Y78 Recall Gone Wrong: 54k Miles on HO Injectors in an SO Engine

[deocder]

Hey everyone,

I’m looking for some deep-dive technical feedback on a "stutter" I can’t seem to shake. I have a 2019 Ram 2500 with the 6.7L Cummins (Standard Output). 54,000 miles ago, during the Y78 recall (CP4 pump replacement), an out-of-state dealer incorrectly installed High Output (HO) injectors instead of the correct SO units. I brought this to their attention and was assured by the service manager that it would not be a problem. I’ve been running the HO injectors for three years. Immediately after the Y78 work, I started getting excessive regeneration and eventually required multiple forced regenerations from a full DPF. The current mileage on the truck is ~107,000. I've posted this same message on 5thGenRams.

The Damage So Far: I’ve already had to pay for significant consequential damages that I believe stem from the wrong parts:

• Full DPF Replacement: The truck was "chain-smoking" soot, leading to constant regens and eventually a total exhaust failure last month.
• Valvetrain: I’ve had to replace pushrods and rockers, perhaps due to oil dilution.
• Carbon Buildup: My current dealer found the valves caked in carbon (verified by borescope).

The Current Status: I have finally switched the injectors back to the correct SO parts, and the dealer put in CRC decarbonizer to try to clean up the combustion chambers.

The Lingering Problem: Despite the correct injectors being in, I still have a very obvious stutter in 5th and 6th gear between 1200 and 1500 RPM.

Questions:

1. The Stutter: Now that the fueling is corrected, what is the most likely root cause of this 5th/6th gear stutter? Could lingering carbon still be the culprit, or is it more likely that 54k miles of out-of-spec conditions caused damage to the transmission?
2. Liability & Damages: For those who have dealt with major dealership errors on recalls, what is the best way to approach the original dealer for reimbursement of "consequential damages"?
3. Documentation: Are there specific technical documents or logs I should insist on from my current dealer to prove that the "wrong part" directly caused these secondary failures?
4. I have AlfaOBD and a bypass module if needed.

I’m trying to build a solid case to ensure the original shop is held responsible for the damages caused by their error during a safety recall.

Appreciate any advice or experiences you can share.

Thanks,
Adam

NOTICE: This communication is made for settlement purposes only and is not to be used as evidence in any legal proceeding.

 

[Brutal_HO]

Do you have part numbers?


You also left out the fact that your Y78 recall was performed following a CP4 failure leading to fuel system contamination and the subsequent frequent regen issues you experienced. Seems perhaps you drove it knowing of frequent regen and fuel dilution. If so, that's on you.

 

[deocder]

Thanks for the reply. Yes, the recall work was done because the CP4 failed. The dealership initially blamed it on contaminated fuel which I had an independent company come it to test and determined it was not contaminated. They then found the CP4 failed and did the recall work. They had the truck for 54 days.

Here are the kit numbers straight from the Y78 documentation:

Correct Kit (SO): CSRLY783AA. R8444791AA, Fuel Injectors (Cummins 5364205)

Incorrect Kit (HO) installed during my Y78: CSRLY782AA. R8444790AA, Fuel Injectors (Cummins 5364204)

Regarding the "on me" comment—I have to disagree. This wasn't a case of ignoring a check engine light; it was a factory-mandated safety recall performed by Mopar-certified experts.

I didn't "knowingly" drive with fuel dilution or regen issues, I knowingly and repeatedly took the truck to authorized dealerships to address those exact symptoms. Every time, I was told the truck was operating within spec or given a forced regen.

An owner is entitled to expert reliance. I relied on the people at the dealership to perform the repair correctly. Despite me catching a hardware mismatch that they created, I was assured, by the expert that “it wouldn't be a problem.”

It’s hard to troubleshoot a part error when the professionals are telling you the computer is happy and the numbers are in the green.

The DPF didn't fail due to neglect; it failed because it was fed a soot rich diet for over 54k miles due to a botched recall service. The latest dealer I took it to actually investigated what I had been telling other dealers all along…”this truck has the wrong injectors.” They confirmed with their field engineer that it surely was in fact a problem.