NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
283 reports31,000 miles · Jul 28, 2015
Steering
WE JUST GOT OUR 2012 RAM 2500 OUT OF THE SHOP FOR THE STEERING LOCKING UP. THE FIRST TIME WE TOOK THE TRUCK INTO A DODGE DEALER, GREENWOOD, IN GILROY, CA, TOLD US THEY COULDN'T DUPLICATE THE PROBLEM AND DIDN'T OFFER ANY KIND OF RESOLUTION. THE SECOND TIME WE TOOK THE TRUCK IN,TO THE SAME DODGE DEALER IN GILROY, CA, FOR THE SAME…
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WE JUST GOT OUR 2012 RAM 2500 OUT OF THE SHOP FOR THE STEERING LOCKING UP. THE FIRST TIME WE TOOK THE TRUCK INTO A DODGE DEALER, GREENWOOD, IN GILROY, CA, TOLD US THEY COULDN'T DUPLICATE THE PROBLEM AND DIDN'T OFFER ANY KIND OF RESOLUTION. THE SECOND TIME WE TOOK THE TRUCK IN,TO THE SAME DODGE DEALER IN GILROY, CA, FOR THE SAME ISSUE, ON JULY 6TH, THEY SAID AGAIN, THEY COULD NOT DUPLICATE THE ISSUE. HOWEVER, THEY SAID THEY FOUND METAL IN THE STEERING PUMP FLUID. THEY SAID, THE WARRANTY AGREES TO PAY FOR THE PUMP, BUT THE PART WOULD NOT BE IN THAT FRIDAY OR THE FOLLOWING WEEK. WE HAD A CAMPING TRIP SCHEDULED AND ASKED IF IT WAS SAFE TO DRIVE? THEY WOULD NOT INDICATE. WE HAD MADE AN APPOINTMENT TO BRING THE TRUCK BACK IN ON JULY 19TH. ON JULY 24TH, SERVICE DEPARTMENT SAID, THE PUMP WAS AN UPGRADE AND THE WARRANTY COMPANY WOULDN'T PAY FOR THE NEW FITTING AND HOSE REQUIRED FOR THE UPGRADED PUMP. WE TOLD THEM TO GO AHEAD AND REPLACE THE PUMP WITH THE UPGRADED STEERING PUMP AND FITTING/HOSE. WE COMPLAINED TO THE DEALER'S MANAGEMENT AND THEY PAID FOR THE FITTING/HOSE AND FINALLY GAVE US OUR TRUCK ON SATURDAY, JULY 25TH. ON JULY 27TH, I HEARD ABOUT THE BUY BACK THE GOVERNMENT IS ISSUING TO FCA US LLC AND DECIDED TO SEND YOU MY PROBLEM WITH THE STEERING ON OUR 2012 DODGE RAM 2500 DIESEL 4X4.
NHTSA ODI #10744304
60,000 miles · Jul 27, 2015
Steering
WHEN ACCELERATION FROM A START AND TURING TO THE RIGHT I HEAR A GRINDING NOISE UNDER THE DASH ..AROUND THE ENGINE COMPARTMENT. HAD A RECALL ON THIS TRUCK LESS THAN A YEAR ....... DEALERSHIP INDICATED THAT THIS WOULD HELP ....... THE NOISE STILL EXISTS AND HASN'T AFFECTED THE PERFORMANCE OF THE TRUCK....... I AM MORE CONCER…
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WHEN ACCELERATION FROM A START AND TURING TO THE RIGHT I HEAR A GRINDING NOISE UNDER THE DASH ..AROUND THE ENGINE COMPARTMENT. HAD A RECALL ON THIS TRUCK LESS THAN A YEAR ....... DEALERSHIP INDICATED THAT THIS WOULD HELP ....... THE NOISE STILL EXISTS AND HASN'T AFFECTED THE PERFORMANCE OF THE TRUCK....... I AM MORE CONCERNED WITH THIS NOISE SINCE THE MEDIA NEWS ON DODGE RECALLS.......CONCERNED??
