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2015 Jeep Patriot

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2015 Jeep Patriot do not stand out strongly from the model-year median of 188.

About this comparison →

When problems were reported

Mileage at the reported incident

215 reports with mileage · 99 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.

  • Engine. Review the 103 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 63 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 50 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

14 crash reports6 fire reports15 injury reports

Unknown Or Other complaints

53 reports
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179,000 miles · Apr 10, 2019
Electronic Stability Control (esc)Fuel/propulsion SystemUnknown Or Other

JEEP PATRIOT CONVERTER RECALL MY 2015 JEEP PATRIOT COMPLETELY SHUT DOWN ON ME AND WAS UNABLE TO BE PUT INTO EITHER A DRIVE OR REVERSE OPTION. THE JEEP SHUT DOWN AND COULD NOT BE DRIVEN DUE TO THE CADILLAC CONVERTER. THE TRANSMISSION ON THE JEEP BECAME PHYSICALLY TORN INTO PIECES WHILE IT WAS OVERWORKED DUE TO THE CONVERTER IS…

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JEEP PATRIOT CONVERTER RECALL MY 2015 JEEP PATRIOT COMPLETELY SHUT DOWN ON ME AND WAS UNABLE TO BE PUT INTO EITHER A DRIVE OR REVERSE OPTION. THE JEEP SHUT DOWN AND COULD NOT BE DRIVEN DUE TO THE CADILLAC CONVERTER. THE TRANSMISSION ON THE JEEP BECAME PHYSICALLY TORN INTO PIECES WHILE IT WAS OVERWORKED DUE TO THE CONVERTER ISSUE, AND MY EXHAUST SYSTEM WAS OVERWORKED. ACCELERATION BECAME AN ISSUE AS WELL. HAD TO HAVE THE JEEP TOWED, AND REPAIRED WITH HIGH COSTS DUE TO THE SERIOUS PROBLEM OF IT NOT BEING DRIVEABLE. I HAD THE CONVERTER REPLACED, THE TRANSMISSION REPLACED, AND OTHER SMALL REPAIRS IN ORDER TO FIX IT AND SAVE IT. I HAVE NOT HAD ANY ISSUE WITH THE ENGINE AS OF YET, AND AM HOPING TO AVOID ANY IN THE FUTURE. I JUST BECAME AWARE OF THE NATIONAL RECALL FOR JEEP PATRIOTS AND THEIR CONVERTER MALFUNCTIONS. PLEASE ADVISE ME HOW I CAN GO ABOUT SENDING MY RECEIPTS FOR THESE REPAIRS TO BE REIMBURSED.

NHTSA ODI #11195434

34,000 miles · Apr 5, 2019
Unknown Or Other

I OWN A 2015 JEEP PATRIOT WITH 34,000 MILES ON THE JEEP. OVER THE PAST WEEK MY JEEP HAS FAILED ME. IT STALLED WHILE DRIVING 3 TIMES. IN ADDITION WHILE DRIVING, THE JEEP WAS JERKING , HESITATING AND THE RPM'S DROPPING TO ZERO WITH NO WARNING AT ALL. A TOTAL LOSS OF POWERSTEERING AND BRAKES OCCURED AS WELL. THE THIRD TIME RESU…

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I OWN A 2015 JEEP PATRIOT WITH 34,000 MILES ON THE JEEP. OVER THE PAST WEEK MY JEEP HAS FAILED ME. IT STALLED WHILE DRIVING 3 TIMES. IN ADDITION WHILE DRIVING, THE JEEP WAS JERKING , HESITATING AND THE RPM'S DROPPING TO ZERO WITH NO WARNING AT ALL. A TOTAL LOSS OF POWERSTEERING AND BRAKES OCCURED AS WELL. THE THIRD TIME RESULTED IN ME ALMOST GETTING HIT AND LEFT ME STRANDED ON THE ROAD. AFTER GETTING MY JEEP TOWED TO THE LOCAL LEE JEEP ( FORT WALTON BEACH FL) THE SERVICE DEPARTMENT CANNOT LOCATE AN ISSUE WITH THE JEEP. THE JEEP HAS STALLED OUT ON THEM, BUT CANNOT GET A CODE. SO NOW I AM WITH OUT A CAR, HAVING TO PAY FOR A RENTAL OUT OF MY POCKET AND I AM A SINGLE TEACHER. THIS IS POOR SERIVE AND AN EXTREME SAFETY ISSUE. AFTER DOING RESEARCH IT SEEMS THAT IS AN ISSUE FOR MULTIPLE JEEP PATROITS OF VARIOUS MAKES AND MODELS AND JEEP IS AWARE OF THE SITUATION AND HAS RECALLED OTHER YEARS, BUT NOT THE 2015 WHICH IS HAVING THE SAME ISSUE. THE ISSUE SEEMS TO BE THE CRANKSHAFT/ CAMSHAFT SENOR WIRE HARNESS ( SAFTEY RECALL S89 FOR THE 2016 MODEL) ALSO THE SAME ISSUE WITH LATER MODELS AS WELL. THE DEALERSHIP HAS HAD MY JEEP FOR 3 DAYS NOW AND NO SOLUTION IN SIGHT. MANY OTHER JEEP OWNERS HAVE BEEN IN THE SAME SHOES AS I AM NOW. WITH A JEEP THAT HAS ONLY 34,000 MILES, SUCH FAILURES SHOULD NOT OCCUR AND SUCH EXPENSES SHOULD BE PASSED ONTO THE OWNER FOR SUCH A WIDESPREAD AND KNOWN ISSUE.

