NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
297 reports79,692 miles · Sep 8, 2016
Suspension
WHILE DRIVING EITHER PULLING OUR 30FT 5TH WHEEL OR WHILE NOT TOWING, HIT ROUGH SPOT IN ROAD TRUCK SHAKES VIOLENTLY AND IS HARD TO CONTROL EVEN BRAKING! HAS BEEN SERVICED IN MAY 2016 AND CHANGED TORQUESTIONS BAR. SAME SCENARIO HAS CONTINUED FOR 3 MONTHS ONLY MORE OFTEN. SUPPOSEDLY WAS FIXED BEFORE 2 1/2 MONTHS TRIP TO AK, BC & Y…
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WHILE DRIVING EITHER PULLING OUR 30FT 5TH WHEEL OR WHILE NOT TOWING, HIT ROUGH SPOT IN ROAD TRUCK SHAKES VIOLENTLY AND IS HARD TO CONTROL EVEN BRAKING! HAS BEEN SERVICED IN MAY 2016 AND CHANGED TORQUESTIONS BAR. SAME SCENARIO HAS CONTINUED FOR 3 MONTHS ONLY MORE OFTEN. SUPPOSEDLY WAS FIXED BEFORE 2 1/2 MONTHS TRIP TO AK, BC & YT. BACK AGAIN FOR SAME SCENARIO AS IT OCCURS MORE OFTEN! TRUCK IS ALWAYS IN MOTION AND BETWEEN 45 & 65MPH WHEN THIS OCCURS BOTH COUNTRY ROADS AND FREEWAY/HIGHWAY! THIS IS A SERIOUS UNCONTROLLABLE SCENARIO THAT COULD CAUSE ACCIDENT FOR DRIVER AND OTHER CARS ON THE ROAD WHEN THIS HAPPENS. EUGENE, OR
NHTSA ODI #10904661
Mileage unknown · Sep 2, 2016
Electrical SystemUnknown Or Other
I HAD MY TRUCK TOWED INTO THE DEALERSHIP FOR A "NO START". PROBLEM DID CONTINUE WITH THE DEALER A FEW TIMES WITH NO CODES. THE PROBLEM IS THAT THE TRUCK WOULD START AND THEN WHEN YOU TRY TO RESTART VEHICLE, IT WOULD NOT START. DEALERSHIP CONCLUDED THAT IT WAS A SOFTWARE ISSUE, THAT NEEDED TO BE UPDATED WITH THE SOME MODULE IN TH…
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I HAD MY TRUCK TOWED INTO THE DEALERSHIP FOR A "NO START". PROBLEM DID CONTINUE WITH THE DEALER A FEW TIMES WITH NO CODES. THE PROBLEM IS THAT THE TRUCK WOULD START AND THEN WHEN YOU TRY TO RESTART VEHICLE, IT WOULD NOT START. DEALERSHIP CONCLUDED THAT IT WAS A SOFTWARE ISSUE, THAT NEEDED TO BE UPDATED WITH THE SOME MODULE IN THE TRUCK. UNFORTUNATELY, I HAD TI PAY FOR THIS UPDATED, IN WHICH THIS PROBLEM SHOULD HAVE BEEN CONSIDERED A FACTORY ISSUSE. WHICH IN MY OPINION THAT THE DODGE CORP. SHOULD HAVE COVERED THIS EXPENSE. I SEEN ON THE INTERNET WITH OTHER PEOPLE HAVING THE SAME PROBLEM.