NHTSA ODI #10744061
Mileage unknown · Jul 27, 2015
Electrical SystemFuel System, Diesel
I HAVE RECEIVED A NOTICE OF RECALL 2 TIMES SINCE DECEMBER 1,2014 FOR DIESEL FUEL HEATER ELECTRICAL CONNECTOR AND HAVE BEEN TO THE DODGE DEALER SEVERAL TIMES TO GET THIS TAKEN CARE OF. THE DEALER STATES THAT THEY DO NOT HAVE THE PARTS. THIS HAS BEEN OVER 8 MONTHS NOW AND I AM NOW EXPERIENCING ELECTRICAL PROBLEMS WITH THIS VEHICLE…
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I HAVE RECEIVED A NOTICE OF RECALL 2 TIMES SINCE DECEMBER 1,2014 FOR DIESEL FUEL HEATER ELECTRICAL CONNECTOR AND HAVE BEEN TO THE DODGE DEALER SEVERAL TIMES TO GET THIS TAKEN CARE OF. THE DEALER STATES THAT THEY DO NOT HAVE THE PARTS. THIS HAS BEEN OVER 8 MONTHS NOW AND I AM NOW EXPERIENCING ELECTRICAL PROBLEMS WITH THIS VEHICLE AS WELL AS WHAT APPEARS TO BE A STICKING THROTTLE AS I DRIVE. THIS IS A SERIOUS SITUATION AS THE VEHICLE DOES NOT SLOW DOWN WHEN RELEASING THE THROTTLE. IT ALSO AT IDLE WILL INCREASE THE RPM ON IT'S OWN. UPDATE 9/15/15*CW THE FUEL HEATER WAS FIXED. THE ELECTRICAL PROBLEM STILL EXISTS WITH HIGH IDLE AND THE VEHICLE ONLY SLOWED DOWN WHEN THE BRAKE WAS APPLIED. THE HIGH IDLE AND CONSTANT INSTANCES OF FAILURE OF THE VEHICLE TO SLOW DOWN WAS A RECURRING PROBLEM AS WELL AS THE INABILITY TO OBTAIN INFORMATION FROM THE VEHICLES INFORMATION PORT STILL EXISTS. UPDATED 10/01/15*JB
NHTSA ODI #10743840
40,000 miles · Jul 27, 2015
Steering
WHILE ENTERING HIGHWAY AND GETTING UP TO SPEED ONTO I95, TRUCK STARTED TO VIBRATE. I BACKED OFF THEN TRIED AGAIN TO ACCELERATE, AT THIS TIME THE STEERING WHEEL VIOLENTLY SHOCK IN MY HANDS LEFT AND RIGHT RAPIDLY. I LET OFF SPEED AND IT WASN'T UNTIL I GOT INTO THE BREAK DOWN LANE AT APPROX. 45 MPH THAT I WAS ABLE TO STEER THE VE…
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WHILE ENTERING HIGHWAY AND GETTING UP TO SPEED ONTO I95, TRUCK STARTED TO VIBRATE. I BACKED OFF THEN TRIED AGAIN TO ACCELERATE, AT THIS TIME THE STEERING WHEEL VIOLENTLY SHOCK IN MY HANDS LEFT AND RIGHT RAPIDLY. I LET OFF SPEED AND IT WASN'T UNTIL I GOT INTO THE BREAK DOWN LANE AT APPROX. 45 MPH THAT I WAS ABLE TO STEER THE VEHICLE WITHOUT ANY SHAKING OF THE STEERING WHEEL. I THEN PULLED OUT AGAIN AND RESUMED. THE INCIDENT HAS HAPPENED A FEW ADDITIONAL TIMES MOSTLY WHILE TRANSFERRING FROM SOLID PAVEMENT TO CROSSING BRIDGES. I MADE APPOINTMENT DISCUSSING THE ISSUE. I TOOK TRUCK IN THEY ROTATED TIRES AND IT WAS GONE FOR A LITTLE WHILE. NOW HERE IT IS JULY AND THE TRUCK IS STARTING TO REACT THAT WAY AGAIN, MOSTLY WHILE TRAVELING ON BRIDGES. THE LEFT ARM HAD PREVIOUS BEEN REPLACED AND STILL HAVE THIS ISSUE.
