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2010 Dodge RAM 1500

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2010 Dodge RAM 1500 do not stand out strongly from the model-year median of 520.

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When problems were reported

Mileage at the reported incident

354 reports with mileage · 132 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Power Train. Review the 229 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 71 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 61 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

26 crash reports3 fire reports10 injury reports

Power Train complaints

229 reports
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40,000 miles · Aug 11, 2012
Power Train

WHILE TRAVELING AT SPEED OF 15 MPH,HEARD LOUD BANG FROM REAR THE TRUCK SHOOK. VEHICLE WAS TOWED TO DEALERSHIP WHERE THEY DETERMINED THE DIFFERENTIAL BROKE DUE TO MECHANICAL FAILURE. THEY DID NOT SAY ANYTHING ABOUT TRANSMISSION. ORDERED PARTS ARE ON BACK ORDER. *TR

NHTSA ODI #10470231

39,200 miles · Aug 10, 2012
Power Train

WHILE ON VACATION I WAS DRIVING 45 MPH AND HEARD A WHINNING NOISE COMING FROM THE REAR OF TRUCK. IT GOT LOUDER AND LOUDER VERY QUICKLY AND THEN I HEARD A LARGE BANGING NOISE AND THE REAR WHEELS FROZE UP CAUSING THE TRUCK TO SKID TO A STOP IN THE MIDDLE OF THE ROAD. GOT OUT OF SAID TRUCK AND NOTICED THE REAR OF THE DRIVESHAFT LA…

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WHILE ON VACATION I WAS DRIVING 45 MPH AND HEARD A WHINNING NOISE COMING FROM THE REAR OF TRUCK. IT GOT LOUDER AND LOUDER VERY QUICKLY AND THEN I HEARD A LARGE BANGING NOISE AND THE REAR WHEELS FROZE UP CAUSING THE TRUCK TO SKID TO A STOP IN THE MIDDLE OF THE ROAD. GOT OUT OF SAID TRUCK AND NOTICED THE REAR OF THE DRIVESHAFT LAYING ON THE GROUND. PUT IT IN 4 WHEEL DRIVE TO GET OF THE ROAD AND NOTICED THE REAR WHEELS WERE LOCKED SOLID AND WAS BARELY ABLE TO GET THE TRUCK TO MOVE TO GET OF THE ROAD. THE PINION NUT CAME LOOSE CAUSING THE DRIVESHAFT TO FALL OFF IN TURN THE PINION MOVED IN THE REAR AXEL CAUSING CATASTROPHIC FAILURE INSIDE THE REAR DIFFERENTIAL. *TR

NHTSA ODI #10470152

30,000 miles · Aug 6, 2012
Power Train

THE VEHICLE BEGAN MAKING A WHINING NOISE IN THE REAR DURING DECELERATION, BOTH FROM SIMPLY LETTING OFF THE ACCELERATOR AND BRAKING. NOISE BEGAN 50 MILES FROM RESIDENCE, AND PROGRESSIVELY BECAME LOUDER ON THE DRIVE HOME. AT ROUGHLY 17 MILES FROM MY CURRENT RESIDENCE, A LOUD NOISE WAS HEARD FOLLOWED BY MORE LOUD RUMBLING AND SMO…

