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My reluctor wheel failure story

11887 Views 64 Replies 19 Participants Last post by  biodiesel
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So I've been running the pre EPA GDE hot tune and trans tune since July 2019 and have driven around 35000 miles with it. Not having the EGR active was a big comfort to me and I had the mindset that since it's closed off I likely won't ever have the EGR cooler failure due to thermal fatigue.

Well this winter I had begun smelling unfiltered diesel exhaust in the cab when remote starting the truck to warm up but it would go away after the engine warmed. One cold morning in March this year I smelled coolant so I popped the hood and with a flashlight I spotted a couple drips of coolant coming off the EGR cooler.

I had been hoping to avoid the recall but I had a week long camping trip coming up and I'd be pulling a travel trailer so decided I'll get dealership to perform the EGR recall. I opted to not keep my original ECU so I knew this meant I'd either need to upgrade to the EPA complaint GDE Tunes or try buying a used ECU and programming to my truck. I chose to just get the EPA tune and move on.

I first used my GDE trans flash tool to return the truck trans back to stock tune so that my tool could be used for the EPA compliant tune I would be purchasing.

My service department at the dealership where I factory ordered the truck was great. They ordered the EGR parts under the recall, performed the repair and of course flashed my truck to their newest software. The whole process took only one week.

The newest software as you all know included the "band-aid" fix to allow the engine to continue to operate if the reluctor/tone wheel fails.

Well spring break arrives and we hit the road starting the 8 hr drive to our destination. The wife and I decided on traveling at night so our 8 month old daughter would sleep thru most of it. 3 hours from home @12:15am we were pulling into a small town in the middle of nowhere, the highway came to a stop light, when it turned green I began to take off and the truck lurched forward and stumbled dramatically then the dash lit up with warnings and went to limp mode. We were fortunate enough to be close to a gas station and I was able to limp into the parking lot. 12mph was as fast as I could go.

I checked the codes with my reader and it was crank sensor error. I immediately knew it was the reluctor wheel that failed and our trip was over. Ended up having to tow the truck and the travel trailer 170 miles back home.

Long story short if I hadn't just had the recall done I would have been stuck in the middle of an intersection with a trailer.

My dealership was quick to order the $42 reluctor wheel for me, only took a week. Unfortunately it was $1350 in labor to replace it due to having to drop the transmission to access the part. If you're curious what a failed reluctor wheel looks like here are some pics. The magnetic tape around the wheel had fractures all throughout and a couple chunks finally let loose just under 118000 miles.
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There's no software update available for the non-AEM trucks. Those trucks are not EPA compliant so FCA cannot update the software. This is why they get a new part. AEM trucks get the software update to keep the truck running in the event of a tone ring failure. If the ring fails, FCA will likely cover it under the AEM extended warranty.

It's a safety recall and FCA is doing what is required. Nothing more, nothing less...
Only the sensor is covered. The tone ring is not.
And not all tone rings are suspect. Seems the early ones were made by someone else or a different configuration ?
Only the sensor is covered. The tone ring is not.
True, but FCA has been good about it.
It was obviously a change of manufactures or design and material since the first ones havent had any problems and are not part of the recall.
Wrong. My 2014 ED was built one day before the start of the recall. Since I did not qualify for the recall when the toner wheel failed as I was at the end of the on ramp for Interstate 40 it just quit. No limp mode. Coasted to the shoulder. If I had made it onto the Interstate I probably wouldn't be typing this right now. $1492 repair bill 2 months later and that is a whole different deal. Don't use Bayird Dodge in West Memphis for service.
Does anyone know if FCA is coming up with a replacement for the rings in the failure list, meaning a new design or materials?
Does anyone know if FCA is coming up with a replacement for the rings in the failure list, meaning a new design or materials?
Yes a new part.
Wrong. My 2014 ED was built one day before the start of the recall. Since I did not qualify for the recall when the toner wheel failed as I was at the end of the on ramp for Interstate 40 it just quit. No limp mode. Coasted to the shoulder. If I had made it onto the Interstate I probably wouldn't be typing this right now. $1492 repair bill 2 months later and that is a whole different deal. Don't use Bayird Dodge in West Memphis for service.
1 day.. Unfortunately for you that "ring" could have slipped through the cracks. So close they should have made it right with you .
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Yes a new part.
I may have missed it. But when did we find out it was going to be a re designed part? The current gen3 engine is also using this same ring.
I may have missed it. But when did we find out it was going to be a re designed part? The current gen3 engine is also using this same ring.
There was a certain run of bad wheels. They are no longer being used. Not sure if the actual part number has changed.

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Can you tell me (us?) why if you didn't get the AEM update, you get a reluctor wheel replacement but if you did get the update, all you get is a firmware/flash update? It seems like you'd want to replace the bad parts for everyone. I know at the end of the day it's probably about the cost to replace the reluctor wheels but it seems strange to me.
Hi kmcintyre,
The wheel replacement is for a specific population of vehicles. Our engineering team has determined that the W58 software flash remedy will mitigate the safety related defect. If you are experiencing an issue related to a loss of the crankshaft signal, please contact your dealer & send us a message so we can assist further.
Rob
Ram Cares
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I was thinking That they were gonna come out with a completely new design for our trucks. However after reading the safety recall it appears that there are no redesigned parts coming down the pipeline.
Out of all the issues with this truck, the tone ring is the only issue that concerns me when going down the road.
UPDATE

