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November 12, 2021 NHTSA CAMPAIGN NUMBER: 21V880000
High Pressure Fuel Pump May Fail
An engine stall increases the risk of a crash.
NHTSA Campaign Number: 21V880
Manufacturer Chrysler (FCA US, LLC)
Components FUEL SYSTEM, DIESEL
Potential Number of Units Affected 222,410
Summary
Chrysler (FCA US, LLC) is recalling certain 2019-2020 Ram
2500, 3500 pickup trucks, and Ram
3500, 4500, and 5500 cab chassis vehicles equipped with Cummins 6.7L Turbo Diesel engines. The High Pressure Fuel Pump (HPFP) may fail, resulting in a sudden engine stall without warning.
Remedy
Dealers will replace the HPFP, update the Powertrain Control Module (PCM) software, and inspect and replace additional fuel system components as necessary, free of charge. Interim owner notification letters to inform owners of the safety recall were mailed on January 4, 2022. Owner notification letters were mailed on May 17, 2022. Phase 2 owner notification letters are expected to be mailed on March 2, 2023. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC’s number for this recall is Y78.
Notes
Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.
Check if your Vehicle has a Recall
New Safety Recall Advanced Communication – Y78
FCA US LLC (FCA US) has announced a safety recall on certain 2019 through 2020 Model Year (D2) Ram 3500 Pickup, (DD) Ram
3500 Cab Chassis, (DJ) Ram
2500 Pickup and (DP) Ram
4500/5500 Cab Chassis vehicles equipped with a 6.7L diesel engine.
REASON FOR THIS SAFETY RECALL
Some of the above vehicles may have been built with a High Pressure Fuel Pump (HPFP) that could fail prematurely. A high pressure fuel pump failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Fuel starvation may result in an unexpected loss of motive power, which can cause vehicle crash without prior warning.
SERVICE ACTION
FCA US will conduct a voluntary safety recall to replace the HPFP, update the Powertrain Control Module (PCM) software, and inspect and, if necessary, replace additional fuel system components. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 1st Quarter of 2022.
Revision June 2022
Dealer Service Instructions for:
Safety Recall Y78 / NHTSA 21V-880 High Pressure Fuel Pump
NOTE: Remedy Not Available has been updated. A new LOP has been added for fuel disposal. Floor Plan information has been added. A duplicate tool number was removed from the Special Tools list. The naming for the fuel tanks in the Repair description and Parts list has been updated.
Effective immediately all repairs on involved vehicles are to be performed according to this recall. Service Bulletin (TSB) 18-054-21 Rev. A is no longer applicable for the vehicles involved in this recall. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this recall.
Remedy Available
2020 (D2) Ram 3500 Pickup
2020 (DD) Ram 3500 Cab Chassis
2020 (DJ) Ram 2500 Pickup
2020 (DP) Ram 4500/5500 Cab Chassis
Remedy Not Available
2019* (D2) Ram 3500 Pickup
2019* (DD) Ram 3500 Cab Chassis
2019* (DJ) Ram 2500 Pickup
2019* (DP) Ram 4500/5500 Cab Chassis
* Remedy only available for 2019 models with open Recall W57, VB6, W03 or Y21.
NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine.
NOTE: Some vehicles above may have been identified as not involved in this recall and therefore have been excluded from this recall.
IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
The high pressure fuel pump (HPFP) on about 222,400 of the above vehicles may fail prematurely. A high pressure fuel pump failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Fuel starvation may result in an unexpected loss of motive power, which can cause vehicle crash without prior warning.
Repair
Vehicles delivered to the dealer in good running condition should complete HPFP replacement only. See Service Procedures A and B.
If the vehicle is brought to the dealer not running, the technician will follow the current diagnostic procedure to determine if there was an HPFP failure. If HPFP failure was determined, replacement of both the HPFP and tank assembly(s) is required, including fuel system cleaning. Tank assemblies are complete, production style units with pump module and tank. See Service Procedures A through D.
Alternate Transportation
Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that HPFP replacement and system cleaning is required and the vehicle must be held overnight.
Parts Information
Part Number | Description |
CSRLY781AA | Fuel Pump Upfit Kit |
Each package contains the following components: | |
Quantity | Description |
1 | 68573988AA, Pump, Fuel (Cummins 568362) |
1 | 68573990AA, Pilot Adapter (Cummins 5684299) |
1 | 68573989AA, Fuel Pump Adapter (Cummins 5684301) |
1 | 68573991AA, Jumper Harness (Cummins 5683566) |
1 | 68573993AA, Fuel Pump Support (Cummins 5684303) |
1 | 68573994AA, Threaded Spacer (Cummins 5685063) |
1 | 68573995AA, Injector Fuel Supply Tube (Cummins 5684069) |
1 | 68573996AA, Fuel Supply Tube (Cummins 5687735) |
1 | 68573997AA, Fuel Drain Tube (Cummins 5684067) |
1 | 68573999AA, Rail Plug (Cummins 5688160) |
1 | 68574000AA, ECM Bracket (Cummins 5684423) |
1 | 68573998AA, Connector, Quick Disconnect (Cummins 5688063) |
1 | 68578594AA, Swivel Tie Mount (Cummins 5689139) |
1 | 68359768AF, Power Steering Line (Cummins 5708745) |
2 | 68578595AA, Bolt, Low Profile (Cummins 5689141) |
2 | 04638665, Screw, Hex Flange Head (Cummins 3900678) |
1 | 04429446, Hex Flange Head Screw (Cummins 3901446) |
2 | 68578596AA, Screw, Socket Head Cap (Cummins 3420835) |
1 | 04429114, Hex Flange Head Screw (Cummins 3902114) |
1 | 04429630, Screw, Hex Flange Head (Cummins 3900630) |
1 | 68444371AA, Seal, O Ring (Cummins 5362113) |
1 | 69086175AA, Spring Washer (Cummins 5256193) |
1 | 68533229AA, Quick Disconnect Connector (Cummins 5624797) |
1 | 05086769AA, Hex Nut (Cummins 4890634) |
3 | 68038172AA, Wire Tie (Cummins 3062329) |
1 | 04429689, Nut (Cummins 3900589) |
For truck requiring tank replacement and fuel system cleaning, order one of the following.
CSRLY782AA Fuel Injector Kit H.O.
Each package contains the following components:
Quantity | Description |
6 | R8444790AA, Fuel Injectors (Cummins 5364204) |
1 | 68447760AA , Fuel Rail (Cummins 5348915) |
1 | 68479996AA, Fuel Line 1 (Cummins 5585171) |
1 | 68479997AA, Fuel Line 2 (Cummins 5585172) |
1 | 68479998AA, Fuel Line 3 (Cummins 5579140) |
1 | 68479999AA, Fuel Line 4 (Cummins 5585174) |
1 | 68480000AA, Fuel Line 5 (Cummins 5585175) |
1 | 68480003AA, Fuel Line 6 (Cummins 5585176) |
1 | 68417030AA, High Pressure Connector (Cummins 5473265) |
1 | 68157291AA, Fuel Filter, On Engine (Cummins 5260529) |
1 | 68436631AA, Fuel Filter, Chassis-mounted (Cummins 5708759) |
CSRLY783AA Fuel Injector Kit S.O.
Each package contains the following components:
Quantity | Description |
6 | R8444791AA, Fuel Injectors (Cummins 5364205) |
1 | 68447760AA, Fuel Rail (Cummins 5348915) |
1 | 68479996AA, Fuel Line 1 (Cummins 5585171) |
1 | 68479997AA, Fuel Line 2 (Cummins 5585172) |
1 | 68479998AA, Fuel Line 3 (Cummins 5579140) |
1 | 68479999AA, Fuel Line 4 (Cummins 5585174) |
1 | 68480000AA, Fuel Line 5 (Cummins 5585175) |
1 | 68480003AA, Fuel Line 6 (Cummins 5585176) |
1 | 68417030AA, High Pressure Connector (Cummins 5473265) |
1 | 68157291AA, Fuel Filter, On Engine (Cummins 5260529) |
1 | 68436331AA, Fuel Filter, Chassis-mounted (Cummins 5708759) |
For truck requiring tank replacement and fuel system cleaning, order the following.
CSRLY78AAA Campaign Kit
Each package contains the following components:
Quantity | Description |
2 | 69002992AA, Fuel Injector Banjo Washer |
1 | 68005162AA, Gasket |
Part Number | Qty. | Description |
68231618AC | 1 | 28 Gallon Tank Assembly Option (Sales Code NGC) |
68379693AG | 1 | 50 Gallon Tank Assembly Option (Sales Code NFC) |
68489122AB | 1 | 22 Gallon Midship Tank Assembly Option |
(Sales Code NFA) | ||
68489152AB | 1 | 52 Gallon Tank Assembly Option (Sales Code NFH) |
68231617AF | 1 | 32 Gallon Tank Assembly Option (Sales Code NFX) |
68231616AF | 1 | 31 Gallon Tank Assembly Option (Sales Code NFT) |
06506497AA | 4 | Bolts, Rear Drive Shaft (match to vehicle) |
06509166AA | 4 | Bolts, Rear Drive Shaft (match to vehicle) |
Parts Return
Render the recalled HPFP unusable and discard.
The fuel injectors will be subject to parts return. There is a core charge for the injectors. Follow the standard process for return.
Special Tools
The following special tools are required to perform this repair:
➢ NPN | wiTECH MicroPod II![]() |
➢ NPN | Laptop Computer |
➢ NPN | wiTECH Software |
➢ 7471B | Barring Tool |
➢ 2065500140 | Holder, Fuel Pump Gear |
➢ 1023 | Puller |
➢ 9688A | Cap Adapter, Power Steering Pump |
➢ C-4207-A | Vacuum Pump, Hand |
➢ 8978A | Decay Tool, Fuel |
➢ 2065600140 | Kit, Caps and Cover (Cummins) |
Service Procedure
See PDF Bellow…
Chronology :
- On October 13, 2021, the FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation as a result of warranty claims associated with the HPFP alleging a loss of motive power on 2019-2020 MY Ram
2500, 3500, and 4500/5500 vehicles.
- During October 2021, FCA US TSRC reviewed vehicle records and met with FCA US engineering and the supplier to review the issue, and understand the part design and change history.
- As of October 27, 2021, FCA US is aware of 495 customer assistance records, 6,399 warranty claims and zero field reports potentially related to this issue for all markets with dates of receipt ranging from August 28, 2018 to September 20, 2021.
- As of October 27, 2021, FCA US is not aware of any accidents or injuries potentially related to this issue for all markets.
- On November 04, 2021, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.