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THE VEHICLE BEGAN MAKING A WHINING NOISE IN THE REAR DURING DECELERATION, BOTH FROM SIMPLY LETTING OFF THE ACCELERATOR AND BRAKING. NOISE BEGAN 50 MILES FROM RESIDENCE, AND PROGRESSIVELY BECAME LOUDER ON THE DRIVE HOME. AT ROUGHLY 17 MILES FROM MY CURRENT RESIDENCE, A LOUD NOISE WAS HEARD FOLLOWED BY MORE LOUD RUMBLING AND SMOKE FROM DIFFERENTIAL FLUID SLINGING ONTO THE EXHAUST. I TURNED ON TO A SIDE ROAD AND BEGAN COASTING UNTIL REACHING A SAFE LOCATION TO PULL OVER; HOWEVER, BEFORE STOPPING THE REAR DIFFERENTIAL LOCKED UP CAUSING THE TRUCK TO SKID TO A STOP. UPON EXITING THE VEHICLE, I COULD SEE THE DRIVE SHAFT HANGING ON THE GROUND, IT'S REAR CONNECTING BOLTS SHEARED, AND THE DIFFERENTIAL YOKE WAS MISSING. I COULD SEE THE PINION SHAFT SLOPPILY RESTING IN THE THE DIFFERENTIAL WHERE THE YOKE SHOULD HAVE BEEN. I PAID TO HAVE IT HAULED TO THE LOCAL DODGE DEALERSHIP, WHO INDICATED THEY "DID NOT HAVE A QUALIFIED REAR END TECHNICIAN", AND SAID I'D "HAVE TO HAVE IT TOWED TO ANOTHER ONE AT MY PERSONAL EXPENSE" 50 MILES AWAY. AFTER CONTACTING CHRYSLER, THEY REIMBURSED MY TOWING EXPENSE, AND TOWED IT TO THE OTHER DEALERSHIP. THE SECOND DEALERSHIP SAID THE RING AND PINION WERE BROKEN, AND WOULD HAVE TO BE REPLACED ALONG WITH THE CARRIER. AFTER WAITING ONE MONTH WITHOUT MY TRUCK, I CONTACTED THEM AND WAS TOLD THE PARTS NECESSARY TO FIX THE VEHICLE WERE ON BACKORDER, AND WOULD NOT BE AVAILABLE FOR 3 MONTHS. I CALLED CHRYSLER TO EXPEDITE THE PARTS, AND THAT AFTERNOON WAS TOLD THE PARTS HAD ARRIVED, AND WOULD BE FIXED IN 2-3 DAYS. AFTER ONE DAY, I WAS TOLD CHRYSLER OKAYED AFTERMARKET PARTS TO EXPEDITE THE REPAIR, BUT WERE FLAWED PREVENTING CORRECT REPAIR. THEY OFFERED TO LET ME HAVE IT BACK, BUT WARNED ME IT WOULD MAKE MORE NOISE THAN BEFORE. I REQUESTED THAT THEY FIX IT RIGHT OR NOT AT ALL. CHRYSLER THEN INDICATED PARTS WOULD NOT BE AVAILABLE FOR 5 MONTHS. *TR

NHTSA ODI #10469435

34,200 miles · Jul 27, 2012
Power Train

TL* THE CONTACT OWNS A 2010 DODGE RAM 1500. THE CONTACT STATED THAT WHILE DRIVING 45 MPH, A HUMMING SOUND EMITTED FROM THE POWER TRAIN. THE CONTACT APPLIED THE BRAKES AND THE REAR DIFFERENTIAL SEIZED, DESTROYING THE POWER TRAIN. THE CONTACT HAD THE VEHICLE TOWED TO A DEALER. THE DEALER WAS UNABLE TO REPAIR THE VEHICLE DUE TO PAR…

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TL* THE CONTACT OWNS A 2010 DODGE RAM 1500. THE CONTACT STATED THAT WHILE DRIVING 45 MPH, A HUMMING SOUND EMITTED FROM THE POWER TRAIN. THE CONTACT APPLIED THE BRAKES AND THE REAR DIFFERENTIAL SEIZED, DESTROYING THE POWER TRAIN. THE CONTACT HAD THE VEHICLE TOWED TO A DEALER. THE DEALER WAS UNABLE TO REPAIR THE VEHICLE DUE TO PART AVAILABILITY. THE CONTACT THEN TRADED THE VEHICLE TO THE DEALER. THE FAILURE MILEAGE WAS 34,200.

NHTSA ODI #10468024

85,200 miles · Jul 26, 2012
Power Train

TL* THE CONTACT OWNS A 2010 DODGE RAM 1500. THE CONTACT STATED THAT WHILE DRIVING 60 MPH, BOTH OF THE REAR WHEELS LOCKED. AS A RESULT, THE DRIVE SHAFT BROKE OFF THE REAR DIFFERENTIAL. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DETERMINE WHAT CAUSED THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM WHO DID NO…

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TL* THE CONTACT OWNS A 2010 DODGE RAM 1500. THE CONTACT STATED THAT WHILE DRIVING 60 MPH, BOTH OF THE REAR WHEELS LOCKED. AS A RESULT, THE DRIVE SHAFT BROKE OFF THE REAR DIFFERENTIAL. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DETERMINE WHAT CAUSED THE FAILURE. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM WHO DID NOT OFFER ANY ASSISTANCE. THE VIN WAS NOT AVAILABLE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 85,200.