NHTSA ODI #10743647
15,033 miles · Jul 15, 2015
Power Train
AFTER RECEIVING NOTIFICATION FROM DODGE THAT PARTS WERE AVAILABLE TO CORRECT THE DIESEL FUEL HEATER ELECTRICAL CONNECTOR (RECALL P65/NHTSA 14V-635) MY DODGE DEALER (RAIRDON DODGE, BELLINGHAM) TOLD ME THE PARTS FOR THE RECALL WERE ON BACK ORDER FROM DODGE. SUBSEQUENTLY THE CHECK ENGINE LIGHT CAME ON SHORTLY THEREAFTER AND WHEN D…
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AFTER RECEIVING NOTIFICATION FROM DODGE THAT PARTS WERE AVAILABLE TO CORRECT THE DIESEL FUEL HEATER ELECTRICAL CONNECTOR (RECALL P65/NHTSA 14V-635) MY DODGE DEALER (RAIRDON DODGE, BELLINGHAM) TOLD ME THE PARTS FOR THE RECALL WERE ON BACK ORDER FROM DODGE. SUBSEQUENTLY THE CHECK ENGINE LIGHT CAME ON SHORTLY THEREAFTER AND WHEN DIAGNOSED THE PROBLEM WAS WITH THE OXYGEN SENSOR SYSTEM. ONCE AGAIN THE DEALER TOLD ME THAT THE REPAIR PARTS WERE ON BACK ORDER FROM DODGE AND THEY WOULD CALL WHEN THE PARTS ARRIVED, THIS WAS CLOSE TO A MONTH AGO AND IN THE MEANTIME THE TRUCK HAS BEEN PARKED AND NOT BEEN USED. I BELIEVE THAT THIS EXTENDED PERIOD WAITING FOR BACK ORDERED PARTS IS EXCESSIVE AND NEEDS TO BE RECTIFIED, ESPECIALLY WHEN DODGE INDICATED THAT THE PARTS FOR THE RECALL WERE AVAILABLE.
NHTSA ODI #10734222
Mileage unknown · Jul 7, 2015
EngineFuel/propulsion System
TL* THE CONTACT OWNS A 2012 DODGE RAM 2500. THE CONTACT RECEIVED A RECALL NOTICE FOR NHTSA CAMPAIGN NUMBER: 14V635000 (FUEL SYSTEM); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOT NOTIFIED. THE VIN W…
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TL* THE CONTACT OWNS A 2012 DODGE RAM 2500. THE CONTACT RECEIVED A RECALL NOTICE FOR NHTSA CAMPAIGN NUMBER: 14V635000 (FUEL SYSTEM); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOT NOTIFIED. THE VIN WAS UNKNOWN. THE CONTACT HAD NOT EXPERIENCED A FAILURE.
