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My reluctor wheel failure story

11888 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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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.
I think it does come down to if someone is running with or without the w58 bandaid. At least where I travel traffic can be a real pain in the @$$, especially in the dense metro areas i've seen people block disabled autos from getting to the side of the road but then these are probably the same sorts that won't move for emergency responders, but you know how that goes. It's a shame you can't drive your 2015 without some doubt, i'm in the same boat on my 2015. I made a couple trips up to DFW and between heavy traffic, construction I couldn't help but think to myself the whole time if she goes down let it happen out of town.
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It's a shame you can't drive your 2015 without some doubt, i'm in the same boat on my 2015. I made a couple trips up to DFW and between heavy traffic, construction I couldn't help but think to myself the whole time if she goes down let it happen out of town.
We drove the truck from New Mexico to Kansas for Thanksgiving. I hauled an empty trailer there and an old grain wagon back to New Mexico. The trip was 890 miles one way (1,780 miles round trip). That's a lot of rural driving.

We've got several long trips planned for this summer, but we'll be driving the 2020 EcoDiesel. I'm too nervous to take the 2015 until the tone wheel is replaced. I can't afford to be broke down in California, Nevada, Utah, Colorado, South Dakota, Illinois, Missouri, Kansas, Texas, or Oklahoma. Those are all the states we'll be towing through this summer.



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We drove the truck from New Mexico to Kansas for Thanksgiving. I hauled an empty trailer there and an old grain wagon back to New Mexico. The trip was 890 miles one way (1,780 miles round trip). That's a lot of rural driving.

We've got several long trips planned for this summer, but we'll be driving the 2020 EcoDiesel. I'm too nervous to take the 2015 until the tone wheel is replaced. I can't afford to be broke down in California, Nevada, Utah, Colorado, South Dakota, Illinois, Missouri, Kansas, Texas, or Oklahoma. Those are all the states we'll be towing through this summer.



That is fantastic setup you got with both trailers, love New Mexico not familiar with Kansas but can appreciate all the wide open spaces, there's nothing quite like the experience of enjoying all that comes your way on a road trip like that.

I miss the days when you could travel the interstates without so much congestion, how crazy is it when you're hours from nowhere and there's heavy traffic you're just not able to appreciate all that surrounding landscape.
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That is fantastic setup you got with both trailers,
Thank you. We do a lot of towing, so I've got a variety of trailers (equipment trailer, enclosed trailer, travel trailer, and dump trailer). The EcoDiesel is a nice little tow rig for many applications.

love New Mexico not familiar with Kansas but can appreciate all the wide open spaces, there's nothing quite like the experience of enjoying all that comes your way on a road trip like that.
We enjoy seeing the countryside. One thing for sure, many rural towns are turning into ghost towns. People are moving to the big cities.

I miss the days when you could travel the interstates without so much congestion, how crazy is it when you're hours from nowhere and there's heavy traffic you're just not able to appreciate all that surrounding landscape.
The interstates are extremely busy compared to 15 years ago. Once you get off the interstates and away from the major metropolitan areas, the roads are less traveled, and in some cases, desolate. That's one reason why I was motivated to put a 40 gallon in-bed fuel tank in my 2020 EcoDiesel. This allows me to travel in rural areas and not worry about fuel.
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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.
Since I wrote that, I read that our power steering is electric, so the risk isn't as bad as I had thought. I still assume the power brakes would be affected (???), but that's not as serious.
I still assume the power brakes would be affected (???), but that's not as serious.
When the engine dies out, you will lose some braking power, but hopefully there will be sufficient braking power to safely get to the roadside. When towing heavy loads down a mountain grade, I also try to use my transmission and engine braking as much as possible and rely less on the truck brakes. I also have my trailer brakes dialed up just enough that my trailer does much of the stopping. In other words, my trailer stops my truck, which is one reason why I'm still on my OE pads and rotors with 104,000 miles on the truck.
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When the engine dies out, you will lose some braking power, but hopefully there will be sufficient braking power to safely get to the roadside. When towing heavy loads down a mountain grade, I also try to use my transmission and engine braking as much as possible and rely less on the truck brakes. I also have my trailer brakes dialed up just enough that my trailer does much of the stopping. In other words, my trailer stops my truck, which is one reason why I'm still on my OE pads and rotors with 104,000 miles on the truck.
If you squeeze the doohickeys on the trailer brake controllers all the way, does it lock up your trailer brakes?
If you squeeze the doohickeys on the trailer brake controllers all the way, does it lock up your trailer brakes?
It will if you have your setting dialed up. I use the + and - buttons to adjust for my loads.
It will if you have your setting dialed up. I use the + and - buttons to adjust for my loads.
I was asking if you like to have yours set so that it can lock them up or back off from that point.
I was asking if you like to have yours set so that it can lock them up or back off from that point.
If I had to slam on the brakes, the trailer brakes would lock up.
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Greetings TexasRam,
Can you send us a message with your VIN and dealer info? We would like to look into this for you.