NHTSA ODI #10467819

50,000 miles · Jul 26, 2012
Power TrainVehicle Speed ControlWheels

I WAS DRIVING VEHICLE AT 55 MPH ALONG UNDIVIDED 2 LANE HIGHWAY. DIFFERENTIAL BEGAN TO MAKE WHINING NOISE AND THEN WITHIN 1-2 MINUTES THE REAR DIFFERENTIAL LOCKED UP AND THE DRIVE SHAFT YOKE BROKE CAUSING THE DRIVE SHAFT TO DROP TO THE GROUND. DUE TO THE SPEED, VEHICLE CONTROL WAS DIFFICULT WHILE ATTEMPTING TO STOP. ONCE STOPP…

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I WAS DRIVING VEHICLE AT 55 MPH ALONG UNDIVIDED 2 LANE HIGHWAY. DIFFERENTIAL BEGAN TO MAKE WHINING NOISE AND THEN WITHIN 1-2 MINUTES THE REAR DIFFERENTIAL LOCKED UP AND THE DRIVE SHAFT YOKE BROKE CAUSING THE DRIVE SHAFT TO DROP TO THE GROUND. DUE TO THE SPEED, VEHICLE CONTROL WAS DIFFICULT WHILE ATTEMPTING TO STOP. ONCE STOPPED, DRIVE SHAFT YOKE WAS OBVIOUSLY SNAPPED OFF AND PASSENGER SIDE REAR TIRE HAD MELTED RUBBER FROM BEING DRAGGED FOR A FEW HUNDRED FEET WHEN DIFFERENTIAL LOCKED UP. VEHICLE WAS TAKEN TO DEAL AND AFTER 2 WEEKS DETERMINATION WAS MADE THAT SOMETHING SEIZED IN THE DIFFERENTIAL AND CAUSED INTERNALS TO BE DESTROYED. DEALER HAS NOT MENTIONED CURRENT RECALLS OR INVESTIGATIONS. AS OF NOW, I HAVE BEEN TOLD THAT DODGE IS NOT MAKING THE PARTS NEEDED AND THAT A MINIMUM OF 1 MONTH LEAD TIME IS EXPECTED BEFORE PARTS BECOME AVAILABLE. I AM TOLD NO LOANER VEHICLE OR RENTAL CAR WILL BE PROVIDED. *TR

NHTSA ODI #10467805

24,000 miles · Jul 25, 2012
Power TrainUnknown Or Other

I NOTICED THE VEHICLE MAKING A HUMMING/RUBBING SOUND COMING FROM THE REAR END WHEN MOVING 20-35MPH AND COMING TO A STOP. I PARKED THE VEHICLE UNTIL I WAS ABLE TO GET IT TO THE DEALERSHIP, SO THE TECHNICIAN COULD TEST DRIVE AND LOCATE THE PROBLEM. UPON HIS INITIAL LEAVING HE HEARD NOTHING SO HE PROCEEDED TO PICK UP THE SPEED TO …