NHTSA ODI #10903348
70,045 miles · Jul 25, 2016
Electrical SystemEngineExterior Lighting
UPON ACTIVATING THE HIGH BEAM HEAD LIGHTS, ENGINE WILL BEGIN MISSING AND EVENTUALLY STALL. HEADLIGHTS WILL BLINK OFF AND ON. ALL DASH LIGHTS AND ELECTRICAL SYSTEMS WILL ALSO FLUCTUATE POWER (RADIO, WIPERS, TAIL LIGHTS, HAZARDS, FRONT PARKING LIGHTS AND TURN SIGNALS). ALL GAUGES ON THE DASH WILL GO DEAD. WHILE DRIVING ON 7/22…
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UPON ACTIVATING THE HIGH BEAM HEAD LIGHTS, ENGINE WILL BEGIN MISSING AND EVENTUALLY STALL. HEADLIGHTS WILL BLINK OFF AND ON. ALL DASH LIGHTS AND ELECTRICAL SYSTEMS WILL ALSO FLUCTUATE POWER (RADIO, WIPERS, TAIL LIGHTS, HAZARDS, FRONT PARKING LIGHTS AND TURN SIGNALS). ALL GAUGES ON THE DASH WILL GO DEAD. WHILE DRIVING ON 7/22/2016 AT APPROXIMATELY 9:15 PM THE HIGH BEAM HEAD LIGHTS WERE ACTIVATED. THE ENGINE BEGAN TO MISS AND ALL ELECTRICAL SYSTEMS BEGAN TO TURN OFF, AND THEN BACK ON. THE ENGINE STALLED AT APPROX 65 MPH LEAVING NO POWER STEERING. TRUCK WAS ABLE TO BE RESTARTED ONCE IT WAS BROUGHT TO REST ON THE SHOULDER. HIGH BEAMS COULD NOT BE USED OR THE PROBLEM WOULD REPEAT. MAKE: RAM (DODGE) MODEL: 2500 YEAR: 2011 ENGINE/POWERTRAIN: 6.7L CUMMINS TURBO DIESEL W/ 6 SPEED AUTOMATIC.
NHTSA ODI #10888209
35,209 miles · Jul 14, 2016
Electrical System
TRUCK WOULD NOT START DUE TO FAULTY TIMP MODULE. LUCKILY IT WAS PARKED AT HOME, BUT NEEDED TOWED.
NHTSA ODI #10884746
20,000 miles · Jun 7, 2016
Suspension
TL* THE CONTACT OWNS A 2011 RAM 2500. THE CONTACT RECEIVED A RECALL REPAIR FOR NHTSA CAMPAIGN NUMBER: 13V529000 (STEERING), BUT THE REMEDY DID NOT PROVIDE A SOLUTION. THE CONTACT STATED THAT THERE WAS AN EXTENSIVE WOBBLE IN THE FRONT OF THE VEHICLE. THE VEHICLE WAS TAKEN BACK TO THE DEALER A SECOND TIME WHERE IT WAS INDICATED TH…
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TL* THE CONTACT OWNS A 2011 RAM 2500. THE CONTACT RECEIVED A RECALL REPAIR FOR NHTSA CAMPAIGN NUMBER: 13V529000 (STEERING), BUT THE REMEDY DID NOT PROVIDE A SOLUTION. THE CONTACT STATED THAT THERE WAS AN EXTENSIVE WOBBLE IN THE FRONT OF THE VEHICLE. THE VEHICLE WAS TAKEN BACK TO THE DEALER A SECOND TIME WHERE IT WAS INDICATED THAT THE PARTS NEEDED TO BE REPLACED AGAIN. THE DEALER REPLACED THE FRONT TIE RODS, BUT THE FAILURE RECURRED. THE VEHICLE WAS UNABLE TO BE DRIVEN OVER 45 MPH. THE VEHICLE CONTINUED TO WOBBLE IN THE FRONT, WHICH WAS EXTREMELY UNSAFE WHILE DRIVING AT HIGHWAY SPEEDS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE EACH TIME AND PROVIDED NO SOLUTION TO THE DEALER TO ADDRESS THE REPAIR. THE VEHICLE WAS TAKEN BACK TO THE DEALER FOR FURTHER INSPECTION. THE APPROXIMATE FAILURE MILEAGE WAS 20,000.
NHTSA ODI #10872998
35,800 miles · Jun 4, 2016
Service BrakesSteering
WHILE MAKING A TURN AND APPLYING THE BRAKE PEDAL, COMPLETE LOSS OF POWER STEERING CAUSING VEHICLE TO CROSS CENTER LINE OF ROADWAY AND DRIVE INTO ONCOMING TRAFFIC. BRAKE PEDAL ALSO EXTREMELY HARD TO PRESS (POSSIBLY LOSS OF POWER BRAKING AT THE SAME TIME). STEERING RETURNING TO NORMAL SEVERAL SECONDS AFTER RELEASING THE BRAKE PEDA…
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WHILE MAKING A TURN AND APPLYING THE BRAKE PEDAL, COMPLETE LOSS OF POWER STEERING CAUSING VEHICLE TO CROSS CENTER LINE OF ROADWAY AND DRIVE INTO ONCOMING TRAFFIC. BRAKE PEDAL ALSO EXTREMELY HARD TO PRESS (POSSIBLY LOSS OF POWER BRAKING AT THE SAME TIME). STEERING RETURNING TO NORMAL SEVERAL SECONDS AFTER RELEASING THE BRAKE PEDAL. THIS HAPPENED MULTIPLE TIMES TODAY, WITH SHUTTING THE VEHICLE OFF COMPLETELY BETWEEN OCCURRENCES OF THIS FAILURE.