8 Affected Products
Vehicles
19 Associated Documents
Recall 573 Report
RCLRPT-21V880-8103.PDF 217.714KB
Recall Acknowledgement
RCAK-21V880-5836.pdf 645.008KB
Manufacturer Notices(to Dealers,etc) – NSRAC re New Safety Recall Advanced Communication Y78 FCA US LLC (FCA US) has announced a safety recall on certain 2019 through 2020 Model Year (D2) Ram 3500 Pickup, (DD) Ram
3500 Cab Chassis, (DJ) Ram
2500 Pickup and (DP) Ram
4500/5500 Cab Chassis vehicles equipped with a 6.7L diesel engine.
ISSUED Interim Owner Notification Letter(Part 577)
RIONL-21V880-5434.pdf 56.225KB
Manufacturer Notices(to Dealers,etc)
RCMN-21V880-9812.pdf 100.526KB
Defect Notice 573 Report
RCLRPT-21V880-8784.PDF 217.543KB
Miscellaneous Document – Representative copy of a postcard to owners re apology for remedy not available.
RMISC-21V880-3731.pdf 144.296KB
Remedy Instructions and TSB
RCRIT-21V880-8534.pdf 2150.588KB
Manufacturer Notices(to Dealers,etc) – Parts Ordering Issues
RCMN-21V880-0968.pdf 123.929KB
Manufacturer Notices(to Dealers,etc) – Dealer Communication re Critical Recall Y78 and TSB 18-054-21.
ISSUED Owner Notification Letter(Part 577)
RCONL-21V880-2779.pdf 174.278KB
ISSUED Owner Notification Letter(Part 577)
RCONL-21V880-8252.pdf 175.289KB
Manufacturer Notices(to Dealers,etc) – RECALL Y78 UPDATE – COMPLETION OF OTHER RECALLS REQUIRED
RCMN-21V880-6069.pdf 121.728KB
Remedy Instructions and TSB
RCRIT-21V880-5163.pdf 2157.873KB
Recall Quarterly Report #1, 2022-2
RCLQRT-21V880-5476.PDF 211.151KB
Manufacturer Notices(to Dealers,etc) – Dealer Notification re RECALL Y78, 2019MY COMPLETION HANDLING
Recall 573 Report – 8/18/22
RCLRPT-21V880-2815.PDF 218.163KB
Recall 573 Report – 3/1/22
RCLRPT-21V880-8989.PDF 217.744KB
Recall Quarterly Report #2, 2022-3
RCLQRT-21V880-0164.PDF 211.257KB
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For Chrysler recommended J2534 device, see below table.
J2534 Device | Firmware Version |
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UCAN 2 | 1.0 |
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CarDAQ-M |
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Launch wiTECH 2.0
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SEOCONTENT-START
URGENT SAFETY RECALL [RECALL DESCRIPTION] — [YXX /NHTSA XXV-XXX] [MY Make Model] [VIN #] Call 1-800-853-1403 Visit recalls.mopar.com to locate your closest dealer Download the Mopar Owner’s Companion App at either the App or Google Play Stores LOGO VEHICLE PICTURE Dear [CUSTOMER NAME]: Due to a data processing issue, you received a postcard asking to schedule a free repair on your open recall “XXX”. Although recall [XXX] is open on your vehicle, remedy is not yet available. We will contact you again once remedy becomes available. We apologize for any inconvenience this may have caused.
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This notice applies to your vehicle, Y78/NHTSA 21V-880 YOUR SCHEDULING OPTIONS 1. Visit recalls.mopar.com to sign up for email or SMS notifications for when remedy parts become available. You will be asked to provide your Vehicle Identification Number (VIN), provided above 2. Scan below using your smartphone or tablet to sign up to be notified when remedy parts become available 3. Wait for FCA US to contact you again, by mail, with a follow-up recall notice when remedy parts are available 4. Call the FCA Recall Assistance Center at 1-800-853-1403. An agent can sign you up to be notified when remedy parts become available, or answer any other questions you may have DEALERSHIP INSTRUCTIONS Please reference Safety Recall Y78. IMPORTANT SAFETY RECALL High Pressure Fuel Pump Dear [Name], This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. FCA US has decided that a defect, which relates to motor vehicle safety, exists in certain [2019 through 2020 Model Year (D2) Ram 3500 Pickup, (DD) Ram 3500 Cab Chassis, (DJ) Ram 2500 Pickup and (DP) Ram 4500/5500 Cab Chassis] vehicles. WHY DOES MY VEHICLE NEED REPAIRS? The high pressure fuel pump (HPFP) on your vehicle [1] may fail prematurely. A high pressure fuel pump failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Fuel starvation may result in an unexpected loss of motive power, which can increase the risk of a vehicle crash without prior warning. HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE? The remedy for this condition is not currently available. We are making every effort to finalize the remedy as quickly as possible, and will service your vehicle free of charge (parts and labor) when the remedy is available. FCA US will contact you again, by mail, with a follow-up recall notice when the remedy is available. Once you receive your follow-up notice, simply contact your Chrysler, Jeep®, Dodge
or RAM dealer right away to schedule a service appointment [2]. Additional options for your next steps are included on the left side of this notification. We appreciate your patience. WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED? If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online [3]. Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed. We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter. Customer Assistance/Field Operations FCA US LLC VEHICLE PICTURE [Model Year and Model] VIN XXXXXXXXXXXXXXXXX LOGO QR Code [1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information. [2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to safercar.gov. [3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21- 8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement. Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days. Mr. Mrs. Customer 1234 Main Street Hometown, MI 48371
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© Copyright 2022, FCA US LLC, All Rights Reserved (djt) Revision June 2022 Dealer Service Instructions for: Safety Recall Y78 / NHTSA 21V-880 High Pressure Fuel Pump NOTE: Remedy Not Available has been updated. A new LOP has been added for fuel disposal. Floor Plan information has been added. A duplicate tool number was removed from the Special Tools list. The naming for the fuel tanks in the Repair description and Parts list has been updated. Effective immediately all repairs on involved vehicles are to be performed according to this recall. Service Bulletin (TSB) 18-054-21 Rev. A is no longer applicable for the vehicles involved in this recall. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this recall. 2020 (D2) Ram 3500 Pickup 2020 (DD) Ram 3500 Cab Chassis 2020 (DJ) Ram 2500 Pickup 2020 (DP) Ram 4500/5500 Cab Chassis 2019* (D2) Ram 3500 Pickup 2019* (DD) Ram 3500 Cab Chassis 2019* (DJ) Ram 2500 Pickup 2019* (DP) Ram 4500/5500 Cab Chassis * Remedy only available for 2019 models with open Recall W57, VB6, W03 or Y21. Remedy Available Remedy Not Available Safety Recall Y78 – High Pressure Fuel Pump Page 2 NOTE: This recall applies only to the above vehicles equipped with a 6.7L diesel engine. NOTE: Some vehicles above may have been identified as not involved in this recall and therefore have been excluded from this recall. The high pressure fuel pump (HPFP) on about 222,400 of the above vehicles may fail prematurely. A high pressure fuel pump failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Fuel starvation may result in an unexpected loss of motive power, which can cause vehicle crash without prior warning. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject Safety Recall Y78 – High Pressure Fuel Pump Page 3 Vehicles delivered to the dealer in good running condition should complete HPFP replacement only. See Service Procedures A and B. If the vehicle is brought to the dealer not running, the technician will follow the current diagnostic procedure to determine if there was an HPFP failure. If HPFP failure was determined, replacement of both the HPFP and tank assembly(s) is required, including fuel system cleaning. Tank assemblies are complete, production style units with pump module and tank. See Service Procedures A through D. Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that HPFP replacement and system cleaning is required and the vehicle must be held overnight. Repair Alternate Transportation Safety Recall Y78 – High Pressure Fuel Pump Page 4 Part Number Description CSRLY781AA Fuel Pump Upfit Kit Each package contains the following components: Quantity Description 1 68573988AA, Pump, Fuel (Cummins 568362) 1 68573990AA, Pilot Adapter (Cummins 5684299) 1 68573989AA, Fuel Pump Adapter (Cummins 5684301) 1 68573991AA, Jumper Harness (Cummins 5683566) 1 68573993AA, Fuel Pump Support (Cummins 5684303) 1 68573994AA, Threaded Spacer (Cummins 5685063) 1 68573995AA, Injector Fuel Supply Tube (Cummins 5684069) 1 68573996AA, Fuel Supply Tube (Cummins 5687735) 1 68573997AA, Fuel Drain Tube (Cummins 5684067) 1 68573999AA, Rail Plug (Cummins 5688160) 1 68574000AA, ECM Bracket (Cummins 5684423) 1 68573998AA, Connector, Quick Disconnect (Cummins 5688063) 1 68578594AA, Swivel Tie Mount (Cummins 5689139) 1 68359768AF, Power Steering Line (Cummins 5708745) 2 68578595AA, Bolt, Low Profile (Cummins 5689141) 2 04638665, Screw, Hex Flange Head (Cummins 3900678) 1 04429446, Hex Flange Head Screw (Cummins 3901446) 2 68578596AA, Screw, Socket Head Cap (Cummins 3420835) 1 04429114, Hex Flange Head Screw (Cummins 3902114) 1 04429630, Screw, Hex Flange Head (Cummins 3900630) 1 68444371AA, Seal, O Ring (Cummins 5362113) 1 69086175AA, Spring Washer (Cummins 5256193) 1 68533229AA, Quick Disconnect Connector (Cummins 5624797) 1 05086769AA, Hex Nut (Cummins 4890634) 3 68038172AA, Wire Tie (Cummins 3062329) 1 04429689, Nut (Cummins 3900589) Parts Information Safety Recall Y78 – High Pressure Fuel Pump Page 5 For truck requiring tank replacement and fuel system cleaning, order one of the following. CSRLY782AA Fuel Injector Kit H.O. Each package contains the following components: Quantity Description 6 R8444790AA, Fuel Injectors (Cummins 5364204) 1 68447760AA , Fuel Rail (Cummins 5348915) 1 68479996AA, Fuel Line 1 (Cummins 5585171) 1 68479997AA, Fuel Line 2 (Cummins 5585172) 1 68479998AA, Fuel Line 3 (Cummins 5579140) 1 68479999AA, Fuel Line 4 (Cummins 5585174) 1 68480000AA, Fuel Line 5 (Cummins 5585175) 1 68480003AA, Fuel Line 6 (Cummins 5585176) 1 68417030AA, High Pressure Connector (Cummins 5473265) 1 68157291AA, Fuel Filter, On Engine (Cummins 5260529) 1 68436631AA, Fuel Filter, Chassis-mounted (Cummins 5708759) CSRLY783AA Fuel Injector Kit S.O. Each package contains the following components: Quantity Description 6 R8444791AA, Fuel Injectors (Cummins 5364205) 1 68447760AA, Fuel Rail (Cummins 5348915) 1 68479996AA, Fuel Line 1 (Cummins 5585171) 1 68479997AA, Fuel Line 2 (Cummins 5585172) 1 68479998AA, Fuel Line 3 (Cummins 5579140) 1 68479999AA, Fuel Line 4 (Cummins 5585174) 1 68480000AA, Fuel Line 5 (Cummins 5585175) 1 68480003AA, Fuel Line 6 (Cummins 5585176) 1 68417030AA, High Pressure Connector (Cummins 5473265) 1 68157291AA, Fuel Filter, On Engine (Cummins 5260529) 1 68436331AA, Fuel Filter, Chassis-mounted (Cummins 5708759) Parts Information [Continued] Safety Recall Y78 – High Pressure Fuel Pump Page 6 For truck requiring tank replacement and fuel system cleaning, order the following. CSRLY78AAA Campaign Kit Each package contains the following components: Quantity Description 2 69002992AA, Fuel Injector Banjo Washer 1 68005162AA, Gasket Part Number Qty. Description 68231618AC 1 28 Gallon Tank Assembly Option (Sales Code NGC) 68379693AG 1 50 Gallon Tank Assembly Option (Sales Code NFC) 68489122AB 1 22 Gallon Midship Tank Assembly Option (Sales Code NFA) 68489152AB 1 52 Gallon Tank Assembly Option (Sales Code NFH) 68231617AF 1 32 Gallon Tank Assembly Option (Sales Code NFX) 68231616AF 1 31 Gallon Tank Assembly Option (Sales Code NFT) 06506497AA 4 Bolts, Rear Drive Shaft (match to vehicle) 06509166AA 4 Bolts, Rear Drive Shaft (match to vehicle) Render the recalled HPFP unusable and discard. The fuel injectors will be subject to parts return. There is a core charge for the injectors. Follow the standard process for return. Parts Information [Continued] Parts Return Safety Recall Y78 – High Pressure Fuel Pump Page 7 The following special tools are required to perform this repair: ➢ NPN wiTECH MicroPod II ➢ NPN Laptop Computer ➢ NPN wiTECH Software ➢ 7471B Barring Tool ➢ 2065500140 Holder, Fuel Pump Gear ➢ 1023 Puller ➢ 9688A Cap Adapter, Power Steering Pump ➢ C-4207-A Vacuum Pump, Hand ➢ 8978A Decay Tool, Fuel ➢ 2065600140 Kit, Caps and Cover (Cummins) Special Tools Safety Recall Y78 – High Pressure Fuel Pump Page 8 Vehicles delivered to the dealer in good running condition should complete HPFP replacement only. See Service Procedures A and B. If the vehicle is brought to the dealer not running, the technician will follow the current diagnostic procedure to determine if there was an HPFP failure. If HPFP failure was determined, replacement of both the HPFP and tank assembly(s) is required, including fuel system cleaning. See Service Procedures A through D. A. Remove the Original Pump 1. If the fuel system is contaminated, follow procedure C. Install Fuel Tank Assembly and procedure D. Diesel Fuel System Cleaning prior to HPFP replacement. 