Sorry to hear about your troubles. Honestly, I think your situations is the exact reason why many states have adopted lemon laws. You should look into the laws in your state. Of course Ram would prefer to keep the truck until the problem is resolved, but on your side you are out a lot of cash for an asset that you cannot utilize. I wish you the best of luck.

 

Had same issue with exhaust smell. It was the exhaust pipe coming off turbo. Apparently the nuts were started on the bolts but they were never tightened. As far as how to proceed... Tell them what you feel you are owed and see what happens. Maybe you can get some reimbursement for payments or some free services for down the road. Extended warranty maybe?

 

Yea man same exhaust issue here. Haven't taken it to a dealer yet mainly bec I don't want to lose the truck for a month or more. I wrote down that part number and a few other notes to give my dealer when I go to hopefully help assist them. Kind of a pain in the ass, but also expected when owning a first year diesel with all these emission laws. As much as I want to remove all of it, it's nice standing behind this truck and not dying from the diesel fumes. I wouldn't be discouraged at this point from a power train perspective but the leaking cab issue that people are starting to inherit has me worried. I've had a silverado that leaked before, basically impossible to fix. Hopefully this third brake light issue is not that serious. On my Tacoma I used rtv to seal around the light after it was installed on the cab. Worked pretty well.

 

My truck has exactly the same exhaust leak. The pipe between to catlytic converter and turbo has a crack where it mounts to turbo. They found the problem very quickly but have had the truck 2 weeks trying to find the part. They told me the same thing that the part had been revised and was not available yet and the old part was out of stock and could not be re-ordered. They told me last week that the new part was scheduled to be in on Oct. 24. However, they called today and said that one had been located and should arrive early next week. That has been the only problem so otherwise I'm satisfied with the truck. It looks like this leak is a chronic problem since I've seen several posts with the same problem.

 

I would ask them to put some exhaust tape on it and return the truck until the part is in, that way you have the truck, no fumes and they don't have to worry about pissing a customer off.

 

I was able to pick my truck up today. It took 2 weeks to get the part which was quicker than I expected. I was happy with the response from the dealership. The problem was that these parts are not available yet. They only needed the short elbow that connects to the turbo but had to order the entire Catalytic converter assy (#68155790-AC). The picture shows the expansion joint where the converter assy attaches to the turbo was partially broken.

 

I was able to pick my truck up today. It took 2 weeks to get the part which was quicker than I expected. I was happy with the response from the dealership. The problem was that these parts are not available yet. They only needed the short elbow that connects to the turbo but had to order the entire Catalytic converter assy (#68155790-AC). The picture shows the expansion joint where the converter assy attaches to the turbo was partially broken.
View attachment 2984

That looks like metal fatigue taking place in the picture. Not good.

 

Informative picture. Now we really know and can devise a temporary fix if needed.

Thanks.

 

Interesting break in the exhaust...I don't think a dealer would put exhaust tape on it until the new parts arrive...that's a law suit if something happen to someone. It wouldn't surprise me to see a recall for that original part.

 

I am having the same problem but also accompanied by lots of white smoke from under the hood when I stop.

 

Exhaust Leak



Mine had white smoke from under the hood also. It was coming from between the rear of the engine and firewall. I posted the picture of the broken expansion joint above which was the cause of the leak on my truck.

There continues to be more people posting this problem so you would think that a recall would be in order. Also, the corrugated pipe used to make that section appeared to be very thin so I expect more failures on other trucks using this part/design. My dealer told me the part has been redesigned and the new part is not available yet so they had to use a part with the old design to make the repair. I was happy to get the truck back but I would rather have the re-designed part.

As for how to get the repair done quickly, I think the Chrysler customer service line is not terribly helpful. You should call that number and have them establish a case. But after that they are very slow and the case manager that was assigned to me never answered the phone and never had up to date info. The dealership parts manager seemed to have more accurate delivery info. After that, get a rental car from the dealership and then try to work with the dealership parts dept manager while he locates the part. There were very few of these parts becoming available and I don't know how orders from each dealer are priortized.

I reccommend taking a very harsh tone with the customer service reps at Chrysler so they will quickly understand how dissatified you are with the RAM brand. But I would treat the dealership employees with respect and simply ask for their help. They are the ones that will repair the truck in the end so a good relationship with them will help.

 

Same issue - exhasut in cab. One dealer told me that is was from the regen cycle, but my truck was not in regen. Took to another dealer, and they wont let me have the truck back due to the exhaust leak. still waiting to hear what is broken - maybe the cat conv assy like stated in this thread. Once I find out I will post what was the issue.

 

Well as suspected Catalytic Converter Assy bellows is blown out and entire assy has to be replaced. $2179 for assy - covered under warranty. Lead time is several weeks as the part is back ordered. Customer service states Chrylser/Fiat is working on replacement of bellows of the assembly. No time was given for the updated repaired part. Not sure if I am getting another Cat Conv Assy with the same bellows that will have the same issue in 3K miles.??