NHTSA ODI #10732445
82,000 miles · Jul 4, 2015
Steering
DRIVING ON FREEWAY 55 MPH TOWING HEAVY DUTY CONCRETE TRAILER ( 2 AXLE 4 YARD W/REAR MOUNTED MIXER) AND TRUCK VIOLENTLY STARTED SHAKING BAD , LEAVING ME WITH NO CONTROL . HAVE INVESTED OVER$1000 IN PARTS ALONE, WITH NO LUCK. NOW AM REPLACING ALL TIE RODS AND BALL JOINTS $500 (PARTS ALONE), TO SEE WHAT HAPPENS. THOUGH I HAVE READ…
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DRIVING ON FREEWAY 55 MPH TOWING HEAVY DUTY CONCRETE TRAILER ( 2 AXLE 4 YARD W/REAR MOUNTED MIXER) AND TRUCK VIOLENTLY STARTED SHAKING BAD , LEAVING ME WITH NO CONTROL . HAVE INVESTED OVER$1000 IN PARTS ALONE, WITH NO LUCK. NOW AM REPLACING ALL TIE RODS AND BALL JOINTS $500 (PARTS ALONE), TO SEE WHAT HAPPENS. THOUGH I HAVE READ THERE IS NO FIX??? CANT SELL IT CUZ I OWE 36,000 AND IT IS ONLY WORTH 25,000. I AM 3 MONTHS BEHIND ON PAYMENTS CUZ I NEED TRUCK FOR WORK TO MAKE MONEY, BUT HAS BEEN IN SHOP (UNRELATED WOULD NOT START) FOR 3 WEEKS AND $1300 MORE DOLLARS, FOR SOME FUEL MODULE B.S. AND MY FINANCE COMPANY WANTS TO KNOW WHERE THEIR MONEY IS, AND WHAT IS WRONG WITH THE TRUCK? SO I ASK THEM WHICH MONTH THEY WOULD LIKE TO KNOW ABOUT. THESE TRUCKS ARE GARBAGE!!!! NEVER BUY DODGE ( PROBABLY WHY THEY CHANGED NAME OF TRUCKS TO "RAM") SOME LEGAL MAMBO JUMBO TO SAVE THEIR ASS. AND THE GOVERNMENT BAILED THEM OUT FOR WHAT???? WHAT BROUGHT ME HERE WAS A SEARCH FOR TIE RODS, CAUSE I BELIEVE THAT TO BE MY PROBLEM. AFTER READING ALL THE COMPLAINTS ABOUT TIE RODS BREAKING, I WILL NOW REPLACE ALL TIE RODS ON MY OWN DIME, BECAUSE MY LIFE IS WORTH MORE THAN $1000 DOLLARS OF PARTS. THERE IS DEFINITELY SOMETHING BEING COVERED UP. WHY IN THE HELL CAN DEALERS ONLY GET 15 PARTS (B.S.) A MONTH, BUT I CAN GO EBAY, AMAZON, (WHICH I AM BY THE WAY) AND HAVE THEM IN A COUPLE DAYS. CAUSE I AM PAYING FOR THEM? IS CHRYSLER THAT BROKE ? CRAPPY PRODUCTS, CRAPPY DESIGN, AND GUESS WHAT, NO ACCOUNTABILITY. RECIPE FOR DISASTER IF YOU ASK ME. UP YOURS DODGE , RAM, CHRYSLER, WHATEVER NAME YOUR HIDING BEHIND THIS MONTH.!!!
NHTSA ODI #10731986
Mileage unknown · Jun 4, 2015
Engine
TL* THE CONTACT OWNS A 2012 DODGE RAM 2500. THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 14V635000 (ENGINE). THE CONTACT RECEIVED A RECALL LETTER IN JANUARY OF 2015. THE DEALER STATED THAT THE PARTS WERE NOT AVAILABLE TO PERFORM THE RECALL REPAIR. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE ISSUE…
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TL* THE CONTACT OWNS A 2012 DODGE RAM 2500. THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 14V635000 (ENGINE). THE CONTACT RECEIVED A RECALL LETTER IN JANUARY OF 2015. THE DEALER STATED THAT THE PARTS WERE NOT AVAILABLE TO PERFORM THE RECALL REPAIR. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE.
