Help! Truck will not start or crank - Dodge Cummins Diesel Forum
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post #1 of 7 (permalink) Old 09-22-2019, 04:37 PM Thread Starter
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Help! Truck will not start or crank

Long time off the forum, used to be username 6_7 but I won't bore you with all those details as I really need some help here. A bit of background, truck is a 2007.5, 6.7 with 68rfe auto trans, 4x4 with only 100k miles and up to this point completely trouble free. Been doing a lot of suspension upgrades with the last piece being some Thuren Alien Arms. Anyway, went to take the truck in for an alignment and that's when the problems started. The whole process felt a bit off as the shop seemed to take way too long for what should be a simple job. On day 2 of them having the truck they asked if I've ever had problems with it not starting. My response was never and immediately headed over to their shop to find it sitting on the alignment rack and sure enough it will not start, details are:

- Key fob seems to work fine and will lock/unlock it
- With key turned to on position things still seem normal from memory but I could be missing something. Stereo works, warning lights on dash are on, fuel gauge moves, etc.
- When key is rotated to start nothing happens and I mean nothing, could't even hear any solenoid clicks.
- They did have the truck sitting for a long time with key on during the alignment struggles.
- Batteries are only 2.5 years old although I haven't been driving the truck much lately. Voltage measured 12.1V and maybe went to 11.9 with key on start. We tried it with a few different battery jump starters with no change and their hand held battery tester said they were OK.
- The mechanic had been doing some research and read about the IOD fuse which he tried pulling out for 10 minutes which did not help
-The mechanic also said he scanned it and didn't see any codes

We disconnected the batteries before leaving to clear anything and they are closed until Tuesday at which point I'll go back for one last try before having it towed. Any ideas on some quick things to check or ways to get it started so I won't need to tow? I've done the shorting the starter relay trick on some old vehicles to get it to crank but wasn't sure if that was a smart thing to do here

Thanks for any help and ideas on this!

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post #2 of 7 (permalink) Old 09-23-2019, 02:39 PM
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OlMoneyPit, had a chance to chase this issue with one of my pals truck and we started tracing the wires from the ignition to the battery and found one of the Fusible link was burned out from inside due to corrosion (Alternator to Passenger Battery). Couldn't find any local parts store that carries the replacement but found someone locally that was able to make one and viola! We might have just got lucky but your description of no start was exactly what he was having... Goodluck

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post #3 of 7 (permalink) Old 09-23-2019, 03:15 PM Thread Starter
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jakeorders, thanks for the reply. Do you remember where about the fusible link was? Engine bay or steering column? Your comment "alternator to passenger battery" confused me a little.
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post #4 of 7 (permalink) Old 09-24-2019, 04:11 PM Thread Starter
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So spent more time with the truck and got it towed home this morning, shop it was at that did the alignment was really helpful but didn't have factory Dodge diagnostics and I figured it would be best to have it home. I have more information on the issue below:

- My Edge CTS2 will not connect properly and switches from CAN to trying other communications
- My RaceMe tuner will also not connect and gives a CAN error #121 "Wrong Communication"
- PRND shift lights are out and "check gauges" is on
- The shop was able to connect with their scanner and got a lot of codes with the most troubling ones being:
C2202 Original VIN Mismatch/Missing
C2206 Vehicle Configuration Mismatch
There were also some lost communication codes with various modules which may be from the problem or from playing around pulling fuses and what not.

Any ideas on where to begin troubleshooting? Thanks!
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post #5 of 7 (permalink) Old 10-10-2019, 03:14 AM Thread Starter
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Update if anyone has ideas...

Got the truck to start again by reflashing the PCM with a recovery file and it seemed to be back to normal. Took it for a drive and at about mile 4 it tried to kill me, felt like it went wide open throttle for a few seconds then completely shut down going 60mph losing the power steering and power brakes. Had to get it towed home again as it wouldn't take another recovery flash. Oddly the next day the flash worked and it started again but now has P268C and so on "injector incompatible data" codes so it looks like possibly the injector balance codes were corrupted and I'm not sure if that could point to a possible source of the problem.

At this point I'm too scared to drive the truck again without some kind of hope that I understand the problem and that it's fixed. I did send the PCM out to be checked and refurbished which I hope solves it but we will see. Definitely would be curious if anyone has other ideas on what the problem could be.

Thanks,
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post #6 of 7 (permalink) Old 10-21-2019, 10:26 PM
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Hey OlMoneyPit, Have you had any luck with your truck? Hopefully the PCM was you culprit??

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post #7 of 7 (permalink) Old 11-01-2019, 03:13 AM Thread Starter
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Wilsonrl, I sent the PCM out to be refurbished and got it back in the truck last weekend. It ran and I drove it a little but it had injector data code errors despite having the correct injector codes programmed in. Scratched my head a lot on that one and after talking to the company they said to send it back, so out came the PCM again and shipped away. What a nightmare, I've owned a lot of vehicles but never one that went from reliable and trust worthy to so messed up with no known root cause.
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