IMPALADAVE64 -did the dealer give you an upgraded part or the same style as the part that was bad?? What if the same issue occurs again??

 

They replaced the broken part with a new part made by the old design. That was the only choice. I hoping that not all the parts made with the old design will fail or by the time it does fail the re-designed part will be available. I wish we had more details like what design is being used on engines that are currently in production and what is the failure rate of the old design.

 

Well is seems that the part I need is a Tube - Pressure Front P/N 68263757AA. It is being drop-shipped from the supplier. ETA Tuesday. Trying to find a picture of it to post.

 

Same issue with my truck. I have had it in twice. The first time the mechanics did not smell the exhaust odor. They told me that I am noticing it because I am not familiar diesels. I informed them that they couldn't be any more mistaken. I have other diesel trucks, and they are all older and roll coal and do not smell in the cab. This afternoon I got it back from the second visit of 3 days. This time they told me that the mechanic contacted Chrysler engineering (what a waste). I was then told this is "normal". They went further to tell me that I should run the AC on max or recirculate so that it does not bring in fresh air. Total insult to a persons intelligence (especially the alleged response from engineering).

 

Exhaust Leak Repair



It's unfortunate how different the customer experience is from dealer to dealer. I called my dealer the second time I saw white smoke coming from the AC vents and the service manager told me to bring the truck in immediately. They diagnosed the problem pretty quickly so I suspect the problem is well known by RAM, especially at this point. You should call RAM customer service and complain about your dealer's lack of response. Also. I would request to speak to the dealer's owner or general manager. There are other threads on this site with pictures of the failed exhaust parts. A service tech also posted that with these trucks you should never smell the traditional diesel exhaust smell because of the the way the exhaust is treated unless there is a leak before the catalytic converter.

 

Even when you select recirculate on the AC you still receive about 10% fresh air from out side. This is so if you do have an exhaust leak coming in the cab someplace you don't end up asphyxiated. Sounds like they didn't contact anyone.

 

I was very close to buying one of these but not after reading these posts. Too bad. Overall the concept of a diesel truck getting 25-27 mpg sounds good but not if you're going to get sick (or worse - death) from carbon monoxide poisoning.

 

Uhhhh pretty sure no one has died. Wish there was a medical term for this notion of "I read it on a forum, everyone must've had same experience, and so will I." "Info-juxtaposition-forumphobia" sounds official to me!

 

Just to add to my post above:
Carbon monoxide poisoning can lead to headaches (as others have mentioned in this thread), confusion and flu-like symptoms.
Chronic exposure can lead to confusion, memory loss and yes, death. People have died in other types of vehicles from exhaust leaks with the associated CO poisoning. Usually they are older vehicles however. If someone does have this problem with their vehicle they need to get it fixed ASAP. Not doubt it can be repaired eventually, especially since it IS a big deal.

Knowledge is power which is why we are talking about it.

 

Maybe this is not the truck for you, if you are that concerned about it.

 

Thanks everyone for sharing this information.

I am having the same problem but have not taken the truck to the dealer yet. Can't be without it right now. My issue started about 6,000 miles. I have about 7,500 on the truck now. So far, this has been the only problem I have had (knock on wood). I love the truck, just need to get this fixed. I plan to talk to the dealer in my area and see what they have to say. I will share all of this info with them as well.

 

Took mine in on Oct 17th for the same problem (exhaust leak). On the 22 they called to inform me that Chrysler had stopped by to inspect truck. I was told I was #11 in the nation as of that day in for the same problem and would be fixed in that order. Yes it is a know problem to Chrysler engineering. Was given a Chrysler 200S (nice car loaner for the next two weeks. This was not my selling dealer as the service dept. there is full of morons (another story). Picked up truck on Oct. 30th fixed!!! Parts used # 68171190AA (oxygen sensor) #68231738AA (??) # 68160679AB (exhaust gasket) & # 68155790AC (exhaust converter).

 

CKD2014, I am in the DFW area too. What dealer did you go to?