2. Open the hood. NOTE: If the vehicle is equipped with an auxiliary battery, when disconnecting and isolating the negative battery cable for the 12-volt system, both batteries will need to be disconnected to power down the vehicle. 3. Disconnect the Intelligent Battery Sensor (IBS) wire harness connector (1) (Figure 1). NOTE: Failure to disconnect the IBS wire harness connector can lead to damage of the IBS wire harness connector. 3. Loosen the ground terminal nut (2) and remove the negative battery cable with IBS from the battery and isolate it (Figure 1). 4. If the vehicle is equipped with an auxiliary battery, loosen the clamp (1) and remove the clamp from the battery and isolate. Service Procedure Figure 1 – Intelligent Battery Sensor (IBS) Safety Recall Y78 – High Pressure Fuel Pump Page 9 WARNING: No sparks, open flames or smoking. Risk of poisoning from inhaling and swallowing fuel. Risk of injury to eyes and skin from contact with fuel. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing. CAUTION: Cleanliness cannot be over emphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. NOTE: Be sure to cap or cover any part of the fuel system after disassembly using Protection Kit, Caps & Covers 2065600140. 5. Remove the oil dip stick (3) (Figure 2). 6. Remove the bolts (1) and the engine cover (2) (Figure 2). 7. Partially raise the vehicle. 8. Remove the left front wheel and tire. 9. Remove the screws (1), if equipped (Figure 3). 10. Remove the push-pin fastener (3) and remove the spat (2) (Figure 3). Service Procedure [Continued] Figure 2 – Engine Cover Figure 3 – Splash Shield Spat Safety Recall Y78 – High Pressure Fuel Pump Page 10 11. Remove the splash shield screws (2) and the push-pins (1) (Figure 4). 12. Remove the wheelhouse splash shield. 13. Loosen the clamp (1) and disconnect the left Charge Air Cooler (CAC) hose (2) from the cooler (Figure 5). Service Procedure [Continued] Figure 4 – Splash Shield Figure 5 – Charge Air Cooler Hose Safety Recall Y78 – High Pressure Fuel Pump Page 11 14. Loosen the clamp (3) and disconnect the left CAC hose (2) from the Exhaust Gas Recirculation (EGR) air flow control valve and remove it (Figure 75. 15. Using the 7471B, position the engine at TDC by rotating the crankshaft until the TDC mark on the vibration damper is at the 12 o’clock position. 16. Cut the cable tie and position aside the bulkhead connector (1) (Figure 6). 17. If equipped, remove the left generator (Refer to 08 – Electrical / 8F Engine System / Charging / GENERATOR / Removal and Installation). 18. Remove the Fuel Rail Noise Silencer (Figure 7). Service Procedure [Continued] Figure 6 – Bulkhead Connector Figure 7 – Fuel Rail Noise Silencer Safety Recall Y78 – High Pressure Fuel Pump Page 12 19. Thoroughly clean rear of injection pump, and attachment points for its fuel lines. Also clean the opposite ends of these same lines at their attachment points. 20. Drain the engine mounted fuel filter. 21. Disconnect the low pressure supply (2) and return (3) lines from the fuel injection pump (Figure 8). 22. Disconnect the low pressure supply line (2) from the fuel filter housing and remove the line (Figure 8). 23. Disconnect the low pressure return line (3) from the fuel filter housing support bracket and remove the line (Figure 8). 24. Remove electrical connectors from the exhaust pressure sensor, EGR cooler bypass, crankcase pressure sensor connectors 1 and 2, fuel injector wire harness, engine harness retainers, EGR temperature sensor, and reposition the harness aside. 25. Remove the fuel pressure sensor connector, CCV oil drain tube from the vehicle, and the injector silencer pad. 26. Remove both high pressure fuel injection pump to rail tube union nuts (4) from the fuel pump only (Figure 8). Service Procedure [Continued] Figure 8 – Fuel Supply Lines Safety Recall Y78 – High Pressure Fuel Pump Page 13 27. Remove the nut (1) and bolt (7) securing the fuel tubes (16, 17). Reinstall bolt (7) (Figure 9). 28. Unscrew both high pressure fuel injection pump to fuel rail fuel tube union nuts and remove the fuel tubes (16, 17) (Figure 9). NOTE: Using the Kit, Caps and Cover (Cummins) 2065600140, cap the fuel rail inlets with appropriately sized caps. 29. Position a drain pan under the power steering pump. NOTE: Do not remove the fitting on the pump that the high pressure hose screws into. If the fitting does come loose, it must be retightened before continuing. NOTE: If the fitting comes out of the pump body, the internal spring and valve parts will drop out of the pump. They cannot be reinstalled properly. Install a new pump. Service Procedure [Continued] Figure 9 – HPFP Lines Safety Recall Y78 – High Pressure Fuel Pump Page 14 30. Using a backer wrench to stabilize the fitting disconnect the pressure hose (4) to the power steering pump (1) and DISCARD the washers (Figure 10). 31. Disconnect the ECU harness and move it out of the way. 32. Remove the nut (1) securing the engine harness to the fuel injection pump support bracket (Figure 11). 33. Remove engine harness clip from the studded fuel pump support bracket bolt and position harness to the side (Figure 11). Service Procedure [Continued] Figure 11 – HPFP Support Bracket Wiring Figure 10 – Power Steering Pressure Hose Safety Recall Y78 – High Pressure Fuel Pump Page 15 34. Remove fuel pump support bracket mounting bolts (2, 3), and remove bracket (1) (Figure 12). NOTE: The gear (1) and pilot adapter (3) will remain on the pump shaft when removing from the housing. NOTE: As the fuel injection pump is pulled away from the gear housing, the pilot adapter might separate from the pump, but the gear (1) will pull the adapter from the gear housing (2). 35. Remove the fuel injection pump mounting nuts (5), and remove the pump (4), pilot adapter (3), and gear (1) from the engine by pulling straight backwards on the pump. Make sure the fuel pump gear does not contact or damage the bore in the gear housing during removal (Figure 13). 36. Using the Holder, Fuel Pump Gear 2065500140 (1), to hold fuel pump gear in place while removing the fuel pump gear mounting nut (2) and washer (Figure 14). Service Procedure [Continued] Figure 12 – HPFP Support Bracket Figure 13 – HPFP Removal Figure 14 – Fuel Pump Gear Holder Safety Recall Y78 – High Pressure Fuel Pump Page 16 37. Remove the fuel injection pump gear (3) using the Puller 1023 (1) and the Step Plate Adapter 8058 (2) (Figure 15). 38. Prepare the new fuel pump for installation. a) Clean the pump gear and pump shaft at machined tapers with an evaporative type cleaner such as brake cleaner. b) Inspect all mounting surfaces on the pump and engine for any nicks, cuts, or damage. Inspect O-ring surfaces for nicks, cuts, or damage. c) Lubricate NEW O-ring (PN 5362113) (1) with engine oil and install onto the pilot adapter (Figure 16). d) Lubricate NEW O-ring on the pump body with engine oil and then install the pilot adapter onto the pump body with the smaller diameter side towards the fuel pump. The adapter bottoms out internally, leaving a gap on the exterior (Figure 17). NOTE: The pilot adapter will press on by hand. Service Procedure [Continued] Figure 15 – Fuel Pump Gear Removal Figure 16 – Blue O-ring O-RING Figure 17 – Pilot Adapter GAP WHEN SEATED PILOT ADAPTER Safety Recall Y78 – High Pressure Fuel Pump Page 17 e) Install the fuel pump gear onto the fuel pump shaft. f) Using a NEW fuel pump washer (PN 5256193), install washer and original nut (PN4890634) to pump shaft and tighten the nut finger tight only. g) Use the fuel pump gear holder to hold the fuel pump gear in place while tightening the fuel pump gear mounting nut to 105 N·m (77 ft. lbs.). h) Install the supply (3) and return (4) quick disconnect fittings onto the pump (Figure 18) as shown below and tighten to 24 N·m (18 ft. lbs.). i) Make sure engine cylinder 1 is at TDC position. B. Install New Fuel Pump 1. Remove the fuel pump mounting studs in the front gear housing (these will not be reused) (Figure 19). a) Take one of the fuel pump mounting nuts (5) and thread it on one of the fuel pump mounting studs with the hex head facing the front gear cover. b) Take a second fuel pump mounting nut and thread it on the same mounting stud with the hex head facing away from the front gear cover. c) Taking a 13mm open end wrench turn the inside nut counterclockwise to unscrew the mounting stud. d) Repeat steps A-C to remove all 3 of the mounting studs. Service Procedure [Continued] Figure 19 – Fuel Pump Mounting Studs Figure 18 – HPFP Supply and Return Fittings Safety Recall Y78 – High Pressure Fuel Pump Page 18 NOTE: The threaded holes from where the fuel pump studs were removed may need chased with a M8 x 1.25 tap to allow proper installation of the fuel pump adapter and fuel pump in the later steps. 2. Remove the bolts retaining the PCM to the PCM mounting bracket. 3. Remove the PCM mounting bracket. 4. Install the gear housing mounting adapter (Figure 20). 5. Install the adapter with the flattened side pointing down so there is clearance for the cam positioning sensor and counterbores facing the fuel pump (Figure 20). 6. Install both of the adapter bolts (PN 3420835) (1) 25mm M8’s in the 2 bolts holes near the engine block (Figure 20). NOTE: It is required to loosely install bolt (PN 3901446) in location (2) to help properly align the adapter before torquing bolts (PN 3420835) (1) (Figure 20). 7. Tighten both bolts (PN 3420835) (1) (Figure 16) to 24 N·m (18 ft. lbs.) 8. Remove the loosely installed bolt (PN 3901446) in location (2) (Figure 20). This will be used in a later step. Service Procedure [Continued] Figure 20 – Gear Housing Mounting Adapter Safety Recall Y78 – High Pressure Fuel Pump Page 19 9. Perform the following phasing procedure anytime the injection pump has been removed and reinstalled. NOTE: Fuel Injection Pump used for illustration has numbers 750 or 754. a) Locate the end of the fuel injection pump shaft (2). Two numbers (750 or 754 and 0 in this example, actual number will vary) are stamped into the end of the shaft (Figure 21). b) Rotate the injection pump shaft until the number 5 (located in the center of number 750 or 754) is positioned at 9 o’clock (1) (Figure 22). Service Procedure [Continued] Figure 21 – HPFP Shaft End Markings (Example) Figure 22 – HPFP Shaft Phasing Safety Recall Y78 – High Pressure Fuel Pump Page 20 10. Using the same top bolts (1) that came out of the original PCM mounting bracket, install them in the new mounting bracket and tighten to 24 N·m (18 ft. lbs.) (Figure 23). 11. Using the provided bottom bolts (PN 5689141) (2) install them into the new mounting bracket and tighten to 24 N·m (18 ft. lbs.) (Figure 23). 