Safety Recall Y78 – High Pressure Fuel Pump – 2019-2020 Ram 2500/3500/4500/5500

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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…

RCRIT-21V880-5163

 


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

MAKE MODEL YEAR
RAM 2500 2019-2020
RAM 3500 2019-2020
RAM 4500 2019-2020
RAM 5500 2019-2020

 


19 Associated Documents

Recall 573 Report

RCLRPT-21V880-8103.PDF 217.714KB

RCLRPT-21V880-8103

 


Recall Acknowledgement

RCAK-21V880-5836.pdf 645.008KB

RCAK-21V880-5836

 


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.

RCMN-21V880-3584.pdf 97.273KB

RCMN-21V880-3584

 


ISSUED Interim Owner Notification Letter(Part 577)

RIONL-21V880-5434.pdf 56.225KB

RIONL-21V880-5434

 


Manufacturer Notices(to Dealers,etc)

RCMN-21V880-9812.pdf 100.526KB

RCMN-21V880-9812

 


Defect Notice 573 Report

RCLRPT-21V880-8784.PDF 217.543KB

RCLRPT-21V880-8784

 


Miscellaneous Document – Representative copy of a postcard to owners re apology for remedy not available.

RMISC-21V880-3731.pdf 144.296KB

RMISC-21V880-3731

 


Remedy Instructions and TSB

RCRIT-21V880-8534.pdf 2150.588KB

RCRIT-21V880-8534

 


Manufacturer Notices(to Dealers,etc) – Parts Ordering Issues

RCMN-21V880-0968.pdf 123.929KB

RCMN-21V880-0968

 


Manufacturer Notices(to Dealers,etc) – Dealer Communication re Critical Recall Y78 and TSB 18-054-21.

RCMN-21V880-5724.pdf 43.74KB

RCMN-21V880-5724

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V880-2779.pdf 174.278KB

RCONL-21V880-2779

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V880-8252.pdf 175.289KB

RCONL-21V880-8252

 


Manufacturer Notices(to Dealers,etc) – RECALL Y78 UPDATE – COMPLETION OF OTHER RECALLS REQUIRED

RCMN-21V880-6069.pdf 121.728KB

RCMN-21V880-6069

 


Remedy Instructions and TSB

RCRIT-21V880-5163.pdf 2157.873KB

RCRIT-21V880-5163

 


Recall Quarterly Report #1, 2022-2

RCLQRT-21V880-5476.PDF 211.151KB

RCLQRT-21V880-5476

 


Manufacturer Notices(to Dealers,etc) – Dealer Notification re RECALL Y78, 2019MY COMPLETION HANDLING

RCMN-21V880-6063.pdf 101.09KB

RCMN-21V880-6063

 


Recall 573 Report – 8/18/22

RCLRPT-21V880-2815.PDF 218.163KB

RCLRPT-21V880-2815

 


Recall 573 Report – 3/1/22

RCLRPT-21V880-8989.PDF 217.744KB

RCLRPT-21V880-8989

 


Recall Quarterly Report #2, 2022-3

RCLQRT-21V880-0164.PDF 211.257KB

RCLQRT-21V880-0164

 


Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V880&docType=RCL

 


 

Reprogramming

Chrysler J2534 Application Overview

 

DRB III Emulator

Flash Availability - J2534/Pass Thru Device

Vehicle to Diagnostic Tool Reference Chart

 

Chrysler Recommended J2534 Devices

For Chrysler recommended J2534 device, see below table.

J2534 Device Firmware Version
CTC Vehicle Box * 1.9
UCAN 2 1.0
Blue Streak -2534 Global Programmer 2.10
Actia I+ME Passthru 2.07

* Chrysler recommends the CTC Vehicle Box Device for Chrysler SCI ECU reprogramming. SCI reprogramming is used on most PCMs and TCMs prior to the introduction of CAN bus vehicles which began in 2004 (Durango).

 

Compatible J2534 Devices

Safety Recall Y78 - High Pressure Fuel Pump - 2019-2020 Ram 2500/3500/4500/5500 | small light CarDAQ-Plus 3 All Makes J2534 Reprogramming Tool
Safety Recall Y78 - High Pressure Fuel Pump - 2019-2020 Ram 2500/3500/4500/5500 | small light CarDAQ-Plus 2 Diagnostic Code Reader and J2534 Programming Tool
Safety Recall Y78 - High Pressure Fuel Pump - 2019-2020 Ram 2500/3500/4500/5500 | small light CarDAQ-Plus
Safety Recall Y78 - High Pressure Fuel Pump - 2019-2020 Ram 2500/3500/4500/5500 | small light CarDAQ-M
Safety Recall Y78 - High Pressure Fuel Pump - 2019-2020 Ram 2500/3500/4500/5500 | small light VSI J2534 ECU Reprogrammer
Safety Recall Y78 - High Pressure Fuel Pump - 2019-2020 Ram 2500/3500/4500/5500 | small light

Bosch Automotive Tools MTECH2 Mastertech II J2534 VCI with Wired/Wireless Capability for OEM Reprogramming and Diagnostics on GM, Ford, FCA, Nissan/Infiniti, Honda/Acura, and Toyota/Lexus Vehicles

Safety Recall Y78 - High Pressure Fuel Pump - 2019-2020 Ram 2500/3500/4500/5500 | small light

RAP2 OEM J2534 Remote Reprogramming Tool

Safety Recall Y78 - High Pressure Fuel Pump - 2019-2020 Ram 2500/3500/4500/5500 | small light

BOSCH Automotive Tools MTECH2 Mastertech II J2534 VCI

Safety Recall Y78 - High Pressure Fuel Pump - 2019-2020 Ram 2500/3500/4500/5500 | small light

Autel MaxiFlash VCI Vehicle Communication Interface J2534 PassThru ECU Programming Device Bluetooth Connection Internet Update Support CAN FD, 4 CAN Channels, DoIP, D-PDU Works with PC or Autel MS909

Safety Recall Y78 - High Pressure Fuel Pump - 2019-2020 Ram 2500/3500/4500/5500 | small light

GODIAG J2534

 


Click on the link below to:

Download J2534 Application

(Install the wiTECH 2.0 J2534 Application on your computer)

Download the Setup Utility

(Configure your microPod/MDP device)

Launch wiTECH 2.0

(Once subscription and users are assigned to a tool please follow this link to access wiTECH)

https://www.mopartsp.com/support

 


Chrysler J2534 Manual

wiTECH Software

www.techauthority.com

 


 

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