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I NOTICED THE VEHICLE MAKING A HUMMING/RUBBING SOUND COMING FROM THE REAR END WHEN MOVING 20-35MPH AND COMING TO A STOP. I PARKED THE VEHICLE UNTIL I WAS ABLE TO GET IT TO THE DEALERSHIP, SO THE TECHNICIAN COULD TEST DRIVE AND LOCATE THE PROBLEM. UPON HIS INITIAL LEAVING HE HEARD NOTHING SO HE PROCEEDED TO PICK UP THE SPEED TO 55MPH TO CHECK FOR VIBRATION IN A NEUTRAL COAST DOWN. UPON REACHING 45MPH THE DRIVE-SHAFT COMPLETELY SNAPPED AND SEPARATED FROM THE REAR END ASSEMBLY, RESULTING IN THE REAR END COMPLETELY LOCKING UP AND SENDING THE TRUCK SPINNING OUT OF CONTROL AND THE DRIVE SHAFT SWINGING VIOLENTLY UNDERNEATH THE TRUCK UNTIL THE TRUCK CAME TO REST IN THE MIDDLE OF THE ROAD. UPON FURTHER INSPECTION WHEN THE TRUCK WAS TOWED BACK TO THE DEALERSHIP THE TECHNICIAN NOTICED THE RACK AND PINION ASSEMBLY COMPLETELY UNTHREADED ITSELF FROM THE DRIVESHAFT RESULTING IN A CATASTROPHIC FAILURE OF THE REAR END. AS A RESULT IT COMPLETELY DESTROYED THE GEARS AND COMPONENTS WITHIN THE REAR END HOUSING INCLUDING DEEP GASHES INTO THE HOUSING ITSELF RENDERING IT UNSAFE TO RE-BUILD ON. THE DEALERSHIP HAS SINCE ORDERED A WHOLE NEW REAR END ASSEMBLY TO BE PURCHASED AND PLACED ON THE TRUCK AND CURRENTLY WAITING ON PARTS AS I WRITE THIS LETTER. *TR

NHTSA ODI #10467683

7,000 miles · Jul 23, 2012
Power Train

DRIVING TRUCK AT APPROXIMATELY 65 MPH TO PASS ANOTHER VEHICLE. HEARD A LOUD, HIGH PITCHED MOANING/WHINING SOUND. TRUCK LOST POWER, PULLED OVER TO SIDE OF ROAD. WALKED AROUND TRUCK TO LOOK FOR CAUSE OF PROBLEM, SAW SMOKE, SMELLED BURNED METAL, SAW OILY SHEEN ON BACK OF TRUCK & ON FENDER. LOOKED UNDER TRUCK, SAW A HOLE WHERE A…

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DRIVING TRUCK AT APPROXIMATELY 65 MPH TO PASS ANOTHER VEHICLE. HEARD A LOUD, HIGH PITCHED MOANING/WHINING SOUND. TRUCK LOST POWER, PULLED OVER TO SIDE OF ROAD. WALKED AROUND TRUCK TO LOOK FOR CAUSE OF PROBLEM, SAW SMOKE, SMELLED BURNED METAL, SAW OILY SHEEN ON BACK OF TRUCK & ON FENDER. LOOKED UNDER TRUCK, SAW A HOLE WHERE A PLUG SHOULD HAVE BEEN IN REAR DIFFERENTIAL BOX. NOTIFIED DODGE ROADSIDE ASSISTANCE FOR TOW, CONTACTED DODGE/CHRYSLER CUSTOMER CARE TO REPORT PROBLEM, ACTIVATE WARRANTY. TRUCK BROUGHT TO DODGE DEALERSHIP WHO DENIED WARRANTY, CLAIMED VANDALISM THE CAUSE OF THE MISSING PLUG, NOT DEFECT. PURSUED THIS WITH DODGE WHO CONTINUED TO DENY FAULT. ONLY SUBMITTING THIS NOW BECAUSE SAW AN ARTICLE ONLINE ABOUT DIFFERENTIAL FAILURE ON DODGE, JEEP PRODUCTS. DUE TO DENIAL OF WARRANTY COVERAGE HAD TO PAY OVER $900 OUT OF POCKET AND SUBMIT CLAIM TO INSURANCE COMPANY. *TR

NHTSA ODI #10467174

27,000 miles · Jul 19, 2012
Power Train

DRIVING HOME FROM DINNER, STARTED TO HEAR A LOUD WHINNING NOISE COMING FROM THE REAR END STARTED TO SLOW DOWN THEN NEXT THING I KNEW I HEARD A LOUD THUMP DRIVE SHAFT FELL OFF AND REAR END LOCKED UP. DEALER REPAIRED IT BUT I AM ALWAYS SCARED IT COULD HAPPEN AGAIN AND MAYBE AT HIGHER SPEEDS. IAM STARTING TO NOTICE THIS IS STARTING…