NHTSA ODI #10872527
60,000 miles · Apr 25, 2016
Suspension
DEATH WOBBLE AT HIGHWAY SPEEDS 2 RECALLS FOR TIE RODS HAVE BEEN PEFORMED. THIS PROBLEM IS CONTINUING, MOST RECENTLY ON 4/24/2016.
NHTSA ODI #10861403
38,000 miles · Apr 19, 2016
SteeringSuspension
DEAR SIR OR MA'AM, I AM WRITING YOU TO REPORT A SEVERE PROBLEM THAT OCCURRED TO ME ON 3/5/16, AND AGAIN ON 4/9/16. I WAS TRAVELING AT APPROXIMATELY 65 MPH ON BOTH OCCASIONS ON WASHINGTON STATE HIGHWAYS. THE FRONT END OF MY 2011 RAM 2500 PICK UP BEGAN TO SHAKE VIOLENTLY. IT WAS SO INTENSE THAT I WAS AFRAID THAT I MIGHT LOSE C…
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DEAR SIR OR MA'AM, I AM WRITING YOU TO REPORT A SEVERE PROBLEM THAT OCCURRED TO ME ON 3/5/16, AND AGAIN ON 4/9/16. I WAS TRAVELING AT APPROXIMATELY 65 MPH ON BOTH OCCASIONS ON WASHINGTON STATE HIGHWAYS. THE FRONT END OF MY 2011 RAM 2500 PICK UP BEGAN TO SHAKE VIOLENTLY. IT WAS SO INTENSE THAT I WAS AFRAID THAT I MIGHT LOSE CONTROL OF THE VEHICLE. I SLOWED DOWN AND PULLED TO THE SIDE OF THE ROAD AND THE PROBLEM STOPPED. AFTER I GOT BACK ON THE ROAD I TRAVELED ABOUT A MILE, AND THE PROBLEM OCCURRED AGAIN. MY WIFE BROUGHT THE TRUCK INTO A REPAIR SHOP ON 3/7/16 TO SEE IF THERE WAS A PROBLEM WITH THE TIRES OR SUSPENSION. THE SHOP SAID THE TIRES WERE BALANCED AND THAT THEY DID NOT FIND ANY OBVIOUS PROBLEM WITH THE SUSPENSION. AFTER A QUICK INTERNET SEARCH I DISCOVERED A NUMBER OF PEOPLE DESCRIBING THE EXACT PROBLEM THAT I HAD EXPERIENCED. THEY REFERRED TO IT AS THE 'DODGE DEATH WOBBLE' MUCH TO MY SURPRISE, THIS DOES NOT SEEM TO BE AN ISOLATED INCIDENT. IT SEEMS TO BE CAUSED BY THE STEERING DESIGN ('Y' TYPE VS. 'T' TYPE?) I AM HOPING THAT YOU WILL INITIATE AN INVESTIGATION INTO THIS PROBLEM AND ULTIMATELY MANDATE THAT FCA US LLC (DODGE) ISSUE A RECALL FOR ALL VEHICLES AFFECTED BY THIS DESIGN FLAW BEFORE SOMEONE GETS HURT. I CONTACTED DODGE CORPORATE HQ AND I HAVE ATTACHED THEIR RESPONSE.
NHTSA ODI #10860445
110,000 miles · Apr 6, 2016
SteeringSuspension
TL* THE CONTACT OWNS A 2011 RAM 2500. WHILE DRIVING APPROXIMATELY 65 MPH, THE VEHICLE DROVE OVER A BUMP AND THE STEERING WHEEL SHOOK VIOLENTLY. THE VEHICLE VIBRATED AND CAUSED THE VEHICLE TO BECOME VERY UNSTABLE. AFTER REDUCING THE SPEED TO 30 MPH, THE VEHICLE DROVE NORMALLY. THE FAILURE OCCURRED ON TWO OTHER OCCASIONS. THE CAUS…
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TL* THE CONTACT OWNS A 2011 RAM 2500. WHILE DRIVING APPROXIMATELY 65 MPH, THE VEHICLE DROVE OVER A BUMP AND THE STEERING WHEEL SHOOK VIOLENTLY. THE VEHICLE VIBRATED AND CAUSED THE VEHICLE TO BECOME VERY UNSTABLE. AFTER REDUCING THE SPEED TO 30 MPH, THE VEHICLE DROVE NORMALLY. THE FAILURE OCCURRED ON TWO OTHER OCCASIONS. THE CAUSE OF THE FAILURE WAS NOT DIAGNOSED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 110,000.