NHTSA ODI #10723378
35,000 miles · May 21, 2015
Electrical SystemFuel/propulsion SystemVehicle Speed Control
I WAS GIVEN NOTICE OF RECALL ON DECEMBER 9TH 2014.RECEIVED ANOTHER NOTICE THIS MONTH ON THE FUEL HEATER. I HAVE BEEN TO THE DEALER SEVERAL TIMES AND THEY DO NOT HAVE THE PART.IT HAS BEEN OVER 6 MONTHS SINCE THE FIRST RECALL NOTICE THEN THEY SEND ANOTHER ONE AND STILL DO NOT HAVE THE PARTS.WHAT GOOD IS A RECALL OF A DANGEROUS SIT…
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I WAS GIVEN NOTICE OF RECALL ON DECEMBER 9TH 2014.RECEIVED ANOTHER NOTICE THIS MONTH ON THE FUEL HEATER. I HAVE BEEN TO THE DEALER SEVERAL TIMES AND THEY DO NOT HAVE THE PART.IT HAS BEEN OVER 6 MONTHS SINCE THE FIRST RECALL NOTICE THEN THEY SEND ANOTHER ONE AND STILL DO NOT HAVE THE PARTS.WHAT GOOD IS A RECALL OF A DANGEROUS SITUATION WITH THE VEHICLE AND THE MANUFACTURE DOES NOT SUPPLY THE PARTS! I HAVE ALSO HAD A PROBLEM AND MADE A REPORT BEFORE ABOUT THE TRUCK NOT STOPPING OR SLOWING DOWN.THE ELECTRONIC THROTTLE STICKS AND THIS IS VERY DANGEROUS.
NHTSA ODI #10717828
20,000 miles · May 18, 2015
Exterior Lighting
TL* THE CONTACT OWNS A 2012 DODGE RAM 2500. WHILE DRIVING AT DUSK AT APPROXIMATELY 70 MPH, THE HEADLIGHTS ACTIVATED AND THEN INDEPENDENTLY DISENGAGED. THE HEADLIGHTS WERE MANUALLY ENGAGED IN ORDER TO CONTINUE DRIVING. ON A SEPARATE OCCASION, THE TAIL LIGHTS FAILED TO ILLUMINATE. IN ADDITION, THE THREE BRAKE STOP LIGHTS FAILED. T…
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TL* THE CONTACT OWNS A 2012 DODGE RAM 2500. WHILE DRIVING AT DUSK AT APPROXIMATELY 70 MPH, THE HEADLIGHTS ACTIVATED AND THEN INDEPENDENTLY DISENGAGED. THE HEADLIGHTS WERE MANUALLY ENGAGED IN ORDER TO CONTINUE DRIVING. ON A SEPARATE OCCASION, THE TAIL LIGHTS FAILED TO ILLUMINATE. IN ADDITION, THE THREE BRAKE STOP LIGHTS FAILED. THE VEHICLE WAS TAKEN TO THE TWICE DEALER, WHO INFORMED THERE WAS AN ELECTRICAL SHORTAGE WITHIN THE FUSE BOX AND THE CIRCUIT BOARD NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE VEHICLE WAS NOT REPAIRED FOR RECENT FAILURE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 20,000.
NHTSA ODI #10717130
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.
Jul 22, 2015
Chrysler (FCA US LLC) is recalling certain model year 2012-2014 Ram 1500, 2500, 3500, 4500, and 5500 trucks manufactured January 18, 2011, to October 7, 2014, and equipped with the Electronic Vehicle Information Center option. The affected vehicles have a steering wheel wiring harness that may rub against the driver air bag module retainer spring.
Consequence & remedy
Consequence: This abrasion may result in an electrical short that could cause driver's frontal air bag to unexpectedly deploy. Inadvertent deployment of the air bag may increase the risk of injury and the possibility of a vehicle crash.
Remedy: Chrysler will notify owners, and dealers will inspect, repair as necessary, and secure the steering wheel wiring harness. Additionally, protective caps will be added to the air bag retainer spring ends. These repairs will be done free of charge. The recall began on September 18, 2015. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is R36.
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.
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.