12. Install the PCM to the new mounting bracket with the same hardware originally removed. Tighten to 24 N·m (18 ft. lbs.). 13. Position the injection pump to mounting flange on gearhousing while aligning injection pump shaft through back of injection pump gear. Be sure the number 5 is still at the 9o’clock position (1) (Figure 22). 14. With a clean rag, wipe the back side of the camshaft gear to remove residual oil. It is only necessary to wipe the portion of the camshaft gear which is accessible through the fuel pump bore in the gear housing. 15. The pump will need to be rotated to fit correctly in the space available. 16. Install the long 60 mm capscrew (PN 3901446) (1) first loosely (yellow bolt in picture below) (Figure 24). 17. Then install the two shorter 40 mm capscrews (PN 3900678) (2) (blue bolt in picture below) (Figure 24). 18. Ensure that the fuel pump is sitting flush to the adapter face. Service Procedure [Continued] Figure 24 – HPFP Bolts Figure 23 – New PCM Bracket Safety Recall Y78 – High Pressure Fuel Pump Page 21 19. Ensure that there is adequate clearance to the cam position sensor and the paint cap is removed if needed. 20. Tighten the fuel pump capscrews to 24 N·m (18 ft. lbs.). 21. Remove the old fuel line standoff (2) (Figure 25). 22. Loosely install the tail support bracket on the fuel pump using bolt (PN 3902114) (1) 30mm M8 (Figure 25). 23. Loosely install the fuel line standoff to block through the tail support (5685063) (2) (Figure 25). 24. Tighten both ends of the fuel pump tail support to 24 N·m (18 ft. lbs.). 25. The main engine harness tie down bracket (1) will be originally positioned on the harness as shown (Figure 26). Service Procedure [Continued] Figure 25 – HPFP Tail Support Bracket Figure 26 – Original Main Harness Tie Down Orientation Safety Recall Y78 – High Pressure Fuel Pump Page 22 26. The tie down bracket MUST be loosened so it can be rotated and positioned to be secured to the leg of the fuel pump tail support to ensure there is no twisting of the main engine harness trunk as seen in Figure 25. The tie down bracket can be loosened by inserting a small flat head screwdriver into location (2) (Figure 27). Service Procedure [Continued] Figure 27 – New Main Harness Tie Down Orientation Safety Recall Y78 – High Pressure Fuel Pump Page 23 27. With the tie down bracket still loose around the trunk of the main engine harness, secure the tie down bracket to the tail of the fuel pump tail support as seen below using bolt (PN 3900630) (3). Tighten bolt (PN 3900630) (3) to 10 N·m (7 ft. lbs.). Tighten the tie down bracket around the trunk of the main engine harness using the zip closure (Figure 28). 28. Check pin in the wire harness connector for corrosion, damage, or dirt intrusion. Also, check all the PCM pins for being bent. Repair as necessary. 29. Connect the engine and transmission wire harness connector to the PCM and rotate the latches closed. 30. Install the fasteners securing the engine wire harness and the transmission wiring harness to the PCM and torque them to 10 N·m (7 ft. lbs.). 31. Connect the new low-pressure return line bracket (PN 5684067) to the fuel filter support. 32. Connect the new low-pressure supply line (PN 5687735) to the fuel filter housing. 33. Connect the low-pressure supply and return lines to the fuel pump. Service Procedure [Continued] Figure 28 – Tie Down Bracket Secured Safety Recall Y78 – High Pressure Fuel Pump Page 24 34. Initially finger tighten both HPFP to fuel rail supply tube union nuts at the pump and at the fuel rail. Make sure the bracket slot aligns to the standoff, slide bracket along the tube to align if slightly off (Figure 29). 35. Finger tighten the M8 nut (PN 3900589) (1) (Figure 29). 36. Tighten the union nut at the pump first, then the fuel rail to 55 N·m (41 ft. lbs.) (Figure 29). 37. Tighten the HPFP to fuel rail supply line bracket bolt (5685063) M8 115mm to proper torque 20 N·m (15 ft. lbs.). 38. Ensure there is no interference with the breather hose, pull the breather hose away from the High-Pressure line if there is contact. NOTE: There will only be ONE HPFP to fuel rail supply line. 39. The second supply port in the rail will need to be blocked off using rail block off (PN 5688160) and tighten to 55 N·m (41 ft. lbs.). Do not install the rail block off with power tools. NOTE: The rail block off nut is a onetime use part. If this nut is ever loosened or removed, it must be replaced with a new block off nut. 40. If not already installed, use the provided fuel line isolator and install on rail to injector line #4 as shown (2) (Figure 30). Service Procedure [Continued] Figure 29 – HPFP to Fuel Rail Supply Line Figure 30 – Fuel Line Isolator Safety Recall Y78 – High Pressure Fuel Pump Page 25 41. Using NEW washers, install the new pressure line (PN 5708745) (4) to the power steering pump assembly (1), using a backer wrench to stabilize the fitting tighten the bolt to 50 N·m (37 ft. lbs.) (Figure 31). 42. Reattach the standoff clip between the drain line and the harness. 43. Connect the female side of the new jumper harness to the engine wiring harness that originally attached to the FQS. 44. Connect the male side of the jumper to the FQS on the fuel pump. 45. Tie down the jumper using the provided zip-tie (PN 3062329) (1) as shown in (Figure 32). Service Procedure [Continued] Figure 31 – Power Steering Pressure Hose Figure 32 – Securing Jumper Harness Safety Recall Y78 – High Pressure Fuel Pump Page 26 46. Using the provided zip-ties (PN 3062329) attach the swivel bracket to the fuel line standoff and secure the wire harness pig tail to the swivel bracket (Figure 33). 47. Install the isolator pad for the injectors. 48. Install the harness that goes over the top of the engine and it’s connectors. 49. Install the bulkhead connector at the cowl. 50. Install the left Charge Air Cooler (CAC) hose (2) to the EGR air flow control valve and tighten the clamp (3) to 11 N·m (8 ft. lbs.) (Figure 5). 51. Connect the left CAC hose (2) to the cooler and tighten the clamp (1) to Install the engine cover (2) and tighten the bolts (1) to (Figure 5). 52. Check the power steering fluid level. As measured on the side of the reservoir, the level should indicate between MAX and MIN when the fluid is at normal ambient temperature. Adjust the fluid level as necessary. 53. Install the engine cover (2) and tighten the bolts (1) to 10 N·m (89 in. lbs.) (Figure 2). 54. Install the oil dip stick (3) (Figure 2). 55. Connect the negative battery cables. 56. Install the splash shield. 57. Install the wheel and tire and torque to the proper value in Service Library. Service Procedure [Continued] Figure 33 – Swivel Bracket to Fuel Line Standoff ZIP TIES Safety Recall Y78 – High Pressure Fuel Pump Page 27 NOTE: A certain amount of air becomes trapped in the fuel system when fuel system components on the supply and/or high-pressure side are serviced or replaced. Fuel system priming is accomplished using the electric fuel transfer (lift) pump. NOTE: The fuel transfer (lift) pump is self-priming: When the ignition switch is turned to the run position (without cranking engine), the pump operates for a minimum of 30 second. In cold temperatures, the lift pump operates for up to 35 seconds. Two priming cycles (each with a duration of 30 seconds) must be performed any time the fuel system is serviced. 58. Be sure fuel is present at fuel tank. 59. Turn ignition switch to the “RUN” position. This will operate fuel transfer pump for a minimum of 30 seconds. Turn the ignition switch “OFF”. NOTE: Install a battery charger to ensure battery voltage does not drop below 13.2 volts. Do not allow the charging voltage to climb above 13.5 volts during the flash process. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 60. Connect the wiTECH micro pod II to the vehicle data link connector. 61. Place the ignition in the “RUN” position. 62. Open the wiTECH 2.0 website. 63. Enter your “User id” and “Password” and your “Dealer Code”, then select “Sign In” at the bottom of the screen. Click “Accept”. 64. From the “Vehicle Selection” screen, select the vehicle to be updated. 65. From the “Action Items” screen, select the “Topology” tab. 66. From the “Topology” tab, select the “ECU” icon. Service Procedure [Continued] Safety Recall Y78 – High Pressure Fuel Pump Page 28 CAUTION: The PCM MUST be programmed with the correct calibration to support the new High Pressure Fuel Injection Pump. If the correct PCM calibration with CP3.3 description is not showing in wiTECH, STOP and contact Star. 67. From the “Flash” tab, compare the “Current Electronic Control Unit (ECU) Part Number” with the “New ECU Part Number” listed. ➢ If the “Current ECU part Number” is the same as the “New Part Number”, proceed to Step 72. ➢ If the “Current ECU part Number” is NOT the same as the “New Part Number”, continue with Step 68. 68. From the flash ECU agreement page, agree to terms by checking the box. NOTE: This flash procedure requires the ignition to be cycled “OFF” then back to the “RUN” position. Follow the on-screen prompts. 69. Select “Flash ECU” and then follow the wiTECH screen instructions to complete the flash. 70. Select “View All DTCs” then “Clear All DTCs” and select “Close”. 71. Using wiTECH, perform the “Oil Life Restore” procedure located in the ECM “Misc Functions”. 72. Place the ignition in the “OFF” position and then remove the wiTECH micro pod II device from the vehicle. 73. Turn the ignition switch to the “RUN” position. This will complete an additional priming cycle and operate the fuel transfer pump for a minimum of 30 seconds. 74. Start the engine. If the engine does not start after 25 seconds, turn the ignition switch to the “OFF” position, and leave it off for at least 2 minutes. Repeat the previous step until the engine starts. When engine does start, allow the engine to idle for a minimum of 30 seconds. The engine may run erratically and be noisy for a few minutes. This is a normal condition. Service Procedure [Continued] Safety Recall Y78 – High Pressure Fuel Pump Page 29 CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between cranking intervals. WARNING: The fuel injection pump supplies extremely high fuel pressure to each individual injector through the high-pressure lines. Fuel under this amount of pressure can penetrate the skin and cause personal injury. Wear safety goggles and adequate protective clothing. Do not loosen fuel fittings while engine is running. WARNING: Engine may start while cranking starter motor. 75. Fuel system priming is now completed. WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: Mopar® Power Steering Fluid + 4 or Mopar® ATF+4 Automatic Transmission Fluid is to be used in the power steering system. Both Fluids have the same material standard specifications (MS-9602). No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if another fluid is used. Do not overfill the system. CAUTION: If the air is not purged from the power steering system correctly, pump failure could result. NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids. CAUTION: Failure to use a vacuum pump reservoir (1) may allow power steering fluid to be sucked into the hand vacuum pump. Service Procedure [Continued] Safety Recall Y78 – High Pressure Fuel Pump Page 30 76. Tightly insert P/S Cap Adapter 9688A (4) into the mouth of the reservoir (3) (Figure 34). 77. Attach Hand Vacuum Pump C-4207-A (2), or equivalent, with reservoir (1) attached to the P/S Cap Adapter 9688A (4) (Figure 34). CAUTION: Do not run the vehicle while vacuum is applied to the power steering system. Damage to the power steering pump can occur. NOTE: When performing the following step make sure the vacuum level is maintained during the entire time period. 78. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a minimum of three minutes. 79. Slowly release the vacuum and remove the special tools. 