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Failure mode - Cummins 5.9L Diesel (Dodge Ram HD)
APPS (throttle position sensor) failure / dead pedal (24v)
Reliability tier: verified - verify before ordering, see /disclosure/
Symptoms
- dead spot in the pedal around a fixed rpm, delayed or no throttle response, then full slam
- intermittent: comes back after a key-cycle (the classic re-calibration symptom)
Root cause
The 24v Accelerator Pedal Position Sensor (dual potentiometer + idle-validation) wears in a band; the ECM sees conflicting tracks and cuts throttle. A key-cycle recalibration temporarily masks it.
Diagnosis
- re-calibrate the APPS first (documented key-cycle procedure); if the dead band returns, replace the sensor
- log the APPS voltage tracks against pedal travel to find the worn band
Fixes
replace the APPS (or the pedal assembly); perform the documented recalibration after install ()
Prevalence
common