typically $1,600+. RAM made design change to fix issue but no recall issued.
Recalls/TSBs owners mention: No recall despite documented history since 2008. Manufacturer aware per complaint narratives but chose not to issue recall. Design improvement exists but not retrofitted to existing vehicles.
Engine ticking noise on cold start—exhaust manifold bolt wear or lifter/cam wear
Cold-start engine ticking or knocking sound most noticeable at startup, diminishing after 1–3 minutes as engine warms. Occurs year-round. May indicate exhaust manifold bolt looseness or potential cam and lifter wear. Some owners report similar noise related to crankshaft bearing or crankshaft failures.
When: Observed starting at approximately 30,000 miles; persists through vehicle ownership
Symptoms owners cite: Ticking or knocking noise at cold start; Noise decreases as engine warms; Noise present in all seasons
Repairs/costs cited: No repairs documented in narratives for ticking-only complaints. Owners performed visual inspection finding no broken bolts but concern remains. Other complaints mention misfire codes related to cam/lifter wear.
Recalls/TSBs owners mention: No field service bulletins or recalls for cold-start ticking noted in complaints.
Cam and lifter wear at low mileage
Camshaft and valve lifters wear prematurely, generating misfire codes. Failures observed at 60,000–120,000 miles in 5.7L HEMI engines. Owners report this is a known issue in online forums.
When: 60,000–120,000 miles
Symptoms owners cite: Misfire code; Loss of power; Rough running
Codes mentioned: Misfire codes (unspecified in narrative)
Repairs/costs cited: Requires cam and lifter replacement or full engine replacement in some cases. Repair costs thousands to tens of thousands.
Recalls/TSBs owners mention: No recall or service bulletin noted in complaint narrative.
Post-recall stalling and loss of power due to unfinished recalls
Multiple owners received recall notices for fuel system and engine/cooling but parts were not available for weeks to months. Vehicle continued to be driven with known defects, resulting in stalling at highway speeds, loss of power steering and brakes, and fire risk.
When: Varies; often during gap between recall notice and parts availability (months to years)
Symptoms owners cite: Vehicle stalls without warning; Loss of power at highway speeds; Unable to accelerate; Check engine light; Loss of power steering and brakes
Codes mentioned: Related to NHTSA Campaign 22V406000 and 23V411000
Repairs/costs cited: Recalls issued but parts on backorder indefinitely in many cases. Owners left driving unsafe vehicles.
Recalls/TSBs owners mention: NHTSA Campaign 22V406000 (Fuel System, Diesel) and 23V411000 (Engine and Engine Cooling). Recall parts unavailable for extended periods; manufacturer did not provide loaner vehicles or interim remedies in most cases reported.
Synthesized from 230 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.