TL* THE CONTACT OWNS A 2011 RAM 3500. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE TRANSMISSION EXPERIENCED HARD SHIFTING WITH, SERVICE FOUR WHEEL DRIVE MESSAGE DISPLAYED ON THE INSTRUMENT PANEL. THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE LOCAL DEALER AND MANUFACTURER WERE NOT NOTIFIED OF THE FAILURE. THE C…
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TL* THE CONTACT OWNS A 2011 RAM 3500. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE TRANSMISSION EXPERIENCED HARD SHIFTING WITH, SERVICE FOUR WHEEL DRIVE MESSAGE DISPLAYED ON THE INSTRUMENT PANEL. THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE LOCAL DEALER AND MANUFACTURER WERE NOT NOTIFIED OF THE FAILURE. THE CONTACT INDICATED THAT THE FAILURE BEGAN AFTER THE VEHICLE WAS REPAIRED UNDER THE NHTSA CAMPAIGN NUMBER: 17V821000 (POWER TRAIN). THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 171,000.
NHTSA ODI #11330463
Mileage unknown · May 28, 2018
Power Train
DEALERSHIP IS NOT TENDING TO THE RECALL.. KEEP SAYING PART IS NOT AVAILABLE. BEEN ABOUT 8 MONTHS.
NHTSA ODI #11098346
Mileage unknown · Apr 19, 2018
Power TrainService Brakes
2011 DODGE RAM 3500. CONSUMER WRITES IN REGARDS TO BRAKE TRANSMISSION SHIFT INTERLOCK SAFETY RECALL.. *LD THE CONSUMER STATED THE VEHICLE WAS PLACED INTO PARK WITH THE ENGINE RUNNING AND THE PARKING BRAKE ON. THE VEHICLE ROLLED ACROSS THE HIGHWAY AND INTO IN ELECTRICAL POLE. THERE WAS A RECALL RELATED TO THE FAILURE, BUT THE …
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2011 DODGE RAM 3500. CONSUMER WRITES IN REGARDS TO BRAKE TRANSMISSION SHIFT INTERLOCK SAFETY RECALL.. *LD THE CONSUMER STATED THE VEHICLE WAS PLACED INTO PARK WITH THE ENGINE RUNNING AND THE PARKING BRAKE ON. THE VEHICLE ROLLED ACROSS THE HIGHWAY AND INTO IN ELECTRICAL POLE. THERE WAS A RECALL RELATED TO THE FAILURE, BUT THE PARTS WERE UNAVAILABLE.*JS
NHTSA ODI #11089408
170,000 miles · Dec 13, 2017
Power Train
WHILE DRIVING BACK TO OUR HOTEL THE TRUCK WOULDN'T SHIFT INTO GEAR AFTER 3RD AND PUT ITSELF INTO LIMP MODE. THERE WAS NO SIGN OF ANY ISSUES PRIOR TO THIS, THE TRUCK WAS DRIVING NORMAL AND THEN ALL OF A SUDDEN IT DID THIS. WE HAVE A BULLY DOG TUNER AND IT DIDN'T SHOW ANY CODES AT FIRST UNTIL WE DROVE IT IN LIMP MODE FOR AN HOUR…
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WHILE DRIVING BACK TO OUR HOTEL THE TRUCK WOULDN'T SHIFT INTO GEAR AFTER 3RD AND PUT ITSELF INTO LIMP MODE. THERE WAS NO SIGN OF ANY ISSUES PRIOR TO THIS, THE TRUCK WAS DRIVING NORMAL AND THEN ALL OF A SUDDEN IT DID THIS. WE HAVE A BULLY DOG TUNER AND IT DIDN'T SHOW ANY CODES AT FIRST UNTIL WE DROVE IT IN LIMP MODE FOR AN HOUR AT 40KMH TO GET BACK TO OUR HOTEL. SINCE WE WERE ON VACATION WE HAD TO WAIT FOR A SHOP TO OPEN AT WHICH TIME WE FOUND THAT IT WAS THE VALVE BODY THAT LET GO. I HAVE READ THAT THERE ARE MANY ISSUES WITH THE 68RFE ON DODGE FORUMS AND I AM NOT SURE WHY THERE HASN'T BEEN A RECALL DONE FOR THIS?