Rob
Ram Cares
Well. I'm unfortunately in the same boat. My 2016 1500 eco diesel that just hit 100k just had a reluctor wheel failure. My truck will turn over after cranking for 3-5 seconds. I just can't climb hills or accelerate when needed. Dealer said it will be about 12-15 days before repair, ordering parts then labor. Oh ya, and the dealer wants $2000 for putting on a $40.00 part.
Well. I'm unfortunately in the same boat. My 2016 1500 eco diesel that just hit 100k just had a reluctor wheel failure. My truck will turn over after cranking for 3-5 seconds. I just can't climb hills or accelerate when needed. Dealer said it will be about 12-15 days before repair, ordering parts then labor. Oh ya, and the dealer wants $2000 for putting on a $40.00 part.
Is your vin# is the sequence of covered trucks, keep in mind some dealers won't check to see if it is in the recall sequence you'd guess it warranty work isn't as profitable as a paying customer.
Is your vin# is the sequence of covered trucks, keep in mind some dealers won't check to see if it is in the recall sequence you'd guess it warranty work isn't as profitable as a paying customer.
How do you verify the vin# for this as potential recall?
Is your vin# is the sequence of covered trucks, keep in mind some dealers won't check to see if it is in the recall sequence you'd guess it warranty work isn't as profitable as a paying customer.
They would replace the sensor if bad but not the reluctor wheel.
They would replace the sensor if bad but not the reluctor wheel.
It's covered under warranty. What year is your truck?
Well. I'm unfortunately in the same boat. My 2016 1500 eco diesel that just hit 100k just had a reluctor wheel failure. My truck will turn over after cranking for 3-5 seconds. I just can't climb hills or accelerate when needed. Dealer said it will be about 12-15 days before repair, ordering parts then labor. Oh ya, and the dealer wants $2000 for putting on a $40.00 part.

It's covered under warranty. What year is your truck?
2016 Ram 1500 just hit 100k miles. There is an extension on warranty X78 120 months or 120k miles, but the warranty does not specify covering the reluctor wheel ($40 part), just covers the sensor ($440 part). And they are located right next to each other after having to remove the transmission. Could you clarify why you think it is covered?
2016 Ram 1500 just hit 100k miles. There is an extension on warranty X78 120 months or 120k miles, but the warranty does not specify covering the reluctor wheel ($40 part), just covers the sensor ($440 part). And they are located right next to each other after having to remove the transmission. Could you clarify why you think it is covered?
This is a seperate 'targeted' recall, FCA really went the cheap route on the Tone wheel issue. The part had a manufacturer defect which FCA claims is only certain vin's they mailed letters to those affected if you're a second owner its unlikely you received a letter as well as the dealer may not dig enough to see if the its covered because technically it's not a recall. The best part of this folly is that FCA won't pay until it fails and you're stuck getting it to a shop.

Those who received the letter later had to submit claim forms for reimbursement.

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2016 Ram 1500 just hit 100k miles. There is an extension on warranty X78 120 months or 120k miles, but the warranty does not specify covering the reluctor wheel ($40 part), just covers the sensor ($440 part). And they are located right next to each other after having to remove the transmission. Could you clarify why you think it is covered?
The recall covers the tone wheel. Often times, the magnet comes flying off and takes out the sensor with it. The warranty is good for 8 years/unlimited miles. You need to find a new dealer. I had mine replaced a few months ago for FREE!
The recall covers the tone wheel. Often times, the magnet comes flying off and takes out the sensor with it. The warranty is good for 8 years/unlimited miles. You need to find a new dealer. I had mine replaced a few months ago for FREE!

What is your dealer name and number?

I would love to see what they have to say about my situation. My problem is they say the sensor is fine but the tone wheel is bad. Pretty much the sensor is covered by warranty but not the wheel.
What is your dealer name and number?

I would love to see what they have to say about my situation. My problem is they say the sensor is fine but the tone wheel is bad. Pretty much the sensor is covered by warranty but not the wheel.
When the defective tone wheel de-laminates it often times destroys the sensor but it is replaced as it could be may be functional but is damaged it is better to replace while accessible.

This is a damaged tone wheel ->
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