NHTSA ODI #11194052

57,000 miles · Mar 1, 2019
Unknown Or Other

WITHOUT CAUSE THE PASSENGER SIDE FRONT SEAT HEAD REST DEPLOYED. THERE ARE PIECES OF PLASTIC INSIDE THAT PREVENT IT FROM BEING RESET. RESEARCH DETERMINED SEVERAL LIKE COMPLAINTS AND FAILURE OF CHRYSLER JEEP TO RECALL THESE DEFECTIVE SAFETY DEVICES OR REPAIR THEM. VEHICLE WAS PARKED IN THE GARAGE AT THE TIME OF DEPLOYMENT.

NHTSA ODI #11183409

Mileage unknown · Feb 13, 2019
Electrical SystemStructureUnknown Or Other

SHORTLY AFTER PURCHASE OF NEW 015 JEEP PATRIOT, WATER STARTED TO PENETRATE INSIDE OF CAR. OMING THROUGH FRONT INTERIOR LAMP. TOOK TO DEALERSHIP, FOUND OUT CLOG IN DRAIN OF SUNROOF. 'FIXED' THEN APPX 6 MONTHS LATER, SAE LEAK STARTED. TRIED A DIFFRENT DEALERSHIP TRYING TO ACTUALLY GET IT FIXED FOR GOOD, THEY SAID IT WAS 'FIXED' BU…

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SHORTLY AFTER PURCHASE OF NEW 015 JEEP PATRIOT, WATER STARTED TO PENETRATE INSIDE OF CAR. OMING THROUGH FRONT INTERIOR LAMP. TOOK TO DEALERSHIP, FOUND OUT CLOG IN DRAIN OF SUNROOF. 'FIXED' THEN APPX 6 MONTHS LATER, SAE LEAK STARTED. TRIED A DIFFRENT DEALERSHIP TRYING TO ACTUALLY GET IT FIXED FOR GOOD, THEY SAID IT WAS 'FIXED' BUT PROBLEM HAPPENED AGAIN. THIS CONTINUED FOR THREE YEAS. BROUGHT TO 3-4 DEALERSHIPS PLUS HAD 2 PRIVATE TECHS LOOKED AT IT. I CONTACTED CHRYSLER CORP ANDTHEY 'ASSIGNED A CASE MANAGER' TO OVERSEE REPAIR BUT DEALER STATED THAT CLOG WAS FOUND AGAIN, GAVE CAR BACK AS 'FIXED' BUT AT DELIVERY, WATER WAS STILL LEAKING OUT OF INTERIOR LAMP. DEALER SAID 'ONLY RESIDUAL AND NOTHING HE CAN DO ABOUT IT' I ASKED SEVERAL TIMES AND SUGGESTED THERE SHOULD BE A RECALL. THIS VEHICLE HAS BEEN SUCH TROUBLE FOR TH PAST THREE YEARS. WATER FLOWS ALL DOWN THE DASH AND ELECTRIAL COMPONENTS. IF YOU GOOGLE, YOU WILL SEE HUNDREDS OF PATRIOT OWNERS HAVE THE SAME PROBLEM. THE ONLY 'FIX' THAT DEALERSHIP/'WATER SPECIALISTS ' HAVE EVER PERFORMED IS 'CLEARING CLOG DRAIN OF SUNROOF. I AM NOT SURE WHY IT KEEPS CLOGGING. THE LAST DEALER STATED THAT IT IS GENERAL MAINTENANCE. I HVE OWNED MANY CARS WTH SUNROOFS ND HAVE NEVER HAD TO CLEAR DRAIN AS GENERAL MAINTENTANCE. THIS PROBLEM OCCURS IF VEHICLE IS STATIOERY OR IN MOTION. IT HAS OCCURRED WHILE DRIVING ON A MAJORY HIGHWAY CAUSING GREAT DISTRACTION.