NHTSA ODI #11054477
25,000 miles · Jan 2, 2016
Power Train
VEHICLE REPEATEDLY GETS STUCK IN PARK, BUT INDICATES REVERSE. WILL NOT START OR MOVE. TRANSFER CASE IS NOT ALLOWED TO MOVE TO NEUTRAL, BECAUSE SHIFT INDICATOR LEVER INDICATES IT IS IN REVERESE. SO CALLED "EMERGENCY OVERRIDE PROCEDURE" DOES NOT WORK. BATTERIES MUST BE DISCONNECTED FOR 30 MINUTES BEFORE SHIFT LEVER CAN BE RELEASED…
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VEHICLE REPEATEDLY GETS STUCK IN PARK, BUT INDICATES REVERSE. WILL NOT START OR MOVE. TRANSFER CASE IS NOT ALLOWED TO MOVE TO NEUTRAL, BECAUSE SHIFT INDICATOR LEVER INDICATES IT IS IN REVERESE. SO CALLED "EMERGENCY OVERRIDE PROCEDURE" DOES NOT WORK. BATTERIES MUST BE DISCONNECTED FOR 30 MINUTES BEFORE SHIFT LEVER CAN BE RELEASED. AFTER HAVING THE VEHICLE TOWED TO THE DEALERSHIP (AT MY OWN EXPENSE) UPON THE FIRST OCCURENCE, I WAS INFORMED THIS WOULD NEVER HAPPEN AGAIN. UNFORTUNATELY IT HAS HAPPENED TWICE SINCE THEN AND I AM MOST ASSURED IT WILL HAPPEN AGAIN.
NHTSA ODI #10817412
125,000 miles · Oct 15, 2015
Power TrainFire
I HAVE A COMPLAINT NUMBER ALREADY BUT I DID NOT SEND PHOTOS. MY NUMBER IS 10782106. INCLUDED ARE THE PHOTOS OF THE HOLE IN THE FLOOR BOARD WHERE THE FRONT DRIVE SHAFT PENETRATED THE CAB BETWEEN THE DRIVERS LEGS. I CAN ALSO OBTAIN A REPORT FROM THE LOCAL FIRE DEPT. AS THEY WERE CALLED TO PUT OUT THE RESULTING FIRE.
NHTSA ODI #10782434
122,000 miles · Oct 14, 2015
Power TrainFire
ON JULY 21, 2015 WHILE DRIVING ON I-40 NEAR NEWPORT TN. THERE WAS A LOUD NOISE THAT CAME FROM MY 2011 DODGE RAM 3500 TRUCK. AFTER THE LOUD NOISE THE TRANSMISSION WAS UNRESPONSIVE AND THERE WERE NO BRAKES AT ALL. MY FRIEND, WHO WAS DRIVING AND HAS CDL, GENTLY PRESSED THE EMERGENCY BRAKE AND SAFELY PULLED OFF TO THE SIDE OF I-40. …
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ON JULY 21, 2015 WHILE DRIVING ON I-40 NEAR NEWPORT TN. THERE WAS A LOUD NOISE THAT CAME FROM MY 2011 DODGE RAM 3500 TRUCK. AFTER THE LOUD NOISE THE TRANSMISSION WAS UNRESPONSIVE AND THERE WERE NO BRAKES AT ALL. MY FRIEND, WHO WAS DRIVING AND HAS CDL, GENTLY PRESSED THE EMERGENCY BRAKE AND SAFELY PULLED OFF TO THE SIDE OF I-40. ONCE THE TRUCK CAME TO A STOP A FIRE ERUPTED FROM UNDERNEATH THE VEHICLE. A TENNESSEE STATE TROOPER SOON ARRIVED AND CALLED FOR THE NEWPORT FIRE DEPT WHO ARRIVED WITHIN A FEW MINUTES TO PUT THE FIRE OUT. AFTER THE FIRE WAS PUT OUT ONE OF THE FIREMEN NOTICED SMOKE IN THE CAB. UPON FURTHER INVESTIGATION HE FOUND A HOLE ABOUT THE SIZE OF A GOLF BALL IN THE DRIVERS SIDE FLOORBOARD. THAT WAS THE LOUD BANG. THEY ALSO NOTICED A LOT OF METAL HANGING FROM UNDER THE TRUCK AND CONCLUDED THE DRIVE SHAFT HAD FALLEN OUT OF THE VEHICLE. I CALLED AAA AND HAD THE TRUCK TOWED TO THE CLOSEST DODGE DEALERSHIP WHICH IS IN NEWPORT. IT WAS 5 WEEKS BEFORE THEY EVEN LOOKED AT THE TRUCK AND THEN THE SERVICE MANAGER SAID IT WAS A MECHANICAL FAILURE LIKE NOTHING HE HAD EVER SEEN. IT SEEMS AS THOUGH THE DRIVE SHAFT FAILURE CAUSED A CHAIN