80. Adjust the fluid level as necessary. 81. Repeat Step 78 through Step 80 until the fluid no longer drops when vacuum is applied. 82. Start the engine and cycle the steering wheel lock-to-lock three times. NOTE: Do not hold the steering wheel at the stops. Service Procedure [Continued] Figure 34 – 9688A and C-4207-A Safety Recall Y78 – High Pressure Fuel Pump Page 31 83. Stop the engine and check for leaks at all connections. 84. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the procedure as necessary. 85. Clean any leaked fluid from the frame. 86. Close the hood and return the vehicle to the customer. C. Install Fuel Tank Assembly WARNING: The fuel system may be under a constant pressure (even with the engine off). Before servicing the fuel pump module, the fuel system pressure must be released. NOTE: Two different procedures may be used to drain fuel tank: using a diagnostic scan tool to activate the fuel pump relay and drain the fuel tank or remove the fuel pump. Due to a one-way check valve installed into the fuel fill opening fitting at the tank, the tank cannot be drained conventionally at the fill cap. 1. Disconnect the fuel supply line quick-connect fitting at the engine fuel filter. 2. Install the appropriate Fuel Line Adapters/Fitting from the Decay Tool, Fuel 8978A. Route the opposite end of this hose to a diesel fuel draining station. 3. Using a scan tool, activate the fuel pump and drain the tank until empty. 4. Raise and support the vehicle. Service Procedure [Continued] Safety Recall Y78 – High Pressure Fuel Pump Page 32 5. If equipped, remove the fuel tank skid plate. See Service Library 13 – Frame and Bumpers / Under Body Protection / PLATE, Skid, Fuel Tank / Removal and Installation. 6. Remove the rear drive shaft from the rear axle and properly support it to prevent damage. See Service Library 03 – Differential and Driveline / Driveshaft / SHAFT, Drive, Rear / Removal and Installation. 7. Using a suitable hydraulic jack with a fuel tank adapter, support the fuel tank. 8. Remove the two nuts (1) and both fuel tank support straps (2) (Figure 35). 9. Partially lower the fuel tank to gain access to the fuel lines. 10. Loosen the clamp (3) and disconnect the fuel filler hose (Figure 36). 11. Loosen the clamp (1) and disconnect the fuel vent hose (Figure 36). 12. Disconnect the fresh air vent hose (2) (Figure 36). Service Procedure [Continued] Figure 35 – Fuel Tank Straps (Sales Code NFT Shown) Figure 36 – Fuel Tank Connections (Sales Code NFT Shown) Safety Recall Y78 – High Pressure Fuel Pump Page 33 13. Disconnect the fuel pump module wire harness connector (2) (Figure 37). 14. Disconnect the fuel supply (1) and return line (3) quick-connect fitting at the fuel pump module (Figure 37). 15. Disconnect the DEF pipes from the clip behind the tank shield (Figure 38). 16. Lower the fuel tank and remove from hydraulic jack. 17. Secure the new fuel tank assembly on a suitable hydraulic jack with a fuel tank adapter. 18. Partially raise the fuel tank allowing access for fuel line connection. 19. Connect the DEF pipes to the clip behind the tank shield (Figure 38). 20. Connect the fuel supply (1) and return (3) line quick connect fitting to the fuel pump module (Figure 37). 21. Connect the fuel pump module wire harness connector (2) (Figure 37). 22. Connect the fresh air vent hose (2) (Figure 36). Service Procedure [Continued] Figure 37 – Fuel Pump Module Connections (Sales Code NFT Shown) Figure 38 – DEF Pipe Clip (Sales Code NFT Shown) PIPE CLIP Safety Recall Y78 – High Pressure Fuel Pump Page 34 23. Connect the fuel vent hose and securely tighten the clamp (1) (Figure 36). 24. Connect the fuel filler hose and securely tighten the clamp (3) (Figure 36). 25. Raise the fuel tank until snug to the body. Install the fuel tank straps (2) and tighten the nuts (1) (Figure 35). • Fuel Tank Mounting Straps Nuts (Mid-Ship) 50 N·m (37 ft. lbs.) • Fuel Tank Mounting Bolts (Rear) 61 N·m (45 ft. lbs.) 26. Remove the hydraulic jack. 27. Install the rear drive shaft. See Service Library 03 – Differential and Driveline / Driveshaft / SHAFT, Drive, Rear / Removal and Installation. 28. If equipped, install the fuel tank skid plate. See Service Library 13 – Frame and Bumpers / Under Body Protection / PLATE, Skid, Fuel Tank / Removal and Installation. 29. Connect the negative battery cable(s). Service Procedure [Continued] Safety Recall Y78 – High Pressure Fuel Pump Page 35 D. Diesel Fuel System Cleaning NOTE: Do not attempt to flush any of the high pressure fuel components using Brakleen or similar harsh solvent cleaners. This may cause damage to any internal coatings. For an effective repair, all high pressure fuel system components should be replaced. CAUTION: Cleanliness cannot be over emphasized when handling or replacing diesel fuel system components. This especially includes the fuel injectors, high-pressure fuel lines and fuel injection pump. Very tight tolerances are used with these parts. Dirt contamination could cause rapid part wear and possible plugging of fuel injector nozzle tip holes. This in turn could lead to possible engine misfire. Always wash/clean any fuel system component thoroughly before disassembly and then air dry. Cap or cover any open part after disassembly. Before assembly, examine each part for dirt, grease or other contaminants and clean if necessary. NOTE: Be sure to cap or cover any part of the fuel system after disassembly using Protection Kit, Caps & Covers 2065600140. NOTE: Follow the Diesel Fuel System Cleaning Procedure under 14 – Fuel System / Fuel Delivery, Diesel / Standard Procedure. Service Procedure [Continued] Safety Recall Y78 – High Pressure Fuel Pump Page 36 1. Reinstall the fuel tank, leaving the chassis fuel return line disconnected at the tank. 2. Fill the tank with 21 gallons of fresh fuel. 3. Remove the chassis mounted fuel filter element. 4. Place an appropriate catch basin under the fuel filter housing to capture all fuel expelled during the next steps. 5. Turn the ignition to run and allow the in-tank fuel pump to run a complete cycle (approx. 15 seconds). Capture all of the fuel expelled from the filter housing. 6. Using wiTECH, navigate to the PCM “Actuators” tab, and perform the Lift Pump Relay routine to activate the in-tank fuel pump. This routine will run the pump for 20 seconds. Capture all fuel expelled from the fuel filter housing. 7. Repeat step 6 two additional times. 8. Install a NEW chassis mounted fuel filter element. 9. Place an appropriate catch basin under the engine mounted fuel filter housing to capture all fuel expelled during the next steps. 10. Open the drain valve and drain the engine mounted fuel filter housing. 11. Remove the filter element. Leave the drain valve open at this time. 12. Thoroughly clean the filter housing bowl of all debris. 13. Using wiTECH, perform the Lift Pump Relay routine to activate the in-tank fuel pump. The fuel filter housing will begin to fill. If necessary, stop the routine before the housing begins to overflow. 14. Allow the housing to fully drain and clean out any additional debris that is present. Service Procedure [Continued] Safety Recall Y78 – High Pressure Fuel Pump Page 37 15. Repeat steps 12 and 13 two additional times. 16. Install a NEW fuel filter element and tighten the cap to 31 N·m (23 ft. lbs.). 17. Close the fuel filter housing drain valve. 18. Disconnect the fuel supply hose from the high pressure fuel injection pump. 19. Connect a suitable hose to the fuel supply hose, and route it into a suitable container. 20. Using wiTECH, perform the Lift Pump Relay routine to activate the in-tank fuel pump for 1 complete cycle to flush any contaminates out of the supply line. NOTE: Be sure to reattach the fuel supply hose previously disconnected. 21. Replace the high pressure fuel rail. 22. Replace all 6 fuel injectors, and injector connector tubes. 23. Install NEW high pressure fuel rail to fuel injector fuel tube. 24. Install NEW high pressure fuel injection pump to rail supply tubes. 25. Attach a suitable hose to the fuel return line fitting left disconnected at the tank in step 1. 26. Route the hose into a suitable container. 27. Start the engine and allow it to run until approximately 2-3 gallons of fuel has been captured from the fuel return line. This ensures that any debris in any of the remaining fuel return system components, including the cylinder head, has been fully expelled from the system. 28. Reconnect the chassis fuel return line at the tank. 29. Top off the fuel tank with fresh fuel if necessary and verify the repair. Service Procedure [Continued] Safety Recall Y78 – High Pressure Fuel Pump Page 38 This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration. Process Steps to obtain the California Proof of Correction form: a. Access the “DealerCONNECT” website. b. Select the “Service” tab. c. Under the “Publications” heading, select the “ePublishing” link. d. Sign in using your Dealer Code and Password. e. Select the “Proof of Correction form”. Complete Proof of Correction Form for California Residents Safety Recall Y78 – High Pressure Fuel Pump Page 39 Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims paid will be used by FCA to record recall service completions and provide dealer payments. Use the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Replace HPFP and Reprogram PCM 14-Y7-81-82 3.5 hours Replace HPFP, Fuel Lines, Fuel Injectors Fuel Tank Assembly, Fuel Rail, Fuel Filters Flush Fuel System and Reprogram PCM 14-Y7-81-83 9.3 hours Related Labor Operations Fuel Allowance for Safety Recall Y78 95-14-01-56 Related Labor Operations Dual Alternator Equipped 14-Y7-81-61 0.5 hours Adaptive Steering System Equipped 14-Y7-81-62 0.6 hours (Sales Code SJE) Drain Fuel (52 Gallon Tank Only) 14-Y7-81-63 0.7 hours Drain Fuel (50 Gallon Tank Only) 14-Y7-81-64 0.6 hours Drain Fuel (32, 31 or 28 Gallon Tanks Only) 14-Y7-81-65 0.4 hours Drain Fuel (22 Gallon Tank Only) 14-Y7-81-66 0.3 hours Disposal of Contaminated Diesel Fuel 95-14-04-50 * (*receipt required) Floor Plan Reimbursement 95-95-95-97 Calculate See Below Completion Reporting and Reimbursement Safety Recall Y78 – High Pressure Fuel Pump Page 40 Add the cost of the recall parts package plus applicable dealer allowance to your claim. In addition, enter “MATL” in the Part Number section of your claim with the applicable Material Allowance where appropriate. Floor Plan Reimbursement represents the vehicle’s average daily allowance (see table below) multiplied by the number of days the vehicle was in dealer inventory and not available for sale. This reimbursement is limited to the number of days from the date of the stop sale to the date that the remedy was made available. Note: If the vehicle was received by your dealership (KZX date) AFTER the stop sale date, you will use the KZX date instead of the stop sale date. For this Recall, the stop sale was initiated on 11/18/2021 and the remedy was made available on 05/10/2022, therefore, the number of days cannot exceed 172 days. Vehicle Average Daily Allowance 2019-2020 (D2) Ram 3500 Pickup 2019-2020 (DD) Ram 3500 Cab Chassis 2019-2020 (DJ) Ram 2500 Pickup 2019-2020 (DP) Ram 4500/500 Cab Chassis NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. To view this notification on DealerCONNECT, select “Global Recall System” on the Service tab, then click on the description of this notification. Completion Reporting and Reimbursement [Continued] Dealer Notification Safety Recall Y78 – High Pressure Fuel Pump Page 41 All involved vehicle owners known to FCA are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is attached. All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner’s name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the “Service” tab and then click on “Global Recall System.” Your dealer’s VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services / Field Operations FCA US LLC Owner Notification and Service Scheduling Vehicle Lists, Global Recall System, VIP and Dealer Follow Up Additional Information This notice applies to your vehicle, Y78/NHTSA 21V-880 YOUR SCHEDULING OPTIONS 1. RECOMMENDED OPTION Call your authorized Chrysler / Dodge / Jeep® / RAM Dealership 2. Call the FCA Recall Assistance Center at 1-800-853-1403. An agent can confirm part availability and help schedule an appointment 3. Visit recalls.mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App. Get access to recall notifications, locate your nearest dealer, and more through this website or Mopar Owner’s Companion App. You will be asked to provide your Vehicle Identification Number (VIN) to protect and verify your identity. The last eight characters of your VIN are provided above. DEALERSHIP INSTRUCTIONS Please reference Safety Recall Y78. IMPORTANT SAFETY RECALL High Pressure Fuel Pump Dear [Name], This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. FCA US has decided that a defect, which relates to motor vehicle safety, exists in certain [2019 through 2020 Model Year (D2) Ram 3500 Pickup, (DD) Ram 3500 Cab Chassis, (DJ) Ram 2500 Pickup and (DP) Ram 4500/5500 Cab Chassis] vehicles. It is extremely important to take steps now to repair your vehicle to ensure the safety of you and your passengers. WHY DOES MY VEHICLE NEED REPAIRS? The high pressure fuel pump (HPFP) on your vehicle [1] may fail prematurely. A high pressure fuel pump failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Fuel starvation may result in an unexpected loss of motive power, which can increase the risk of a vehicle crash without prior warning. HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE? FCA US will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer will replace the HPFP, update the Powertrain Control Module (PCM) software, and inspect and, if necessary, replace additional fuel system components. The estimated repair time is between 4 to 12 hours depending on vehicle configuration. In addition, your dealer will require your vehicle for proper check-in, preparation, and check-out during your visit, which may require more time. Your time is important to us, so we recommend that you schedule a service appointment to minimize your inconvenience. Please bring this letter with you to your dealership. TO SCHEDULE YOUR FREE REPAIR, CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY CALIFORNIA RESIDENTS The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the Safety Recall service is performed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof that the Safety Recall has been performed. In order to ensure your full protection under the emissions warranty provisions, it is recommended that you have your (vehicle or engine) serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your (vehicle or engine). WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED? If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [3] Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed. We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter. Customer Assistance/Field Operations FCA US LLC [Model Year and Model] VIN XXXXXXXXXXXXXXXXX LOGO VEHICLE PICTURE QR Code [1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information. [2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424- 9153), or go to safercar.gov. [3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement. Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days. Mr. Mrs. Customer 1234 Main Street Hometown, MI 48371
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This notice applies to your vehicle, Y78/NHTSA 21V-880 YOUR SCHEDULING OPTIONS 1. RECOMMENDED OPTION Call your authorized Chrysler / Dodge / Jeep® / RAM Dealership 2. Call the FCA Recall Assistance Center at 1-800-853-1403. An agent can confirm part availability and help schedule an appointment 3. Visit recalls.mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App. Get access to recall notifications, locate your nearest dealer, and more through this website or Mopar Owner’s Companion App. You will be asked to provide your Vehicle Identification Number (VIN) to protect and verify your identity. The last eight characters of your VIN are provided above. DEALERSHIP INSTRUCTIONS Please reference Safety Recall Y78. IMPORTANT SAFETY RECALL High Pressure Fuel Pump Dear [Name], This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. FCA US has decided that a defect, which relates to motor vehicle safety, exists in certain [2019 through 2020 Model Year (D2) Ram 3500 Pickup, (DD) Ram 3500 Cab Chassis, (DJ) Ram 2500 Pickup and (DP) Ram 4500/5500 Cab Chassis] vehicles. It is extremely important to take steps now to repair your vehicle to ensure the safety of you and your passengers. WHY DOES MY VEHICLE NEED REPAIRS? The high pressure fuel pump (HPFP) on your vehicle [1] may fail prematurely. A high pressure fuel pump failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Fuel starvation may result in an unexpected loss of motive power, which can increase the risk of a vehicle crash without prior warning. HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE? FCA US will repair your vehicle [2] free of charge (parts and labor). To do this, your dealer will replace the HPFP, update the Powertrain Control Module (PCM) software, and inspect and, if necessary, replace additional fuel system components. The estimated repair time is between 4 to 12 hours depending on vehicle configuration. In addition, your dealer will require your vehicle for proper check-in, preparation, and check-out during your visit, which may require more time. Your time is important to us, so we recommend that you schedule a service appointment to minimize your inconvenience. Please bring this letter with you to your dealership. TO SCHEDULE YOUR FREE REPAIR, CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY CALIFORNIA RESIDENTS The State of California requires the completion of emission recall repairs prior to vehicle registration renewal. Your dealer will provide you with a Vehicle Emission Recall Proof of Correction Form after the Safety Recall service is performed. Be sure to save this form since the California Department of Motor Vehicles may require that you supply it as proof that the Safety Recall has been performed. In order to ensure your full protection under the emissions warranty provisions, it is recommended that you have your (vehicle or engine) serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your (vehicle or engine). WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED? If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [3] Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed. We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter. Customer Assistance/Field Operations FCA US LLC [Model Year and Model] VIN XXXXXXXXXXXXXXXXX LOGO VEHICLE PICTURE QR Code [1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information. [2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424- 9153), or go to safercar.gov. [3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement. Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days. Mr. Mrs. Customer 1234 Main Street Hometown, MI 48371
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This notice applies to your vehicle, Y78/NHTSA 21V-880 FOR RECALL QUESTIONS 1. RECOMMENDED OPTION Call your authorized Chrysler / Dodge / Jeep® / RAM / Dealership. 2. Call the FCA Recall Assistance Center at 1-800-853-1403. An agent can confirm if there are any recall repairs which must be performed on your vehicle 3. Visit recalls.mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App. Get access to recall notifications, locate your nearest dealer, and more through this website or Mopar Owner’s Companion App. You will be asked to provide your Vehicle Identification Number (VIN) to protect and verify your identity. The last eight characters of your VIN are provided above. DEALERSHIP INSTRUCTIONS Please reference Safety Recall Y78. IMPORTANT SAFETY RECALL High Pressure Fuel Pump Dear [Name], This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. FCA US has decided that a defect, which relates to motor vehicle safety, exists in certain [2019 through 2020 Model Year (D2) Ram 3500 Pickup, (DD) Ram 3500 Cab Chassis, (DJ) Ram 2500 Pickup and (DP) Ram 4500/5500 Cab Chassis] vehicles. RECALL DESCRIPTION The High Pressure Fuel Pump (HPFP) on your vehicle [1] may fail prematurely. An HPFP failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Fuel starvation may result in an unexpected loss of motive power, which can increase the risk of a vehicle crash without prior warning. YOUR VEHICLE HAS ALREADY BEEN REMEDIED According to our service records, the HPFP has already been replaced on your vehicle. Therefore, your vehicle has been remedied and this safety recall does not need to be performed. This notification is provided for your records only. There is nothing more that you need to do. WHAT IF I HAVE QUESTIONS REGARDING THIS RECALL? If you believe the HPFP in your vehicle [2] has not been replaced or have questions or concerns which your dealer is unable to resolve, please contact the FCA Group Recall Assistance Center at either fcarecalls.com or 1 800-853-1403. WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED? If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online. [3] Once we receive and verify the required documents, reimbursement will be sent to you within 60 days. If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed. We apologize for any inconvenience, but are sincerely concerned about your safety. Thank you for your attention to this important matter. Customer Assistance/Field Operations FCA US LLC [Model Year and Model] VIN XXXXXXXXXXXXXXXXX LOGO VEHICLE PICTURE QR Code [1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information. [2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC 20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424- 9153), or go to safercar.gov. [3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement. Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days. Mr. Mrs. Customer 1234 Main Street Hometown, MI 48371
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11/18/2021 New Safety Recall Advanced Communication – Y78 FCA US LLC (FCA US) has announced a safety recall on certain 2019 through 2020 Model Year (D2) Ram 3500 Pickup, (DD) Ram 3500 Cab Chassis, (DJ) Ram 2500 Pickup and (DP) Ram 4500/5500 Cab Chassis vehicles equipped with a 6.7L diesel engine. VINs identified as being involved in this campaign are currently live and searchable. Stop sale is in effect for the above-identified vehicles. Vehicles impacted by a stop sale are eligible for reimbursement allowance through the Recall Floorplan Reimbursement Policy (RFPRP), which can be requested upon recall claim submission. REASON FOR THIS SAFETY RECALL Some of the above vehicles may have been built with a High Pressure Fuel Pump (HPFP) that could fail prematurely. A high pressure fuel pump failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Fuel starvation may result in an unexpected loss of motive power, which can cause vehicle crash without prior warning. SERVICE ACTION FCA US will conduct a voluntary safety recall to replace the HPFP, update the Powertrain Control Module (PCM) software, and inspect and, if necessary, replace additional fuel system components. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 1st Quarter of 2022. We ask that you please take the time to ensure that your personnel are aware of this communication and are prepared to execute a customer friendly process for inquiries regarding involved vehicles. Customer Services Field Operations FCA US LLC IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Involved vehicles can be determined by using the VIP inquiry process.
