2016 RAM 3500 Problems: 12 Known Issues

How to Fix

Dealers perform the fix free of charge: they inspect the software and, if needed, flash the engine or powertrain control module. Have the dealer confirm VIN eligibility and campaign completion history; an open-recall lookup is not a complete repair history. Do not use cruise control until it is done. If cruise control will not disengage while driving, brake firmly and steadily, shift the transmission to neutral, and place the vehicle in park once it has stopped. Chrysler customer service: 1-800-853-1403.

How to Fix

Dealers perform the correction free of charge: they inspect the software and flash the engine or powertrain control module. The recall began June 4, 2018, and Chrysler customer service is 1-800-853-1403. Enter your VIN at nhtsa.gov/recalls to confirm your specific 3500 configuration is covered and that the flash was completed. Avoid using cruise control until the software update is done. If cruise control cannot be disengaged on the road, apply the brakes firmly and steadily, shift into neutral, then put the truck in park once it has stopped.

How to Fix

Replace the grid heater relay (Mopar 56055666AB or equivalent). The relay is located on the intake manifold or firewall area and is a straightforward replacement. Some owners upgrade to a heavy-duty aftermarket relay rated for higher amperage to extend lifespan. Also inspect the grid heater element itself for damage or corrosion while the relay is being replaced. Budget $80-$250 for parts and labor.

Owner tips & cautions

• TipThe grid heater relay is cheap and easy to replace yourself. Keep a spare in the glovebox if you live in a cold climate — a $30 relay can save you from a no-start situation in winter.
• TipWhen replacing the relay, inspect the connector terminals for heat damage or corrosion. Burned terminals will kill a new relay quickly — replace the pigtail connector if damaged.

How to Fix

Inspect the under-bed wiring junction and connector terminals. Clean corroded terminals with electrical contact cleaner and a wire brush. Apply dielectric grease (Permatex 22058) to all connector terminals to prevent future corrosion. For severely corroded connections, splice in new Weatherpack or Deutsch sealed connectors. Seal the connector junction box with RTV silicone to prevent water intrusion. Budget $50-$300 depending on severity.

Owner tips & cautions

• TipApply dielectric grease to all trailer connector terminals during your annual towing prep. Two minutes of prevention saves hours of roadside troubleshooting with a loaded trailer.
• TipSeal the in-bed connector junction box with Permatex Ultra Grey RTV. The factory seal degrades and lets water pool around the connections, especially after truck bed washes.

How to Fix

For minor issues: Complete fluid and filter change with Mopar ATF+4 (68218057AA) and solenoid pack replacement ($400-800). For overheating prevention: Install an auxiliary transmission cooler and keep temps under 220F. For rebuilds: Use a reputable heavy-duty builder (SunCoast, Randys Worldwide, BD Diesel). A properly built 68RFE with billet shafts, upgraded clutch packs, and triple-disc torque converter ($5,000-8,000) will handle 800+ lb-ft of torque. For 2019+ trucks, the Aisin AS69RC replaced the 68RFE.

How to Fix

For shudder: First try a complete fluid change with Mopar Aisin-specific ATF (68218058AA) - NOT standard ATF+4. If shudder persists, torque converter replacement is needed ($2,000-3,500). Check TSB 21-013-19 for updated converter part number. For overheating: Install an auxiliary transmission cooler ($200-400, B&M or Derale) and reduce towing speed. Ensure the external transmission filter (if equipped) is clean. Some 2013-2018 trucks qualify for extended warranty coverage on the Aisin transmission.

How to Fix

For axle seal leaks: Replace the inner axle seals on the affected side (Mopar 68216218AA, $25-50 each) and inspect the axle shaft for wear at the seal surface. If the axle shaft is grooved, install a Speedi-Sleeve repair sleeve ($30). If brake contamination occurred, replace front brake pads and rotors ($300-500). For u-joint failure: Replace with Spicer Life Series (SPL55-3X) u-joints rated for 3500-class loads ($50-100 per joint, 2 per side). Total repair: $400-1,200 depending on extent.

How to Fix

Free replacement, obtained from Kidde. Chrysler's owner letters direct owners to contact Kidde for a replacement fire extinguisher at no cost — there is no dealer repair to the truck. Reach Kidde at 1-855-262-3540 or www.kidde.com and click 'Product Safety Recall'; Chrysler customer service is 1-800-853-1403 and the FCA recall number is T82. Notifications started February 14, 2018. Confirm your 3500's VIN at nhtsa.gov/recalls, then check your extinguisher's model against the NHTSA list before treating it as safe to rely on.

How to Fix

The repair is free. Chrysler notified owners beginning February 26, 2018, and a RAM dealer will replace the water pump on affected trucks at no charge. If you own a 2013-2017 RAM 3500 with the 6.7L Cummins, enter your 17-digit VIN at nhtsa.gov/recalls to confirm whether campaign 17V562000 (Chrysler recall T51) is still open on your truck. You can also call Chrysler customer service at 1-800-853-1403 and reference recall T51. Given the stated fire risk, do not put off a coolant leak while waiting on the appointment.

How to Fix

For sticking actuator: Remove and clean the VGT actuator and turbo vanes of carbon deposits. Actuator exercise procedure via wiTECH can help prevent sticking. Check TSB 14-001-21 for actuator calibration procedure. If the actuator motor is failed, replace the electronic actuator assembly ($800-1,500, Holset 5497296 or 5610723). If turbo vanes are severely carboned or damaged, complete turbo replacement is needed ($2,500-4,000). Regular highway driving helps keep vanes clean; trucks that idle excessively build up carbon faster.

How to Fix

Remove broken studs using a left-hand drill bit and easy-out extractor set. If the stud breaks flush or below the head surface, a professional machine shop extraction may be needed. Replace all studs with upgraded ARP 247-4206 stud kit, which is stronger than OEM. Always replace the exhaust manifold gaskets during this repair. Budget $400-$1,200 depending on how many studs are broken and whether machine shop extraction is needed.

Owner tips & cautions

• TipARP 247-4206 exhaust manifold stud kit is the definitive upgrade. Stronger than OEM and far less likely to break again. Worth the investment on any Cummins.
• WarningSoak broken studs with PB Blaster for 24+ hours before attempting extraction. Rushing the extraction is how studs break off flush with the head, turning a $400 job into a $1,200 machine shop visit.

How to Fix

Replace the front hub bearing assembly (Timken HA590576 or Moog 515162 are highly rated). The hub bearing is a bolt-on unit on these trucks — 4 bolts from the back of the steering knuckle. Replace both sides if one has failed, as the other is likely not far behind. Use ABS-compatible hub assemblies. Budget $300-$700 per side for parts and labor.

Owner tips & cautions

• TipTimken HA590576 and Moog 515162 are the top choices for replacement. Avoid cheap imported hub bearings — they often fail within 20,000 miles on a 3500 that tows.
• TipWhen one front hub bearing goes, replace both sides. If one failed at 80,000 miles, the other is likely at 85% wear and will fail within 10,000-15,000 miles.