The Largest Pickup Truck Recalls in U.S. History

Pickup trucks play a vital role in the American automotive industry, with well-known brands like Ford, GM, and Dodge leading the way. These vehicles are widely recognized for their durability and resilience, often clocking hundreds of thousands of miles due to responsible ownership. While many issues can be anticipated and mitigated, some problems arise from factory defects that are beyond a driver’s control.

Occasionally, manufacturing issues may occur, either with individual vehicles or widespread defects detected after production has commenced. While most recalls address minor batch concerns, some significant flaws can prompt large-scale recalls. Over the years, notable recall events have occurred, making them a talking point among truck enthusiasts. Here, we will examine some of the most significant truck recalls to fuel your next debate with friends over truck choices.

With numerous recalls occurring over time, specific statistics on affected vehicle types are not always accessible. A prime example is the Takata airbag recall, which has impacted tens of millions of vehicles, including many pickups. Due to the challenge of accurately determining the number of affected trucks, we have concentrated primarily on recalls specific to trucks and have relied on trusted sources like NHTSA and automaker websites, along with estimates from
GoodCarBadCar
when needed.

10 Fiat Chrysler Automobiles (FCA) – 1,021,279 Recalled

2017 Recall

• Trucks recalled: Ram 1500 (2013-2016), Ram 2500 (2013-2016), and Ram 3500 (2014-2016)
• Issue: Rollover side curtain airbags and seat belt pre-tensioners may fail to deploy during a rollover.

In May 2017, FCA initiated a recall for more than 1 million Ram trucks due to a defect in the Occupant Restraint Controller (ORC). Under certain driving conditions, such as off-road maneuvers or when the vehicle is hit, the roll rate sensor could malfunction, disabling the rollover side curtain airbags and seat belt pre-tensioners. This could increase the risk of injury in the event of a crash. To remedy this, FCA provided a free software update for the ORC. Ensuring safety devices function correctly is a priority for all vehicle owners.

9 Ford Motor Company – 1,101,107 Recalled

2017 Recall

• Trucks recalled: 2015-2017 Ford F-150 and 2017 F-250, F-350, F-450, and F-550 Super Duty models
• Issue: Faulty door latches may cause doors to open unexpectedly while driving.

In 2017, Ford issued a recall for more than 1 million trucks due to defective door latches, which could fail while the vehicle was in motion. This would result in the doors opening unexpectedly, creating a hazardous situation where a Ford F-150 might mimic a door-less Bronco. Dealerships were directed to inspect the latches and replace any damaged linkages, while also adding a water shield to help mitigate the issue.

8 Fiat Chrysler Automobiles (FCA) – 1,224,078 Recalled

2022 Recall

• Trucks recalled: Ram 1500 (2019-2022), Ram 2500 (2019-2022), and Ram 3500 (2019-2022)
• Issue: Tailgate may unexpectedly open while driving due to misaligned tailgate strikers.

This situation raises serious concerns when hauling cargo. In 2022, FCA recalled over 1.2 million Ram vehicles due to a problem with the tailgate latch mechanism. Misalignment of tailgate strikers could lead to the tailgate opening unexpectedly while driving, causing loose items to spill onto the road. To address this, dealers were instructed to check the alignment of the tailgate strikers and make necessary adjustments, ensuring safer transport for your next trip to the hardware store.

7 Fiat Chrysler Automobiles (FCA) – 1,227,808 Recalled

2024 Recall

• Trucks recalled: Ram 1500 (2019, 2021-2024)
• Issue: ABS control module disabling the Electronic Stability Control (ESC) system.

A recent recall this year raised significant concerns for Ram 1500 owners. Stellantis announced a recall affecting several model years of Ram 1500 trucks due to a software defect in the ABS control module that could deactivate the Electronic Stability Control (ESC) system, possibly resulting in a loss of vehicle control under specific driving conditions. The solution was a straightforward software update, highlighting the importance of software reliability in modern vehicles.

6 Ford Motor Company – 1,263,051 Recalled

2019 Recall

• Trucks recalled: Ford F-150 (2011-2013)
• Issue: Unexpected transmission downshift into first gear.