 

The original selling dealer was north of Plano, TX. on 75 but 25 miles from my house. I won't mention any names but you can figure it out. Had a starting issue took it in kept it for 3 days, got it back and took it back the next day same problem. Kept it 11 days had crappy rental, they replaced the body control module this time. Picked up got home and wife's key don't work that evening. They failed to tell me to bring in extra set of keys as they need to be reprogramed because of new body control module. Another 25 miles with tolls! Gave me $50.00 off first oil change to make me happy. When I went back to get oil changed they only put 6 quarts in!!!!! I caught this on my way home and called told them that the book says 8 quarts. They told me they had a memo (from who I don't know) that stated the jeeps get 8 and the trucks get 6 due to different types of oil pans. Next morning got up and checked oil nothing on the dip stick. I called them and they repeated the same story and told me something else must be wrong. Not happy with the answer I called the 866 # for Ram. They informed me that it takes 10.5 quarts. Seems we were about 4.5 quarts short. They called the dealership and told them how to change the oil. I had to drive back again 50 miles round trip plus tolls for the extra oil. I do not think they were happy about me calling Ram to tell them how to do their job. I got no compensation this time.
I call RAM with the exhaust leak problem and opened a case and explained why I was not returning to the selling dealer and was there anybody that was competent to work on the truck in the DFW area. They referred me to Richardson Chrysler Jeep Dodge in Richardson TX. They listened to what I had to say I also brought a post from here about the same problem and the fix. They took me to meet their master diesel mechanic to explain the problem. Also talked to the head of the service dept. We looked on line at Chryslers web site but nothing about exhaust problem. He admitted this forum had more info about the problem than Chrysler was going to admit. I felt they went above to keep me informed of what the status was while they had my truck.


Update Nov. 8 2014: Dead battery this morning, jumped off took to dealer on the 7th. Replaced battery it had dead cell. About 9K miles at this point. Last night went to use and would not start had to turn key on and off 4 or 5 times it is not the battery but I am assuming it is the body control module again. If it is intermittent I will have to wait till it leaves me stranded or starts doing it all the time as they may not find the problem easily. Getting time to lemon law this thing!!!!!



Update Nov. 14th 2014: Returned truck to dealer on the 8th for starting problems gave me rental. Called me on Tuesday the 11th to tell me to return rental could not duplicate problem. Returned to dealership in the late afternoon. They went to retrieve truck but was now having starting issues. Got it started and sent me home in it. Next morning on the 12th starter turned over twice and then died, the tell tale signs of a dead battery appear. Had towed in the afternoon to dealership.
I really liked the truck it gave me great fuel millage towed really well and a great ride quality but has had so many issues. I have never had a new vehicle that has averaged once a month in the repair shop since owning it. I have now retained legal council to deal with the problem. Time to unload this headache. I believe these trucks were rushed to market a little to fast for engineering do deal with all the bugs in them.

 

The original selling dealer was north of Plano, TX. on 75 but 25 miles from my house. I won't mention any names but you can figure it out. Had a starting issue took it in kept it for 3 days, got it back and took it back the next day same problem. Kept it 11 days had crappy rental, they replaced the body control module this time. Picked up got home and wife's key don't work that evening. They failed to tell me to bring in extra set of keys as they need to be reprogramed because of new body control module. Another 25 miles with tolls! Gave me $50.00 off first oil change to make me happy. When I went back to get oil changed they only put 6 quarts in!!!!! I caught this on my way home and called told them that the book says 8 quarts. They told me they had a memo (from who I don't know) that stated the jeeps get 8 and the trucks get 6 due to different types of oil pans. Next morning got up and checked oil nothing on the dip stick. I called them and they repeated the same story and told me something else must be wrong. Not happy with the answer I called the 866 # for Ram. They informed me that it takes 10.5 quarts. Seems we were about 4.5 quarts short. They called the dealership and told them how to change the oil. I had to drive back again 50 miles round trip plus tolls for the extra oil. I do not think they were happy about me calling Ram to tell them how to do their job. I got no compensation this time.
I call RAM with the exhaust leak problem and opened a case and explained why I was not returning to the selling dealer and was there anybody that was competent to work on the truck in the DFW area. They referred me to Richardson Chrysler Jeep Dodge in Richardson TX. They listened to what I had to say I also brought a post from here about the same problem and the fix. They took me to meet their master diesel mechanic to explain the problem. Also talked to the head of the service dept. We looked on line at Chryslers web site but nothing about exhaust problem. He admitted this forum had more info about the problem than Chrysler was going to admit. I felt they went above to keep me informed of what the status was while they had my truck.

Are you saying that you drove the truck 25 miles with the oil 4.5 quarts low and again with 2.5 quarts low?

 

Thanks for the information. That's exactly what I was looking for.

 

Today I dropped off my EcoDiesel at the dealer for an exhaust smell coming from the A/C vents at slow speed. Currently my truck has almost 7,000 miles.

 

The Service writer called to tell me that the Tech could not duplicate the problem. I guess I'll have to go for a ride with the Tech tomorrow morning.

Is there an actual TSB for this? The service writer said there was nothing concerning an exhaust leak.

Thanks for any help

 

Thanks y'all. I have read the other threads. I've seen the pictures. I've looked with a flashlight and an inspection mirror behind the turbo and I can't find any areas with soot.

I'll let you know what we find.

 

Taking mine in on Monday because I have been smelling exhaust in the cab. Hopeful they are able to detect it so it can be fixed. Around 2600 miles on mine. Guess we'll see.


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