NHTSA ODI #11179784

65,000 miles · Dec 19, 2018
EngineUnknown Or OtherVehicle Speed Control

AS OF 12/18/2018, MY CAR HAS BEGUN TO DIE AS I PUSH ON THE ACCELERATOR AFTER BEING AT A COMPLETE STOP AT A STOP LIGHT OR STOP SIGN, IT EVEN DIED OUT OF NO WHERE, MY HUSBAND WAS DRIVING BACK HOME AND THANKFULLY THERE WERE NO OTHER CARS BEHIND HIM AS HE WAS PASSING THE INTERSECTION WHEN THE CAR JERKED AND DECIDED TO TURN OF COMPLE…

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AS OF 12/18/2018, MY CAR HAS BEGUN TO DIE AS I PUSH ON THE ACCELERATOR AFTER BEING AT A COMPLETE STOP AT A STOP LIGHT OR STOP SIGN, IT EVEN DIED OUT OF NO WHERE, MY HUSBAND WAS DRIVING BACK HOME AND THANKFULLY THERE WERE NO OTHER CARS BEHIND HIM AS HE WAS PASSING THE INTERSECTION WHEN THE CAR JERKED AND DECIDED TO TURN OF COMPLETELY. HE PUT IT ON PARK AND STARTED UP LIKE NORMAL BUT NO CHECK ENGINE LIGHT CAME ON OR ANYTHING. EVER SINCE I GOT THIS CAR IN FEBRUARY OF 2016, TAKE NOTE THAT MY JEEP ONLY HAS 65000 MILES AND I HAVE NEVER HAD ANY PROBLEMS WITH IT UNTIL NOW. IT IS TERRIFYING BECAUSE EACH TIME IT HAS HAPPENED, CARS BEHIND ME WERE VERY CLOSE TO REAR ENDING MY CAR. THIS IS A BIG AND SCARY ISSUE FOR ME BECAUSE I HAVE READ ON NUMEROUS WEBSITES THAT THEIR JEEP PATRIOTS HAVE DIED ON THE HIGHWAY... I HAVE A 3 MONTH OLD THAT I TAKE BACK AND FORTH TO A BABY SITTER EVERY WEEKDAY, AND THAT IS A HUGE SAFETY ISSUE FOR MY DAUGHTER AND FOR PEOPLE DRIVING AROUND ME AS WELL. I HAVE READ ON A NUMEROUS AMOUNTS OF WEBSITES WHERE OTHER JEEP PATRIOT OWNERS ARE HAVING THE EXACT SAME ISSUE. I KEEP MY OIL CHANGES UP TO DATE AND I JUST CHANGED MY SPARK PLUGS. SO I HAVE NO CLUE WHAT THE PROBLEM MIGHT BE I HAVE NOT TAKEN IT TO HAVE IT CHECKED BECAUSE OF WHAT I HAVE READ I SEE THAT OTHERS HAVE NOT HAD LUCK WITH TAKEN IT TO A SHOP I WOULD HATE FOR THIS ISSUE TO CAUSE SOMEBODY TO REAR END ME ON THE STREETS OR ON THE HIGHWAY. EITHER BEING ON THE STREETS OR THE HIGHWAY, IT COULD CAUSE SERIOUS DAMAGE AND INJURY TO ME, MY 3 MONTH OLD DAUGHTER AND TO THE PEOPLE AROUND ME.HOPEFULLY THEY HAVE A RECALL SOON!