NHTSA ODI #10853789
100,000 miles · Mar 29, 2016
SteeringSuspension
AT HIGHWAY SPEEDS, THE TRUCK BEGINS TO SHAKE VIOLENTLY AND CANNOT BE PROPERLY CONTROLLED. DRIVER MUST IMMEDIATELY REDUCE SPEED OR STOP IN ORDER TO REGAIN CONTROL OF VEHICLE. THIS OCCURS ESPECIALLY IF HITTING ANY KIND OF BUMP AT HIGHWAY SPEEDS, EVEN IF IT IS NEGLIGIBLE. IT IS ENOUGH TO LOSE STABILITY. THE SHAKING IS SO VIOLENT …
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AT HIGHWAY SPEEDS, THE TRUCK BEGINS TO SHAKE VIOLENTLY AND CANNOT BE PROPERLY CONTROLLED. DRIVER MUST IMMEDIATELY REDUCE SPEED OR STOP IN ORDER TO REGAIN CONTROL OF VEHICLE. THIS OCCURS ESPECIALLY IF HITTING ANY KIND OF BUMP AT HIGHWAY SPEEDS, EVEN IF IT IS NEGLIGIBLE. IT IS ENOUGH TO LOSE STABILITY. THE SHAKING IS SO VIOLENT THAT IT IS DIFFICULT TO MAINTAIN A GRIP ON THE STEERING WHEEL. BECAUSE IT HAPPENS WITHOUT WARNING, IT PLACES ALL OCCUPANTS IN DANGER AS WELL AS OTHER MOTORISTS BECAUSE THE VEHICLE CANNOT BE PROPERLY STEERED AND MUST BE IMMEDIATELY SLOWED OR STOPPED, CREATING A ROAD HAZARD TO EVERYONE. THROUGH RESEARCH, WE HAVE BEEN TOLD THIS IS COLLOQUIALLY KNOWN AS THE "DODGE DEATH WOBBLE," AND WAS SUBJECT TO A RECALL PRIOR TO OUR PURCHASE AND WAS NOT DISCLOSED TO US. WE HAVE SINCE ATTEMPTED TO DETERMINE THE EXACT CAUSE OF THE VIOLENT SHAKING AS WELL AS ANY REMEDY FROM THE MANUFACTURER, BUT HAVE ALSO LEARNED THERE IS A PENDING CLASS-ACTION LAWSUIT THAT MAY CAUSE THE MANUFACTURER TO HESITATE TO ADMIT THERE IS A KNOWN PROBLEM WITH THE "REPLACEMENT" PARTS UNDER THE PRIOR RECALL. WE HAVE BEEN FORTUNATE TO NOT HAVE AN ACCIDENT (AND THEREFORE NO POLICE REPORTS, ETC.), THOUGH THERE HAVE BEEN CLOSE CALLS WHEN WE HAD NO CHOICE BUT TO USE THE TRUCK. WE CHOOSE TO TAKE OTHER TRANSPORTATION WHENEVER WE CAN. THIS IS A VERY DANGEROUS DEFECT THAT MUST BE ADDRESSED BEFORE SOMEONE LOSES THEIR LIVES. WE PLAN TO TAKE VIDEO IF WE ARE FORCED TO DRIVE THE TRUCK AGAIN, OR ASK OUR DEALER TO DRIVE IT AND CONFIRM THE DEFECT. THIS BEGAN APPROXIMATELY IN AUGUST, BUT MAY HAVE BEEN BEFORE (I AM FILING COMPLAINT FOR MY HUSBAND) AND TRUCK HAS OVER 100,000 MILES ON IT, BUT I DO NOT HAVE EXACT MILEAGE WITH ME AT WORK. THANK YOU FOR YOUR CONSIDERATION. *TR
NHTSA ODI #10852282
Official recalls
4Dec 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.
Oct 8, 2014
Chrysler Group LLC (Chrysler) is recalling certain model year 2010-2014 Ram 2500, 3500, 4500, and 5500 trucks manufactured March 27, 2009, to September 5, 2013. In the affected vehicles, the electrical connectors of the diesel fuel heater may overheat.