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DRIVING HOME FROM DINNER, STARTED TO HEAR A LOUD WHINNING NOISE COMING FROM THE REAR END STARTED TO SLOW DOWN THEN NEXT THING I KNEW I HEARD A LOUD THUMP DRIVE SHAFT FELL OFF AND REAR END LOCKED UP. DEALER REPAIRED IT BUT I AM ALWAYS SCARED IT COULD HAPPEN AGAIN AND MAYBE AT HIGHER SPEEDS. IAM STARTING TO NOTICE THIS IS STARTING TO BE A BIG DEAL FOR ALOT OF PEOPLE ALSO. GO ON THE RAMFORUMZ.COM FORUM LOOK UNDER THE 2010 YEAR AND THERE ARE PEOPLE TELLING THERE STORIES. I HOPE NOBODY HAS TO LOOSE A LIFE FOR SOMEONE TO TAKE ACTION. *TR

NHTSA ODI #10466630

56,000 miles · Jul 14, 2012
Power Train

I HAVE A 1500 DODGE 4X4. WHILE DRIVING HOME (WITH MY THREE KIDS) I PULLED UP TO A STOP SIGN AND NOTICED WHAT FELT LIKE MY BRAKES GRINDING. I ROLLED DOWN MY WINDOW AND IT WAS VERY LOAD. I DROVE ANOTHER 2 MILES MAYBE, PULLED UP TO ANOTHER STOP SIGN ONLY TO HAVE MY DRIVE SHAFT HIT THE PAVEMENT. A FEW MEN SELLING VEGETABLES ON T…

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I HAVE A 1500 DODGE 4X4. WHILE DRIVING HOME (WITH MY THREE KIDS) I PULLED UP TO A STOP SIGN AND NOTICED WHAT FELT LIKE MY BRAKES GRINDING. I ROLLED DOWN MY WINDOW AND IT WAS VERY LOAD. I DROVE ANOTHER 2 MILES MAYBE, PULLED UP TO ANOTHER STOP SIGN ONLY TO HAVE MY DRIVE SHAFT HIT THE PAVEMENT. A FEW MEN SELLING VEGETABLES ON THE CORNER HELPED PUSH IT BACKWARDS OFF THE ROAD. MY HUSBAND LATER WENT TO PICK IT UP WITH ONE OF HIS TRAILERS AND NOTICED THAT IN 4X4 WITH THE DRIVE SHAFT REMOVED IT WAS STILL LOCKED. THE DEALERSHIP HAS HAD IT FOR THREE WEEKS AND FIRST HAD PROBLEMS WITH THE PARTS, THEN SAID THAT THE PARTS WERE ON BACK ORDER, THEN SAID THAT THE HOUSING WAS DELIVERED BUT THE GEARS HAD TO BE INVESTIGATED AND RELEASED BY A REGIONAL MANAGER IN ORDER TO BE ORDERED. WHAT WOULD HAVE HAPPENED IF THAT HAD HAPPENED DOING 75MPH DOWN THE INTERSTATE THAT I WAS HEADING TOWARDS??? I HAVE LOOKED THROUGH FORUMS AND ONLINE AND NOTICED THAT THIS IS NOT TOO FREQUENT BUT STILL COMMON. WHAT TO DO? THREE WEEKS WITHOUT MY VEHICLE, NO END IN SITE ORDERING THE PIECES OF THE REAR END AND STILL NO ANSWER ON IF THE FRONT END OR TRANSMISSION HAVE ISSUES. *TR

NHTSA ODI #10465662

Official recalls

4

18V160000 · Fuel System, Gasoline:storage:tank Assembly:mounting

Mar 8, 2018

Chrysler (FCA US LLC) is recalling certain 2009-2012 Dodge Ram 1500 trucks currently, or ever registered, in Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. Exposure to environmental conditions such as water mixed with road salt may cause the front fuel tank strap frame "T-Slot" bracket to corrode, possibly causing the fuel tank to drop and make contact with the ground.