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RECALL Y78 UPDATE – COMPLETION OF OTHER RECALLS REQUIRED MAY 2022 Certain Y78 VINs have additional open recalls associated to them. VINs with Recalls Y21, VB6, W03, and W57 require Y78 to be completed first. Failure to complete Y78 first could result in fuel pump damage. Dealer Service Instructions for Y21, VB6, W03, and W57 will be updated to reflect the requirement to complete Y78. Thank you, Mopar
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RECALL Y78, 2019MY COMPLETION HANDLING AUG 2022 The Y78 recall is to be used for 2020MY VINs until further notice. The only 2019MY exception is if the VIN is also open for W57, VB6, W03, or Y21 recalls. In these instances, perform Y78 and the open W57, VB6, W03, or Y21. TSB 18-099-22 is available for 2019 MYs that have been diagnosed to have experienced a high pressure fuel pump failure and are currently down. Thank you, Mopar
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11/11/2021 New Safety Recall Advanced Communication – Y78 FCA US LLC (FCA US) has announced a safety recall on certain 2019 through 2020 Model Year (D2) Ram 3500 Pickup, (DD) Ram 3500 Cab Chassis, (DJ) Ram 2500 Pickup and (DP) Ram 4500/5500 Cab Chassis vehicles equipped with a 6.7L diesel engine. REASON FOR THIS SAFETY RECALL Some of the above vehicles may have been built with a High Pressure Fuel Pump (HPFP) that could fail prematurely. A high pressure fuel pump failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Fuel starvation may result in an unexpected loss of motive power, which can cause vehicle crash without prior warning. SERVICE ACTION FCA US will conduct a voluntary safety recall to replace the HPFP, update the Powertrain Control Module (PCM) software, and inspect and, if necessary, replace additional fuel system components. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 1st Quarter of 2022. We ask that you please take the time to ensure that your personnel are aware of this communication and are prepared to execute a customer friendly process for inquiries regarding involved vehicles. Customer Services Field Operations FCA US LLC
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RECALL Y78 – PARTS ORDERING ISSUES MAY 2022 Mopar is aware of issues surrounding the ordering of parts for Y78 and is actively working to resolve these issues: • Requirement to provide an engine serial number • Message – “Y78 Recall does not match for the VIN” Further communication will be provided on the resolution of these issues. Reminder: The high pressure fuel pump is VIN specific due to the coordination of the software flash update required. DO NOT USE a high pressure fuel pump that is not associated to the correct VIN. If a high pressure fuel pump is installed in the incorrect VIN, acquire the truck and contact STAR for assistance. Thank you, Mopar
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-880 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Chrysler (FCA US, LLC) Submission Date : MAR 01, 2022 NHTSA Recall No. : 21V-880 Manufacturer Recall No. : Y78 Manufacturer Information : Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive CIMS 482-00-91 Auburn Hills MI 48326-2757 Company phone : 1-800-853-1403 Population : Number of potentially involved : 222,410 Estimated percentage with defect : 4 % Vehicle Information : Vehicle 1 : 2019-2020 Ram 2500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 2500 vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a high pressure fuel pump (“HPFP”) that could fail prematurely. The suspect period began on October 11, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 113,720. Production Dates : OCT 11, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 21V-880 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2019-2020 Ram 3500 Cab Chassis Vehicle Type : Body Style : OTHER Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 3500 Cab Chassis vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on November 29, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 11,384. Production Dates : NOV 29, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2019-2020 Ram 4500/5500 Cab Chassis Vehicle Type : Body Style : OTHER Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 4500/5500 Cab Chassis vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on November 29, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 29,720. Production Dates : NOV 29, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 21V-880 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 4 : 2019-2020 Ram 3500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 3500 vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on October 18, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 67,586. Production Dates : OCT 18, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : A high pressure fuel pump failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Fuel starvation may result in an unexpected loss of motive power, which can cause vehicle crash without prior warning. Description of the Cause : NR Identification of Any Warning that can Occur : Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Involved Components : Component Name 1 : Engine Assembly Component Description : 6.7L Cummins Turbo Diesel Standard Output Component Part Number : R3041229AA Part 573 Safety Recall Report 21V-880 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 2 : Engine Assembly Component Description : 6.7L Cummins Turbo Diesel High Output Component Part Number : R3041230AA Component Name 3 : Engine Assembly Component Description : 6.7L Cummins Turbo Diesel Component Part Number : R3041231AA / R3041231AB / R3041233AA / R3041233AB / 53041237BA Supplier Identification : Component Manufacturer Name : Cummins Address : 500 Jackson Street Colombus Indiana 47201 Country : United States Chronology : • On October 13, 2021, the FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation as a result of warranty claims associated with the HPFP alleging a loss of motive power on 2019-2020 MY Ram 2500, 3500, and 4500/5500 vehicles. • During October 2021, FCA US TSRC reviewed vehicle records and met with FCA US engineering and the supplier to review the issue, and understand the part design and change history. • As of October 27, 2021, FCA US is aware of 495 customer assistance records, 6,399 warranty claims and zero field reports potentially related to this issue for all markets with dates of receipt ranging from August 28, 2018 to September 20, 2021. • As of October 27, 2021, FCA US is not aware of any accidents or injuries potentially related to this issue for all markets. • On November 04, 2021, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles. Part 573 Safety Recall Report 21V-880 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to replace the HPFP, update the Powertrain Control Module (“PCM”) software, and inspect and, if necessary, replace additional fuel system components. FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense. How Remedy Component Differs from Recalled Component : The remedy component is a new HPFP design and updated PCM software. Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : **3/1/2022: This will be a phased campaign launch: Phase 1 – all 2020 Ram 2500, 3500, 4500, 5500 equipped with a Cummins 6.7L diesel engine owners will receive a final letter on or about 05/17/2022. Phase 2 – all 2019 Ram 2500, 3500, 4500, 5500 equipped with a Cummins 6.7L diesel engine owners will receive a final letter on or about 09/15/2022. **12/16/2021: All owners will receive an interim letter on or about 01/04/2022. This will be a phased campaign launch: Phase 1 – all 2020 Ram 2500, 3500, 4500, 5500 equipped with a Cummins 6.7L diesel engine owners will receive a final letter on or about 04/05/2022. Phase 2 – all 2019 Ram 2500, 3500, 4500, 5500 equipped with a Cummins 6.7L diesel engine owners will receive a final letter on or about 06/17/2022. **11/12/2021: FCA US will notify dealers and begin notifying owners on or about 01/01/2022. Planned Dealer Notification Date : JAN 01, 2022 – JAN 01, 2022 Planned Owner Notification Date : JAN 01, 2022 – JAN 01, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-880 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Chrysler (FCA US, LLC) Submission Date : NOV 12, 2021 NHTSA Recall No. : 21V-880 Manufacturer Recall No. : Y78 Manufacturer Information : Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive CIMS 482-00-91 Auburn Hills MI 48326-2757 Company phone : 1-800-853-1403 Population : Number of potentially involved : 222,410 Estimated percentage with defect : 4 % Vehicle Information : Vehicle 1 : 2019-2020 Ram 2500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 2500 vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a high pressure fuel pump (“HPFP”) that could fail prematurely. The suspect period began on October 11, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 113,720. Production Dates : OCT 11, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 21V-880 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2019-2020 Ram 3500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 3500 vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on October 18, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 67,586. Production Dates : OCT 18, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2019-2020 Ram 4500/5500 Cab Chassis Vehicle Type : Body Style : OTHER Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 4500/5500 Cab Chassis vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on November 29, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 29,720. Production Dates : NOV 29, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 21V-880 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 4 : 2019-2020 Ram 3500 Cab Chassis Vehicle Type : Body Style : OTHER Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 3500 Cab Chassis vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on November 29, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 11,384. Production Dates : NOV 29, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : A high pressure fuel pump failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Fuel starvation may result in an unexpected loss of motive power, which can cause vehicle crash without prior warning. Description of the Cause : NR Identification of Any Warning that can Occur : Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Involved Components : Part 573 Safety Recall Report 21V-880 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : Engine Assembly Component Description : 6.7L Cummins Turbo Diesel Standard Output Component Part Number : R3041229AA Component Name 2 : Engine Assembly Component Description : 6.7L Cummins Turbo Diesel High Output Component Part Number : R3041230AA Component Name 3 : Engine Assembly Component Description : 6.7L Cummins Turbo Diesel Component Part Number : R3041231AA / R3041231AB / R3041233AA / R3041233AB / 53041237BA Supplier Identification : Component Manufacturer Name : Cummins Address : 500 Jackson Street Colombus Indiana 47201 Country : United States Chronology : • On October 13, 2021, the FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation as a result of warranty claims associated with the HPFP alleging a loss of motive power on 2019-2020 MY Ram 2500, 3500, and 4500/5500 vehicles. • During October 2021, FCA US TSRC reviewed vehicle records and met with FCA US engineering and the supplier to review the issue, and understand the part design and change history. • As of October 27, 2021, FCA US is aware of 495 customer assistance records, 6,399 warranty claims and zero field reports potentially related to this issue for all markets with dates of receipt ranging from August 28, 2018 to September 20, 2021. • As of October 27, 2021, FCA US is not aware of any accidents or injuries potentially related to this issue for all markets. Part 573 Safety Recall Report 21V-880 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 • On November 04, 2021, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles. Description of Remedy : Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to replace the HPFP, update the Powertrain Control Module (“PCM”) software, and inspect and, if necessary, replace additional fuel system components. FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense. How Remedy Component Differs from Recalled Component : The remedy component is a new HPFP design and updated PCM software. Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : **11/12/2021: FCA US will notify dealers and begin notifying owners on or about 01/01/2022. Planned Dealer Notification Date : JAN 01, 2022 – JAN 01, 2022 Planned Owner Notification Date : JAN 01, 2022 – JAN 01, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-880 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Chrysler (FCA US, LLC) Submission Date : DEC 16, 2021 NHTSA Recall No. : 21V-880 Manufacturer Recall No. : Y78 Manufacturer Information : Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive CIMS 482-00-91 Auburn Hills MI 48326-2757 Company phone : 1-800-853-1403 Population : Number of potentially involved : 222,410 Estimated percentage with defect : 4 % Vehicle Information : Vehicle 1 : 2019-2020 Ram 2500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 2500 vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a high pressure fuel pump (“HPFP”) that could fail prematurely. The suspect period began on October 11, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 113,720. Production Dates : OCT 11, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 21V-880 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2019-2020 Ram 3500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 3500 vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on October 18, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 67,586. Production Dates : OCT 18, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2019-2020 Ram 4500/5500 Cab Chassis Vehicle Type : Body Style : OTHER Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 4500/5500 Cab Chassis vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on November 29, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 29,720. Production Dates : NOV 29, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 21V-880 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 4 : 2019-2020 Ram 3500 Cab Chassis Vehicle Type : Body Style : OTHER Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 3500 Cab Chassis vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on November 29, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 11,384. Production Dates : NOV 29, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : A high pressure fuel pump failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Fuel starvation may result in an unexpected loss of motive power, which can cause vehicle crash without prior warning. Description of the Cause : NR Identification of Any Warning that can Occur : Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Involved Components : Part 573 Safety Recall Report 21V-880 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : Engine Assembly Component Description : 6.7L Cummins Turbo Diesel Standard Output Component Part Number : R3041229AA Component Name 2 : Engine Assembly Component Description : 6.7L Cummins Turbo Diesel High Output Component Part Number : R3041230AA Component Name 3 : Engine Assembly Component Description : 6.7L Cummins Turbo Diesel Component Part Number : R3041231AA / R3041231AB / R3041233AA / R3041233AB / 53041237BA Supplier Identification : Component Manufacturer Name : Cummins Address : 500 Jackson Street Colombus Indiana 47201 Country : United States Chronology : • On October 13, 2021, the FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation as a result of warranty claims associated with the HPFP alleging a loss of motive power on 2019-2020 MY Ram 2500, 3500, and 4500/5500 vehicles. • During October 2021, FCA US TSRC reviewed vehicle records and met with FCA US engineering and the supplier to review the issue, and understand the part design and change history. • As of October 27, 2021, FCA US is aware of 495 customer assistance records, 6,399 warranty claims and zero field reports potentially related to this issue for all markets with dates of receipt ranging from August 28, 2018 to September 20, 2021. • As of October 27, 2021, FCA US is not aware of any accidents or injuries potentially related to this issue for all markets. Part 573 Safety Recall Report 21V-880 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 • On November 04, 2021, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles. Description of Remedy : Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to replace the HPFP, update the Powertrain Control Module (“PCM”) software, and inspect and, if necessary, replace additional fuel system components. FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense. How Remedy Component Differs from Recalled Component : The remedy component is a new HPFP design and updated PCM software. Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : **12/16/2021: All owners will receive an interim letter on or about 01/04/2022. This will be a phased campaign launch: Phase 1 – all 2020 Ram 2500, 3500, 4500, 5500 equipped with a Cummins 6.7L diesel engine owners will receive a final letter on or about 04/05/2022. Phase 2 – all 2019 Ram 2500, 3500, 4500, 5500 equipped with a Cummins 6.7L diesel engine owners will receive a final letter on or about 06/17/2022. **11/12/2021: FCA US will notify dealers and begin notifying owners on or about 01/01/2022. Planned Dealer Notification Date : JAN 01, 2022 – JAN 01, 2022 Planned Owner Notification Date : JAN 01, 2022 – JAN 01, 2022 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 21V-880 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Chrysler (FCA US, LLC) Submission Date : AUG 18, 2022 NHTSA Recall No. : 21V-880 Manufacturer Recall No. : Y78 Manufacturer Information : Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive CIMS 482-00-91 Auburn Hills MI 48326-2757 Company phone : 1-800-853-1403 Population : Number of potentially involved : 222,410 Estimated percentage with defect : 4 % Vehicle Information : Vehicle 1 : 2019-2020 Ram 2500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 2500 vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a high pressure fuel pump (“HPFP”) that could fail prematurely. The suspect period began on October 11, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 113,720. Production Dates : OCT 11, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 21V-880 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2019-2020 Ram 3500 Vehicle Type : Body Style : PICKUP TRUCK Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 3500 vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on October 18, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 67,586. Production Dates : OCT 18, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 3 : 2019-2020 Ram 4500/5500 Cab Chassis Vehicle Type : Body Style : OTHER Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 4500/5500 Cab Chassis vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on November 29, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 29,720. Production Dates : NOV 29, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 21V-880 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 4 : 2019-2020 Ram 3500 Cab Chassis Vehicle Type : Body Style : OTHER Power Train : NR Descriptive Information : Some 2019-2020 MY Ram 3500 Cab Chassis vehicles equipped with the Cummins 6.7L Turbo Diesel engine may have been built with a HPFP that could fail prematurely. The suspect period began on November 29, 2018, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were introduced into vehicle production, and ended on November 13, 2020, when Cummins 6.7L Turbo Diesel engines with suspect HPFPs were no longer used in vehicle production. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the Cummins 6.7L Turbo Diesel engine, or were produced before or after the suspect period. The total affected vehicles for this model is 11,384. Production Dates : NOV 29, 2018 – NOV 13, 2020 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : A high pressure fuel pump failure may introduce internally failed component debris into the fuel system potentially causing fuel starvation. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : Fuel starvation may result in an unexpected loss of motive power, which can cause vehicle crash without prior warning. Description of the Cause : NR Identification of Any Warning that can Occur : Vehicle occupants may notice a Malfunction Indicator Lamp illuminating, a fuel leak, abnormal engine noise, or a change in drive quality. Involved Components : Part 573 Safety Recall Report 21V-880 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : Engine Assembly Component Description : 6.7L Cummins Turbo Diesel Standard Output Component Part Number : R3041229AA Component Name 2 : Engine Assembly Component Description : 6.7L Cummins Turbo Diesel High Output Component Part Number : R3041230AA Component Name 3 : Engine Assembly Component Description : 6.7L Cummins Turbo Diesel Component Part Number : R3041231AA / R3041231AB / R3041233AA / R3041233AB / 53041237BA Supplier Identification : Component Manufacturer Name : Cummins Address : 500 Jackson Street Colombus Indiana 47201 Country : United States Chronology : • On October 13, 2021, the FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation as a result of warranty claims associated with the HPFP alleging a loss of motive power on 2019-2020 MY Ram 2500, 3500, and 4500/5500 vehicles. • During October 2021, FCA US TSRC reviewed vehicle records and met with FCA US engineering and the supplier to review the issue, and understand the part design and change history. • As of October 27, 2021, FCA US is aware of 495 customer assistance records, 6,399 warranty claims and zero field reports potentially related to this issue for all markets with dates of receipt ranging from August 28, 2018 to September 20, 2021. • As of October 27, 2021, FCA US is not aware of any accidents or injuries potentially related to this issue for all markets. Part 573 Safety Recall Report 21V-880 Page 5 The information contained in this report was submitted pursuant to 49 CFR §573 • On November 04, 2021, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles. Description of Remedy : Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to replace the HPFP, update the Powertrain Control Module (“PCM”) software, and inspect and, if necessary, replace additional fuel system components. FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense. How Remedy Component Differs from Recalled Component : The remedy component is a new HPFP design and updated PCM software. Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : **8/18/2022: Phase 2 – all 2019 Ram 2500, 3500, 4500, 5500 equipped with a Cummins 6.7L diesel engine owners will receive a final letter on or about 03/02/2023. **3/1/2022: This will be a phased campaign launch: Phase 1 – all 2020 Ram 2500, 3500, 4500, 5500 equipped with a Cummins 6.7L diesel engine owners will receive a final letter on or about 05/17/2022. Phase 2 – all 2019 Ram 2500, 3500, 4500, 5500 equipped with a Cummins 6.7L diesel engine owners will receive a final letter on or about 09/15/2022. **12/16/2021: All owners will receive an interim letter on or about 01/04/2022. This will be a phased campaign launch: Phase 1 – all 2020 Ram 2500, 3500, 4500, 5500 equipped with a Cummins 6.7L diesel engine owners will receive a final letter on or about 04/05/2022. Phase 2 – all 2019 Ram 2500, 3500, 4500, 5500 equipped with a Cummins 6.7L diesel engine owners will receive a final letter on or about 06/17/2022. **11/12/2021: FCA US will notify dealers and begin notifying owners on or about 01/01/2022. Planned Dealer Notification Date : JAN 01, 2022 – JAN 01, 2022 Planned Owner Notification Date : JAN 01, 2022 – JAN 01, 2022 Part 573 Safety Recall Report 21V-880 Page 6 The information contained in this report was submitted pursuant to 49 CFR §573 * NR – Not Reported
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Last update on 2025-04-18 / Affiliate links / Images from Amazon Product Advertising API
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