Consequence & remedy
Consequence: If the connectors overheat, the fuel heater may leak fuel, increasing the risk of a fire.
Remedy: Chrysler will notify owners, and dealers will replace the harness side connector with a silver plated beryllium copper terminal service kit, and inspect the fuel heater for leaks, replacing it as necessary, free of charge. Chrysler issued interim notification to owners on December 8, 2014. The recall began on April 27, 2015. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is P65.
Additional source detail variants (2)
Fuel System, Diesel
Chrysler Group LLC (Chrysler) is recalling certain model year 2010-2014 Ram 2500, 3500, 4500, and 5500 trucks manufactured March 27, 2009, to September 5, 2013. In the affected vehicles, the electrical connectors of the diesel fuel heater may overheat.
Consequence: If the connectors overheat, the fuel heater may leak fuel, increasing the risk of a fire.
Remedy: Chrysler will notify owners, and dealers will replace the harness side connector with a silver plated beryllium copper terminal service kit, and inspect the fuel heater for leaks, replacing it as necessary, free of charge. Chrysler issued interim notification to owners on December 8, 2014. The recall began on April 27, 2015. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is P65.
Engine And Engine Cooling:engine:diesel
Chrysler Group LLC (Chrysler) is recalling certain model year 2010-2014 Ram 2500, 3500, 4500, and 5500 trucks manufactured March 27, 2009, to September 5, 2013. In the affected vehicles, the electrical connectors of the diesel fuel heater may overheat.
Consequence: If the connectors overheat, the fuel heater may leak fuel, increasing the risk of a fire.
Remedy: Chrysler will notify owners, and dealers will replace the harness side connector with a silver plated beryllium copper terminal service kit, and inspect the fuel heater for leaks, replacing it as necessary, free of charge. Chrysler issued interim notification to owners on December 8, 2014. The recall began on April 27, 2015. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is P65.
Nov 6, 2013
Chrysler Group LLC (Chrysler) is recalling certain model year 2008-2012 RAM 2500 4X4 and 3500 4X4 trucks, 2008-2012 Dodge RAM 3500 4x2 Cab Chassis, and model year 2008 Dodge RAM 1500 Mega Cab 4x4. The left tie rod assembly may break.
Consequence & remedy
Consequence: A failure of the tie rod assembly may result in a loss of steering control, increasing the risk of a crash.
Remedy: Chrysler notified owners on January 16, 2014 that dealers would inspect vehicles and replace the steering linkage assembly, if necessary. On or about February 27, 2014, Chrysler ceased its recall remedy program due to parts quality concerns, and then re-initiated it on or about April 14, 2014. 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 N49.
Jul 6, 2011
CHRYSLER IS RECALLING CERTAIN MODEL YEAR 2008-2011 DODGE RAM 2500/3500 4X4, MANUFACTURED FROM FEBRUARY 14, 2008, THROUGH MARCH 28, 2011; MODEL YEAR 2008-2011 DODGE RAM 3500 CAB CHASSIS 4X2, MANUFACTURED FROM FEBRUARY 14, 2008, THROUGH MARCH 28, 2011; AND MODEL YEAR 2008 DODGE RAM 1500 MEGA CAB 4X4, MANUFACTURED FROM FEBRUARY 14, 2008, THROUGH AUGUST 15, 2008, BECAUSE THE LEFT TIE ROD BALL STUD MAY FRACTURE. THIS CONDITION TENDS TO OCCUR DURING LOW SPEED PARKING LOT TYPE MANEUVERS WHEN THE CUSTOMER IS MAKING A TIGHT TURN. ADDITIONALLY, MODEL YEAR 2003-2008 DODGE RAM 2500/3500 VEHICLES MAY HAVE RECEIVED THE AFFECTED TIE ROD ASSEMBLY AS A REPLACEMENT PART DURING NORMAL SERVICE.
Consequence & remedy
Consequence: THIS CONDITION COULD RESULT IN THE POTENTIAL LOSS OF DIRECTIONAL STABILITY IN THE LEFT HAND FRONT WHEEL, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE TIE ROD ENDS FOR RELATIVE ORIENTATION AND REPLACE THE LEFT OUTER TIE ROD AS REQUIRED AND PERFORM A FRONT END TOE ALIGNMENT AS NEEDED. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 3, 2011. OWNERS MAY CONTACT CHRYSLER AT 1-800-853-1403.
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
1EA19001 · 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.
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