Consequence & remedy

Consequence: If the fuel tank were to drop and contact the ground, a fuel leak may result. Additionally, in the event of a crash, the fuel tank may not remain secured to the vehicle, possibly causing a fuel leak. A fuel leak in the presence in an ignition source, can increase the risk of a fire.

Remedy: Chrysler will notify owners and dealers will bolt a bracket reinforcement to the frame, free of charge. The recall began May 2, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is U04.

17V821000 · Power Train:automatic Transmission:lever And Linkage:column Shift

Dec 20, 2017

Chrysler (FCA US LLC) is recalling certain 2016-2017 Ram 3500 Cab Chassis with a Gross Vehicle Weight Rating (GVWR) of less than 10,000 lbs, 2011-2017 Ram 3500, 4500 and 5500 Cab Chassis vehicles, 2009-2017 Ram 1500 and 2010-2017 Ram 2500 and 3500 pickup trucks, all equipped with a column shifter. Pushing the brake pedal for prolonged periods when the vehicle is running and in PARK may cause the Brake Transmission Shift Interlock (BTSI) pin to stick in the open position. With the pin in the open position, the transmission can be shifted out of PARK into any gear without pushing the brake pedal or having the key in the ignition.

Consequence & remedy

Consequence: Being able to shift the transmission without pushing the brake pedal and/or without a key in the ignition can increase the risk of an unintended vehicle rollaway that may result in personal injury or a crash.

Remedy: Chrysler will notify owners, and dealers will update the vehicle software, inspect the BTSI, and, as necessary, replace it, free of charge. The recall began February 26, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is T79.

13V038000 · Power Train:driveline:differential Unit

Feb 6, 2013

Chrysler is recalling certain model year 2009-2012 Ram 1500 trucks manufactured from February 27, 2008, through June 30, 2009, and from December 1, 2009, through October 20, 2011; model year 2009-2011 Dodge Dakota trucks manufactured from February 27, 2007, through June 30, 2009, and from December 1, 2009, through September 30, 2011; model year 2009 Chrysler Aspen trucks manufactured from January 3, 2008, through December 18, 2008; and model year 2009 Dodge Durango trucks manufactured from January 3, 2008, through December 18, 2008. The rear axle pinion nut may loosen due to an undersized pinion spline that can allow relative motion between the nut and companion flange.

Consequence & remedy

Consequence: If the rear axle pinion nut loosens, the axle can lock up and cause a loss of vehicle control and/or a vehicle crash with little warning.

Remedy: On November 7, 2013 Chrysler notified owners that dealers would install a pinion nut retainer, free of charge. In July 2015, and under a consent order with NHTSA, the company agreed to offer owners three options for remedying their vehicles: perform the original remedy, offer to repurchase the vehicle at the fair market value plus 10%, or offer an additional incentive offer towards the purchase of a new Dodge, Jeep, Chrysler, or Fiat vehicle. Chrysler will notify owners of the new recall options in a letter expected to be mailed on August 31, 2015. Owners may contact Chrysler at 1-800-247-9753. Chrysler's recall campaign number is N08.

12V474000 · Power Train:driveline:differential Unit

Oct 2, 2012

Chrysler is recalling certain model year 2009-2010, Ram 1500 and Dodge Dakota trucks, manufactured from July 1, 2009, through November 30, 2009, because the rear axle pinion nut may loosen due to a lack of adhesive.

Consequence & remedy

Consequence: If the rear axle pinion nut loosens, the axle can lock up and cause a loss of vehicle control and/or a vehicle crash with little warning.

Remedy: Chrysler will notify owners, and dealers will install a pinion nut retainer, free of charge. The recall began on June 17, 2013. Owners may contact Chrysler at 1-800-247-9753.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

1

EA19001 · Electrical Overstress

Opened Apr 19, 2019 · Closed Sep 19, 2024

Status: closed (inferred from source dates) · Air Bags: Air Bag/restraint Control Module

The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect.  During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW.  The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications.  The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU.  In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment.  FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle.  Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW.  These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes.  An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time.   In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU.  This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners.  Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW.  The risk associated with the ASIC is equally shared among all OEMS involved in the investigation.  The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage.  There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation.  The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU.  If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC.  Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC.  All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled.  In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024.  With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.