SD Rebel
Spends too much time on here
Getting back to the O.P. question - has anyone figured this out? By "this" I mean that some 5.7s are getting 18-19mpg, and some are getting 11-12. It's NOT the gearing. I have 3.21 gears and I'm getting 12.5 all day, every day. Nothing added to the truck, no mods. Not in 4wd. This is a 2021 Laramie 1500 4wd without eTorq. It is a night edition, which comes standard with 22" wheels and 285/45/22 radials. People pulling trailers getting better mpg than me. I'm using 87 octane fuel. Have not had it to the dealer for this yet - only had it a month so far and still learning. But the O.P. said his dealer has looked at his twice and found nothing. It's really as though they're putting two different engines in the RAMS and calling them the same thing.
BTW, I have a 6.4 hemi in a challenger, and in TRACK mode it's getting about the same as the 5.7 in the RAM - 12MPG. Track mode keeps the tranny in a low gear so that the RPMs are always above 2k. Something is NOT RIGHT with some of the 5.7s in the RAMS!
I don't think anything is wrong at all with any of these engines.
The reason for the high variance in mpg is everything. The gearing, tire type and size, speed, and even the elevation you drive, and probably a few more variables I forgot to mention.
The biggest complainers about MPG are the Rebel owners, why? Because they have the most negative variables to mpg. 33" Duratrac tires with almost M/T treads, 3.92 axle, 1" higher ride height, no active aero all lead to bad mpg. If you look at most threads and Fuelly reports, 11 - 13 mpg is pretty common, especially if they do a lot of city driving. This is common among Rebel owners.
Then you got the guys with smaller smoother street tires, 3.21 axles, normal ride height with active radiator shutters, etc. They are pulling high teens and even low 20s on long drives.
There is a lot of variance in these trucks configurations, every single detail has an effect on mpg. But then you got the drivers. Are they cruising 65 mph in the slow lane all day, or do you have them stop and go 90% of the time? Probably the biggest difference from this variance. In short, I don't think there is anything wrong, you are just seeing the effects of different options, driving conditions and driving styles on these trucks.