NHTSA ODI #11162612

60,000 miles · Nov 25, 2018
EngineFuel/propulsion SystemUnknown Or Other

I AM SEEING MANY SIMILAR COMPLAINTS ABOUT THIS VEHICLE. MY 2015 JEEP PATRIOT USED TO KICK BACK WHILE I WAS ACCELERATING WHICH DEVELOPED INTO A STALL AFTER A COUPLE OF MONTHS. I TOOK IT TO A SHOP AND THEY GAVE ME NEW SPARK PLUGS AND CLEANED MY AIR INTAKE VALVES IN HOPES THAT IT WOULD FIX THE ISSUE. THE CAR GIVES NO WARNING OR COD…

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I AM SEEING MANY SIMILAR COMPLAINTS ABOUT THIS VEHICLE. MY 2015 JEEP PATRIOT USED TO KICK BACK WHILE I WAS ACCELERATING WHICH DEVELOPED INTO A STALL AFTER A COUPLE OF MONTHS. I TOOK IT TO A SHOP AND THEY GAVE ME NEW SPARK PLUGS AND CLEANED MY AIR INTAKE VALVES IN HOPES THAT IT WOULD FIX THE ISSUE. THE CAR GIVES NO WARNING OR CODE TO DESCRIBE WHAT IS HAPPENING. FOR ABOUT A WEEK THERE WERE NO ISSUES AND THEN IT STALLED ON ME TWICE TODAY AND POWER STEERING GOES OUT. I WAS STOPPED AT A RED LIGHT AND ACCELERATED ONCE IT TURNED GREEN BUT IT STALLED BEFORE I COULD MAKE IT ALL THE WAY THROUGH THE INTERSECTION. I COULD BARELY STEER OUT OF THE WAY OF OTHER VEHICLES, HAVE TO PUT MY CAR IN PARK AND SHUT IT OFF. THEN I HAVE TO SIT THERE FOR A COUPLE MINUTES BEFORE RESTARTING THE CAR. THIS IS A HUGE SAFETY ISSUE AND I AM AFRAID TO DRIVE MY CAR ESPECIALLY DURING RUSH HOUR.

NHTSA ODI #11153631

55,000 miles · Jul 19, 2018
Unknown Or OtherVehicle Speed Control

WHILE THE CAR IS IN MOTION AND YOU START TO PRESS THE GAS PEDAL TO ACCELERATE IT STARTS JOLTING AND THEN SLOWS DOWN IN MID TRAFFIC WHEREVER YOU ARE WHILE PRESSING ON THE GAS. I GOT IT LOOKED AT THEY SAID IT WAS THE THROTTLE BODY, SUPPOSED IT GOT FIXED BUT I PAID A LOT OF MONEY AND SOMETIMES IT STILL JOLTS. I REALIZED THAT THIS W…

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WHILE THE CAR IS IN MOTION AND YOU START TO PRESS THE GAS PEDAL TO ACCELERATE IT STARTS JOLTING AND THEN SLOWS DOWN IN MID TRAFFIC WHEREVER YOU ARE WHILE PRESSING ON THE GAS. I GOT IT LOOKED AT THEY SAID IT WAS THE THROTTLE BODY, SUPPOSED IT GOT FIXED BUT I PAID A LOT OF MONEY AND SOMETIMES IT STILL JOLTS. I REALIZED THAT THIS WAS A BIGGER ISSUE WHEN MY MOM AND MY SISTER WHO EACH OWN A COMPASS 2014 & 2015 AND BOTH OF THEIR VEHICLES HAVE NOW PRODUCED THE SAME EXACT PROBLEM ALL OF US GETTING THE SAME ISSUE WHILE ALMOST BEING CRASHED IN TO ON THE HIGHWAY AND ON A MAIN ROAD. OUR CARS ARE ONLY 3-4 YEARS OLD, I'M NOT SURE WHY SO MUCH WORK IS BEING DONE FOR THE SAME SITUATION IN ALL THE JEEP MADE VEHICLES. THE THROTTLE BODY IS SUPPOSEDLY THE ISSUE IN ALL THREE SITUATIONS, MAYBE FOR WHOEVER ELSE OWNS ONE SHOULD KNOW THAT THEY WILL SOON GET THIS PROBLEM IF THEY HAVENT. MY CAR STILL HAD NEVER BEEN THE SAME SINCE GETTING IT "FIXED" BY JEEP "PROFESSIONALS" AT THE DEALERSHIP.