REACTION OF EVENTS, IN A MATTER OF SECONDS THE FRONT DRIVE AXLES, THE TRANSFER CASE FOR THE 4 WHEEL DRIVE, THE MAIN DRIVE SHAFT, THE TRANSMISSION, AND POSSIBLY THE REAR END WERE DESTROYED. I FILED A COMPLAINT WITH CHRYSLER ON AUG 27TH AND THEY HAD AN INDEPENDENT INVESTIGATOR LOOK INTO THE MATTER. HIS FINDINGS STATED THAT WHEN THE TRANSMISSION FLEW APART IT CRUSHED THE BRAKE LINES AND ALSO THE FLUID HITTING THE HOT EXHAUST WAS HOW THE FIRE WAS STARTED. IT WAS DETERMINED THAT ONE OF THE FRONT DRIVE AXLES PENETRATED THE FLOORBOARD ALLOWING SMOKE INTO THE CABIN. I RECEIVED A LETTER FROM CHRYSLER ON SEPTEMBER 18TH THAT STATES THEY " RESPECTFULLY DECLINE ANY ASSISTANCE" IN THE MATTER. THE TRUCK REMAINS AT THE DEALERSHIP AWAITING REPAIR.
NHTSA ODI #10782106
15,000 miles · Jan 28, 2014
Power TrainSteeringSuspension
2011 DODGE RAM 3500. CONSUMER WRITES IN REGARDS TO THE LEFT TIE ROD BALL STUD RECALL NOTICE. *SMD THE CONSUMER STATED 2 MONTHS AFTER OWNING THE VEHICLE, IS WHEN THE PROBLEMS STARTED. THE CONSUMER AND HER HUSBAND DID NOT LIKE THE WAY, THE VEHICLE HANDLED AND STEERED. THE PROBLEM WAS ADDRESSED TO THE DEALER, AT WHICH TIME THEY W…
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2011 DODGE RAM 3500. CONSUMER WRITES IN REGARDS TO THE LEFT TIE ROD BALL STUD RECALL NOTICE. *SMD THE CONSUMER STATED 2 MONTHS AFTER OWNING THE VEHICLE, IS WHEN THE PROBLEMS STARTED. THE CONSUMER AND HER HUSBAND DID NOT LIKE THE WAY, THE VEHICLE HANDLED AND STEERED. THE PROBLEM WAS ADDRESSED TO THE DEALER, AT WHICH TIME THEY WERE INFORMED IT WAS PROBABLY BECAUSE THE TRUCK WAS A DUALLY AND THEY WERE NOT USED TO DRIVING ONE AND IT WOULD TAKE SOME GETTING USED TO. APPROXIMATELY 2-3 WEEKS AFTER THE VISIT, THE CONSUMER AND HER HUSBAND RETURNED TO THE DEALER TO COMPLAIN ABOUT THE HANDLING AND STEERING. THE DEALER PERFORMED AN ALIGNMENT. THEY DROVE THE TRUCK FOR A FEW WEEKS, AND THEY WERE STILL UNHAPPY. APRIL 2, 2012, THE CHECK ENGINE LIGHT ILLUMINATED AND THE VEHICLE WAS RETURNED TO THE DEALER. THE DEALER REPROGRAMMED THE ECM. A MONTH AFTER DRIVING THE VEHICLE, THE CHECK ENGINE LIGHT ILLUMINATED AGAIN. THE DEALER REPLACED THE INTAKE MANIFOLD HEATER AIR TEMP RELAY. THE DEALER THEN MADE AN ADJUSTMENT TO THE STEERING COLUMN. THE CONSUMER DROVE THE VEHICLE FOR 2 MORE MONTHS, THEN THE TIE ROD BROKE ON THE DRIVER'S SIDE . THE DEALER REPLACED THE OUTER TIE ROD END AND RE-ALIGNED THE FRONT END. THE CONSUMER CONTINUED TO COMPLAIN ABOUT THE HANDLING AND STEERING. THE DEALER THEN DISCOVERED THE FRONT TIRES WERE WEARING ON THE OUTSIDE FRONT EDGE. IT WAS DETERMINED THE CHECK ENGINE LIGHT ILLUMINATED DUE TO A BLOCKED OR INCORRECT AIR FILTER WHICH WAS REPLACED AND THE CODES WERE CLEARED. THE CONSUMERS ISSUES WITH THE HANDLING AND STEERING WERE NOT RESOLVED. IN JUNE OF 2013, THERE WAS A PROBLEM WITH THE STEERING COLUMN, WHERE THE CONSUMER WAS UNABLE TO REMOVE THE KEY FROM THE IGNITION. THE TRANSMISSION SHIFTER WAS REPLACED. THE CONSUMER STATED THE TIE ROD BROKE FOR A SECOND TIME. CHRYSLER DETERMINED AFTER THE ORIGINAL FACTORY TIE ROD BROKE AT 15,000, THE REPLACEMENT TIE ROD END AND ALIGNMENT WERE DONE IMPROPERLY BY THE DEALER. THE IMPROPER REPLACEMENT AND ALIGNMENT CAUSED THE FRONT TIRE WEAR ON THE OUTSIDE AND THE SECOND TIE R