A notable recall from February 2019 saw Ford collect over 1.2 million F-150 trucks due to a serious transmission issue. The six-speed automatic transmission was prone to unexpectedly downshifting into first gear, leading to possible loss of control while driving. This could occur in any driving scenario, from city streets to steep highway grades. Ford addressed the issue by reprogramming the powertrain control module at no cost, but the gravity of this recall likely left many owners wary until their trucks were fixed.

5 Toyota – Approximately 1.3 million Trucks Recalled

2009 Recall

• Total Vehicles affected: 4,445,056
• Models recalled: Tacoma (2005-2010), Tundra (2007-2010), and others (2004-2010)
• Issue: Accelerator pedal may get stuck due to an unsecured or incompatible driver’s floor mat, leading to unintended acceleration.

One of the most significant recourses in automotive history occurred at Toyota in 2009, when a recall was initiated that affected more than 4.4 million vehicles due to potential unintended acceleration. This could happen if the accelerator pedal became trapped by a floor mat that was either unstable or not suited to the vehicle. Remedial actions included modifications to the accelerator pedal, adjustments to the floor surface, and updates to ensure brake overrides in specific models. While one might hope that this could be managed by consumers, it seems technology continues to test our capabilities in vehicle management.

4 Fiat Chrysler Automobiles (FCA) – 1,482,874

2017 Recall

• Trucks recalled: Ram 1500 (2009-2017), Ram 2500 and 3500 (2010-2017), Ram 3500, 4500, 5500 Cab Chassis (2011-2017), and Ram 3500 Cab Chassis (<10,000 lbs, 2016-2017)
• Issue: Risk of vehicle rollaway due to Brake Transmission Shift Interlock (BTSI) malfunction.

In 2017, FCA recalled over 1.4 million Ram trucks due to a concern with the Brake Transmission Shift Interlock (BTSI) system. This system could fail, allowing vehicles to shift out of park regardless of whether the engine was running, thereby heightening the risk of rollaway incidents. FCA offered a free software update or part replacement to fix the issue. This has raised significant alarm about the safety of FCA products and their tendency to roll away unexpectedly.

3 Ford Motor Company – 1,619,112 Recalled

2018 Recall

• Trucks recalled: 2015-2018 Ford F-150
• Issue: Risk of fire after seat belt pre-tensioner activation.

Ford’s 2018 recall involved over 1.6 million F-150 trucks due to a potential fire risk associated with the seat belt pre-tensioners. Upon deployment during an accident, these pre-tensioners could ignite materials in the vehicle, like carpet or insulation, potentially causing a fire. To combat this risk, Ford implemented a fix that involved removing certain insulation and wiring harness tape, replacing them with heat-resistant alternatives. This approach likely left many truck owners feeling uneasy.

2 Fiat Chrysler Automobiles (FCA) – Approximately 2.6 Million

2018 Recall

• Total FCA vehicles affected: 4,815,661
• Trucks recalled: Ram 1500 (2014-2019), Ram 2500, 3500, 3500 Cab Chassis (>10,000 lbs), 4500 and 5500 Cab Chassis (2014-2018), Ram 3500 Cab Chassis (<10,000 lbs, 2016-2018)
• Issue: Cruise control may fail to disengage, leading to unintended acceleration.

The 2018 FCA recall affected nearly 4.8 million vehicles, encompassing millions of Ram trucks, due to a malfunction in the cruise control system. The wiring could short-circuit, preventing the driver from deactivating the cruise control via either the brake pedal or manual disengagement. This alarming issue prompted FCA to provide a free software update to address the engine and powertrain control modules, highlighting the importance of electronic reliability in modern vehicles.

1 General Motors (GM) – Approximately 2.7 million Recalled

2014 Recall

• Trucks recalled: Chevrolet Silverado, GMC Sierra (2008-2013)
• Issue: Faulty ignition switches that could shut off the engine, disabling critical safety systems like airbags and power steering.

General Motors faced its largest recall in 2014, which was part of the notorious ignition switch crisis. The defective ignition switches had the potential to prematurely shut off the engine while driving, which disabled critical safety components, leading to numerous accidents and several fatalities. GM issued a recall to replace the faulty switches with redesigned versions that ensured consistent contact and prevented unintended movement out of the “run” position. The company also required dealers to ensure that vehicle keys lacked excessive attachments to minimize the risk of accidental switch movement. This incident remains one of the darkest chapters in U.S. automotive history, serving as a stark reminder that any automaker can encounter grave issues.