NHTSA ODI #11112302

35,000 miles · Apr 17, 2018
Unknown Or Other

VEHICLE WILL STALL OR COMPLETELY DRIVING WHILE AT SPEED EITHER HIGHWAY SPEED OR BACKROADS. I WAS ALMOST HIT BY A TRAIN BECAUSE AS I WAS CROSSING TRACKS IT QUIT. I PLACED IT BACK IN PARK AND WAS ABLE TO RESTART IT IN TIME. IT STALLS OR QUITS 8-10 TIMES A DAY. I HAVE HAD IT AT MY DEALER FOR THE SAME ISSUE 3 TIMES NOW. THIS LAST TI…

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VEHICLE WILL STALL OR COMPLETELY DRIVING WHILE AT SPEED EITHER HIGHWAY SPEED OR BACKROADS. I WAS ALMOST HIT BY A TRAIN BECAUSE AS I WAS CROSSING TRACKS IT QUIT. I PLACED IT BACK IN PARK AND WAS ABLE TO RESTART IT IN TIME. IT STALLS OR QUITS 8-10 TIMES A DAY. I HAVE HAD IT AT MY DEALER FOR THE SAME ISSUE 3 TIMES NOW. THIS LAST TIME THEY HAVE HAD IT A MONTH AND STILL CONTINUE TO TELL ME THEY DON'T KNOW WHAT'S WRONG WITH IT.

NHTSA ODI #11088675

26,830 miles · Mar 22, 2018
Unknown Or Other

THE DRIVERS SIDE FLOOR MAT IS HOOKED BY ONE HOOK WHICH CAUSES THE FLOOR MAT TO SLIDE AROUND AND POTENTIALLY GET JAMMED UNDER THE ACCELERATOR AND IS A SAFETY HAZARD. IT DOES NOT STAY IN PLACE BECAUSE OF THE PHYSICS OF ONE HOOK RATHER THAN TWO. OTHER YEARS MODELS HAVE TWO HOOKS.

NHTSA ODI #11080853

70,000 miles · Mar 6, 2018
EngineFuel/propulsion SystemUnknown Or Other

DRIVING THE JEEP ON THE ROAD AND SUDDENLY IT TURNS OFF AND STEERING WHEEL LOCKS UP, BUT BEFORE IT HAPPENS, NOTICE THE VEHICLE JERKS. THIS HAPPEN WHILE DRIVING ON HIGHWAY 73 GOING HOME FROM THE GROCERY STORE. AFTER I TURN OFF THE ROAD, TURN THE KEY OFF AND SITTING THERE FOR A FEW MINUTES AND TURN THE KEY, IT WILL START AND TAKE…

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DRIVING THE JEEP ON THE ROAD AND SUDDENLY IT TURNS OFF AND STEERING WHEEL LOCKS UP, BUT BEFORE IT HAPPENS, NOTICE THE VEHICLE JERKS. THIS HAPPEN WHILE DRIVING ON HIGHWAY 73 GOING HOME FROM THE GROCERY STORE. AFTER I TURN OFF THE ROAD, TURN THE KEY OFF AND SITTING THERE FOR A FEW MINUTES AND TURN THE KEY, IT WILL START AND TAKE ME A FEW BLOCKS AND THE SAME THING HAPPENS AGAIN. HAVE TO PUSH THE GAS PEDAL TO STAY ON THE ROAD.

NHTSA ODI #11076459

Official recalls

1

15V878000 · Steering:hydraulic Power Assist:hose, Piping, And Connections

Dec 23, 2015

Chrysler (FCA US LLC) is recalling certain model year 2015 Jeep Compass and Patriot vehicles manufactured January 1, 2015, to May 11, 2015. During assembly, the power steering hose retention clamp may have been installed at an incorrect location, resulting in the detachment of the low pressure return hose.

Consequence & remedy

Consequence: If the power steering fluid return hose detaches, it would leak fluid and increase the risk of a fire.

Remedy: Chrysler will notify owners, and dealers will inspect the return power steering hose clamp, repositioning the clamp as necessary, free of charge. The recall began on February 5, 2016. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is R68.

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

4

RQ22002 · Stall From Crankshaft\camshaft Failure

Opened Jul 22, 2022 · Closed Jun 16, 2025

Status: closed (inferred from source dates) · Engine And Engine Cooling:engine:crank/camshaft Position Sensor