NHTSA ODI #10560987
12,000 miles · Sep 5, 2012
Power TrainSteeringStructureCrash
WE PURCHASED A BRAND NEW TRUCK FROM A LOCAL SAVANNAH, GEORGIA DEALER IN 2011. MY HUSBAND WAS DRIVING DOWN THE ROAD AND A TREE FELL ON HIS 9 MONTH OLD TRUCK WITH ONLY 12,000 MILES ON IT. HE HAD BODY DAMAGE ONLY BUT THE TRUCK WAS RENDERED "TOTALED OUT" BY THE INSURANCE COMPANY. WE PAID OFF THE LOAN WITH THE INSURANCE PAY OFF AND T…
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WE PURCHASED A BRAND NEW TRUCK FROM A LOCAL SAVANNAH, GEORGIA DEALER IN 2011. MY HUSBAND WAS DRIVING DOWN THE ROAD AND A TREE FELL ON HIS 9 MONTH OLD TRUCK WITH ONLY 12,000 MILES ON IT. HE HAD BODY DAMAGE ONLY BUT THE TRUCK WAS RENDERED "TOTALED OUT" BY THE INSURANCE COMPANY. WE PAID OFF THE LOAN WITH THE INSURANCE PAY OFF AND THEN, AFTER NEGOTIATIONS, WE BOUGHT THE TRUCK BACK FROM THE INSURANCE COMPANY. WE THEN HAD THE REPAIRS COMPLETED (AGAIN, BODY REPAIRS ONLY). THE TRUCK WAS INSPECTED AND GIVEN A "SALVAGED/REBUILT" TITLE. NOW...DODGE IS REFUSING US ANY FACTORY ENGINE/POWERTRAIN WARRANTY, BUT MORE IMPORTANTLY THEY ARE REFUSING (ALONG WITH THE ORIGINAL LOCAL DEALER) TO REPAIR THE SAFETY RECALLS ON THE VEHICLE. THERE ARE TWO RECALLS: (1) LEFT TIE ROD END AND (2) 2011 DJD2 6.7L ECM FLUSH. WE ARE ALSO TO BELIEVE THAT THE FIRST MOST SEVERE SAFETY RECALL WAS PUT OUT BEFORE THE TRUCK WAS EVEN IN THE CRASH. WE HAVE GOTTEN NO WHERE WITH EITHER DODGE OR THE DEALER THROUGH SEVERAL PHONE CALLS AND SPEAKING WITH SUPERVISORS. BOTH DODGE AND THE DEALERSHIP ARE REFUSING TO DO ANY SAFETY RECALL REPAIRS ON OUR VEHICLE BECAUSE THEY SAY THERE IS A RESTRICTION ON OUR TITLE WHICH PREVENTS THEM FROM MAKING ANY REPAIRS... *TR
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.
Chrysler (FCA US LLC) is recalling certain model year 2011-2014 Dodge Charger Police vehicles, 2007-2013 RAM 3500 Cab Chassis, 2008-2013 RAM 4500 and 5500 Cab Chassis, and 2013 RAM 2500 and 3500 vehicles. The affected vehicles have a 220 amp alternator that may suddenly fail.
Consequence & remedy
Consequence: If the alternator fails, the vehicle may stall without warning, increasing the risk of a crash. There is also the possibility that the alternator may short circuit, increasing the risk of a fire.
Remedy: Chrysler will notify owners, and dealers will replace the alternator with a revised alternator, free of charge. The recall began on December 23, 2016. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is S68.
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.
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.
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
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.
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