I received a check in the mail today from FCA for full reimbursement of my reluctor wheel repair $1450. I’m very happy that RAMCARES reached out and took care of me! FCA sure surprised me with going above and beyond to back up their product even when it’s way passed the warranty and outside of the settlement coverage. Hopefully the reluctor ring issue stays a rare occurrence but if it happens to you it’s possible they will take care of it for you too.
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Wrong. My 2014 ED was built one day before the start of the recall. Since I did not qualify for the recall when the toner wheel failed as I was at the end of the on ramp for Interstate 40 it just quit. No limp mode. Coasted to the shoulder. If I had made it onto the Interstate I probably wouldn't be typing this right now. $1492 repair bill 2 months later and that is a whole different deal. Don't use Bayird Dodge in West Memphis for service.
I take it the engine just died? I just got back from Colorado, where that could have meant a 2000' drop if I couldn't muscle it around a hairpin bend without power steering. Fortunately, I don't think my '19 Classic is at risk from this particular failure.
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UPDATE

I received a check in the mail today from FCA for full reimbursement of my reluctor wheel repair $1450. I’m very happy that RAMCARES reached out and took care of me! FCA sure surprised me with going above and beyond to back up their product even when it’s way passed the warranty and outside of the settlement coverage. Hopefully the reluctor ring issue stays a rare occurrence but if it happens to you it’s possible they will take care of it for you too.
Hi TexasRam,
We're happy to hear that your concern has been resolved! Should any other concerns return in the future, please do not hesitate to reach out.

Rob
Ram Cares
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3 hours from home @12:15am we were pulling into a small town in the middle of nowhere, the highway came to a stop light, when it turned green I began to take off and the truck lurched forward and stumbled dramatically then the dash lit up with warnings and went to limp mode. We were fortunate enough to be close to a gas station and I was able to limp into the parking lot. 12mph was as fast as I could go.
I can confirm if you've had the recall #W58 performed you are able to restart multiple times while in limp mode caused by tone wheel failure. However, it takes longer, 3-4 seconds of cranking before the engine will start.
I'm sorry it happened to you, but I'm glad that someone got to test the new software and explain in detail how it responds. Unfortunately, the W58 really handicaps the truck.

I need to make a decision. Do I let the tone wheel fail on its own and deal with the inconvenience, or should I be proactive and replace it under my own terms? I probably should prepare myself by getting a price quote from the dealer. With 94,500 miles on the truck, I might be on borrowed time.
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I'm sorry it happened to you, but I'm glad that someone got to test the new software and explain in detail how it responds. Unfortunately, the W58 really handicaps the truck.

I need to make a decision. Do I let the tone wheel fail on its own and deal with the inconvenience, or should I be proactive and replace it under my own terms? I probably should prepare myself by getting a price quote from the dealer. With 94,500 miles on the truck, I might be on borrowed time.
I think we ALL have this concern on on minds considering the following coming directly from FCA.

The total affected vehicles for this model is 50,973

How are we supposed to drive our trucks without having the concern for our own safety and that of our passengers, there is a difference between driving on a lonely 2 lane road and being in the 5th lane of heavy traffic while pulling a trailer driving 65 mph. No one should pay with their their lives or those around them.
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I had a tone ring failure on 6/11. Took the vehicle to my dealer and they confirmed it was the tone ring. They thought that the ring was part of the crankshaft and that the entire motor would need to be replaced! After some google research, I called and told them that the ring was a separate part, #68493358. Before calling I contacted 2 other dealers to verify that the part was available. I was a Chrysler service manager for 20+ years so I know my way around their procedures. if the ring had been changed the part number should have been updated to 68493358AB. The "B" signifying that the part had been changed or superseded by a new part. I am now waiting for them to get back to me as to when they can get the truck in.
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I had a tone ring failure on 6/11. Took the vehicle to my dealer and they confirmed it was the tone ring. They thought that the ring was part of the crankshaft and that the entire motor would need to be replaced! After some google research, I called and told them that the ring was a separate part, #68493358AA. Before calling I contacted 2 other dealers to verify that the part was available. I was a Chrysler service manager for 20+ years so I know my way around their procedures. if the ring had been changed the part number should have been updated to 68493358AB. The "B" signifying that the part had been changed or superseded by a new part. I am now waiting for them to get back to me as to when they can get the truck in.
I had a tone ring failure on 6/11. Took the vehicle to my dealer and they confirmed it was the tone ring. They thought that the ring was part of the crankshaft and that the entire motor would need to be replaced! After some google research, I called and told them that the ring was a separate part, #68493358. Before calling I contacted 2 other dealers to verify that the part was available. I was a Chrysler service manager for 20+ years so I know my way around their procedures. if the ring had been changed the part number should have been updated to 68493358AB. The "B" signifying that the part had been changed or superseded by a new part. I am now waiting for them to get back to me as to when they can get the truck in.
Let us know how it goes, not knowing that is a seperate part is a bit concerning, but hopefully you have a good servicing dealer. Glad you were able to safely get out of harms way. If you experience any issues with the process Ram Cares may be able to assist.
How are we supposed to drive our trucks without having the concern for our own safety and that of our passengers
I'm not too concerned for my safety. A tone wheel failure isn't much different than getting a flat tire. When it happens, you have to get to the side of the road as soon as you can.

The problem with tone wheel failures is the truck defaulting to limp mode, which isn't fun if the failure happens in a rural area and/or while towing. Since I'm currently under the AEM warranty, I've been selfishly avoiding taking action on a preventative repair. Since last November, I've intentionally been driving the 2020 EcoDiesel on longer trips. But I can't do that forever. I keep thinking the tone wheel will fail on my 2015 when commuting to work or running errands around town, but it hasn't. And it may not fail while I'm under the AEM warranty. I still have two more years left of the AEM warranty.
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