On December 13, 2016, the National Highway Traffic Safety Administration (NHTSA) received recall 16V-907 from Fiat Chrysler Automobiles (FCA) that identified a safety defect involving crankshaft or camshaft sensor failures on certain 2016 Model Year Dodge Journey, Jeep Compass, and Jeep Patriot vehicles. The failure of the crankshaft or camshaft sensor may lead to a loss of motive power (LOMP) in the recalled vehicles.  Following the receipt of recall 16V-907, the Office of Defects Investigation (ODI) received 127 vehicle owner’s questionnaires (VOQ), in which consumers allege experiencing crankshaft or camshaft failures on similar vehicles not included in the recall.  On July 22, 2022, this Recall Query was opened to further assess the scope, frequency, and safety consequences of the alleged defect described in the recall. During this investigation, ODI sent two information request (IR) letters to FCA.  The first letter was sent on August 15, 2022, and the second on July 12, 2024.  Responses to these IR letters, that included manufacturer claim data related to the alleged defect, were received on September 26, 2022, and September 6, 2024, respectively. Analysis of ODI and FCA claim data identified two failure modes relating to intermittent crankshaft and camshaft sensor loss of signal.  The first failure mode involves a faulty crankshaft or camshaft electrical connector, as identified in recall 16V-907. The second failure mode involves a faulty crankshaft and/or camshaft position sensor.  Both failure modes exhibit intermittent operation of the crankshaft and/or camshaft position sensor that can result in a malfunction indicator lamp (MIL), engine stall while driving, or a no start condition. For the first failure mode, the claim data indicates that the majority of failures resulted in a LOMP and occurred on vehicles covered by recall 16V-907. For the second failure mode, the claim data indicates that the majority of failures resulted in a MIL or no start condition and occurred on vehicles manufactured prior to the vehicles covered by recall 16V-907. VOQ and claim data submitted to NHTSA, involving vehicles built outside the scope of recall 16V-907, commonly do not describe a LOMP.  These claims typically describe experiencing symptoms such as a MIL, Diagnostic Trouble Code (DTC) associated with crank/camshaft position sensor, and subsequent visits to a dealership. A substantially smaller percentage of the complaints allege an actual LOMP ( During production, FCA implemented multiple corrective actions to address the camshaft/camshaft sensor signal issue. The last of which was a software update that occurred in February 2016 and based on the claim data, addressed the crankshaft and/or camshaft position sensor issues that were leading to MIL or no start.  For vehicles built prior to the software update, the sensor failures were normally covered under warranty. FCA’s assessment of the alleged defect is that the subject vehicles (not included in recall 16V-907) are not typically experiencing a LOMP when they have trouble with their crankshaft and/or camshaft position sensor and for that reason it does not represent a safety defect.  FCA states consumers experience multiple warning signs including MIL illumination, drive quality changes, or no start conditions when a crankshaft and/or camshaft position sensor is failing. Based on ODI's analysis of the failure modes, the failure mode for vehicles not included in recall 16V-907 is unlikely to result in LOMP. The data indicates that vehicles not included in the recall experience LOMP at much lower rates than the recalled population.  In addition, ODI is not aware of any related vehicle crashes or injuries in that time.  Given these facts, a safety-related defect trend has not been identified at this time.  Accordingly, this investigation is closed without action. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

EA21002 · Desiccated Air Bag Inflator Rupture

Opened Sep 17, 2021 · No close date supplied

Status: open (inferred from source dates) · Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:passenger Side:inflator Module

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

Additional source detail variants (2)

Air Bags:frontal:driver Side:inflator Module

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

Air Bags:frontal:passenger Side:inflator Module

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

PE19014 · Active Head Rest Inadvertent Deployment

Opened Sep 9, 2019 · Closed Feb 25, 2026

Status: closed (inferred from source dates) · Seats; Seats:front Assembly:head Restraint

The Office of Defects Investigation (ODI) opened PE19014 on September 9, 2019, to investigate 128 consumer complaints alleging that the Active Head Rest (AHR) inadvertently deployed without the occurrence of a crash or other rear impact event in model year (MY) 2014 Jeep Grand Cherokee and Dodge Durango vehicles.When ODI opened the investigation, ODI was aware of thirteen alleged injuries.A small number of Early Warning Reports identified driver and/or passenger front seat AHR inadvertent deployments without a rear impact event.Reported safety consequences resulting from the AHR deployments include concussions, headaches, soft tissue injuries, disorientation, nausea, vomiting and/or loss of vehicle control as a result of being surprised and distracted by being struck in the head by the inadvertent AHR deployment. On September 24, 2019, ODI sent an Information Request (IR) letter to Fiat Chrysler Automobiles (FCA).ODI requested certain detailed information from FCA related to the following subject vehicles: MY 2010-2014 Dodge Avenger 200, MY 2010-2014 Dodge Calber, MY 2010-2014 Chrysler Sebring, MY 2013-2015 Ram Tradesman, MY 2012 Ram Van, MY 2010-2019 Dodge Grand Caravan, MY 2010-2016 Chrysler Town and Country, MY 2010-2017 Jeep Compass, MY 2011-2020 Dodge Durango, MY 2011-2020 Jeep Grand Cherokee, MY 2010-2019 Dodge Journey, MY 2010-2012 Jeep Liberty, MY 2010-2011 Jeep Nitro, and MY 2010-2011 Jeep Patriot vehicles.On December 2, 2019, ODI received a response from FCA that included vehicle production data, consumer complaints, field reports, warranty claims, manufacturer actions, production changes, and other data related to the alleged defect from the start of production (2010) through September 24, 2019.On January 27, 2020, ODI received an update to the December 2, 2019, IR response from FCA.On September 22, 2020, ODI requested additional subject vehicle AHR information from FCA.ODI received FCA's response on October 21, 2020.ODI subsequently received an update to FCA's October 21, 2020, response on February 16, 2021.During the investigation, ODI requested updates to certain IR questions on two occasions.FCA provided updates to question #2 on March 5, 2021, and questions #2 and #5 on May 26, 2023. FCA’s IR response data identified approximately 7.5 million subject vehicles (with approximately 15 million AHR assemblies).Due to the large number of vehicles and failure reports, ODI focused its analysis on the FCA vehicle model with the highest failure rate to represent the worst-case scenario.For this purpose, ODI focused on MY 2012-2015 Jeep Grand Cherokee vehicles for its analysis.This population includes 710,890 vehicles that FCA manufactured between August 19, 2011, and August 8, 2015.ODI identified 2,839 alleged AHR failures within this limited population.ODI identified 263 alleged injuries that were caused by AHR failures in MY 2012-2015 Grand Cherokees vehicles.Of these alleged injuries, ODI categorized them as eighty-two (82) soft tissue (neck/whiplash, bruise) injuries, four (4) concussions, fifty-nine (59) headaches, and one hundred eighteen (118) without a specific injury description.Although complainants have alleged injuries, ODI has been unable to obtain evidence to substantiate or validate any injuries where medical treatment was required.Consumer outreach was conducted by ODI, where sixty-three (63) FCA complainants with alleged injuries were contacted.Twelve of the sixty-three FCA consumers responded and were interviewed by ODI.ODI requested medical records, however, only one response was provided. Attorneys representing the responding complainant provided a synopsis that indicated they had experienced prior neck-related injuries dating to the mid-1990s.ODI also contacted one hundred (100) consumers who submitted Vehicle Owner Questionnaires (VOQ) in an attempt to validate alleged injuries. Despite the efforts of ODI, the office has been unsuccessful at obtaining substantive documentation/evidence supporting complaints that allege serious injuries (where pre-existing medical conditions did not already exist). In addition to the low severity of alleged injuries caused by AHR deployments, there have been eleven alleged crashes and two alleged lane departures within the entire subject vehicle population that has been in the field up to sixteen years (with over 8,500 AHR inadvertent deployments).ODI was not able to validate that the alleged crashes were the result of inadvertent head rest deployments, and the crashes were minor in nature. ODI has conducted a thorough investigation of the alleged safety defect and with up to sixteen years of exposure for some vehicles and over 8,500 inadvertent AHR deployments, no serious crashes or injuries could be validated in the sub-population of focus.The lack of serious injuries validated by ODI with such large period of field exposure is consistent with thework done by NHTSA’s Human Injury Research Division and the Biodynamic Research Corporation, which support that an inadvertent AHR deployment is not likely to cause serious injury.In addition to the low risk of injury, FCA released an extended warranty program that covers inadvertent AHR deployment for ten years / unlimited mileage from the vehicle's in-service date. PE19014 is closed with the FCA extended warranty program.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist, and the Agency reserves the right to take additional action if warranted by new circumstances. To review a complete closing summary, please the attached closing report. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

Additional source detail variants (2)

Seats

The Office of Defects Investigation (ODI) opened PE19014 on September 9, 2019, to investigate 128 consumer complaints alleging that the Active Head Rest (AHR) inadvertently deployed without the occurrence of a crash or other rear impact event in model year (MY) 2014 Jeep Grand Cherokee and Dodge Durango vehicles.When ODI opened the investigation, ODI was aware of thirteen alleged injuries.A small number of Early Warning Reports identified driver and/or passenger front seat AHR inadvertent deployments without a rear impact event.Reported safety consequences resulting from the AHR deployments include concussions, headaches, soft tissue injuries, disorientation, nausea, vomiting and/or loss of vehicle control as a result of being surprised and distracted by being struck in the head by the inadvertent AHR deployment. On September 24, 2019, ODI sent an Information Request (IR) letter to Fiat Chrysler Automobiles (FCA).ODI requested certain detailed information from FCA related to the following subject vehicles: MY 2010-2014 Dodge Avenger 200, MY 2010-2014 Dodge Calber, MY 2010-2014 Chrysler Sebring, MY 2013-2015 Ram Tradesman, MY 2012 Ram Van, MY 2010-2019 Dodge Grand Caravan, MY 2010-2016 Chrysler Town and Country, MY 2010-2017 Jeep Compass, MY 2011-2020 Dodge Durango, MY 2011-2020 Jeep Grand Cherokee, MY 2010-2019 Dodge Journey, MY 2010-2012 Jeep Liberty, MY 2010-2011 Jeep Nitro, and MY 2010-2011 Jeep Patriot vehicles.On December 2, 2019, ODI received a response from FCA that included vehicle production data, consumer complaints, field reports, warranty claims, manufacturer actions, production changes, and other data related to the alleged defect from the start of production (2010) through September 24, 2019.On January 27, 2020, ODI received an update to the December 2, 2019, IR response from FCA.On September 22, 2020, ODI requested additional subject vehicle AHR information from FCA.ODI received FCA's response on October 21, 2020.ODI subsequently received an update to FCA's October 21, 2020, response on February 16, 2021.During the investigation, ODI requested updates to certain IR questions on two occasions.FCA provided updates to question #2 on March 5, 2021, and questions #2 and #5 on May 26, 2023. FCA’s IR response data identified approximately 7.5 million subject vehicles (with approximately 15 million AHR assemblies).Due to the large number of vehicles and failure reports, ODI focused its analysis on the FCA vehicle model with the highest failure rate to represent the worst-case scenario.For this purpose, ODI focused on MY 2012-2015 Jeep Grand Cherokee vehicles for its analysis.This population includes 710,890 vehicles that FCA manufactured between August 19, 2011, and August 8, 2015.ODI identified 2,839 alleged AHR failures within this limited population.ODI identified 263 alleged injuries that were caused by AHR failures in MY 2012-2015 Grand Cherokees vehicles.Of these alleged injuries, ODI categorized them as eighty-two (82) soft tissue (neck/whiplash, bruise) injuries, four (4) concussions, fifty-nine (59) headaches, and one hundred eighteen (118) without a specific injury description.Although complainants have alleged injuries, ODI has been unable to obtain evidence to substantiate or validate any injuries where medical treatment was required.Consumer outreach was conducted by ODI, where sixty-three (63) FCA complainants with alleged injuries were contacted.Twelve of the sixty-three FCA consumers responded and were interviewed by ODI.ODI requested medical records, however, only one response was provided. Attorneys representing the responding complainant provided a synopsis that indicated they had experienced prior neck-related injuries dating to the mid-1990s.ODI also contacted one hundred (100) consumers who submitted Vehicle Owner Questionnaires (VOQ) in an attempt to validate alleged injuries. Despite the efforts of ODI, the office has been unsuccessful at obtaining substantive documentation/evidence supporting complaints that allege serious injuries (where pre-existing medical conditions did not already exist). In addition to the low severity of alleged injuries caused by AHR deployments, there have been eleven alleged crashes and two alleged lane departures within the entire subject vehicle population that has been in the field up to sixteen years (with over 8,500 AHR inadvertent deployments).ODI was not able to validate that the alleged crashes were the result of inadvertent head rest deployments, and the crashes were minor in nature. ODI has conducted a thorough investigation of the alleged safety defect and with up to sixteen years of exposure for some vehicles and over 8,500 inadvertent AHR deployments, no serious crashes or injuries could be validated in the sub-population of focus.The lack of serious injuries validated by ODI with such large period of field exposure is consistent with thework done by NHTSA’s Human Injury Research Division and the Biodynamic Research Corporation, which support that an inadvertent AHR deployment is not likely to cause serious injury.In addition to the low risk of injury, FCA released an extended warranty program that covers inadvertent AHR deployment for ten years / unlimited mileage from the vehicle's in-service date. PE19014 is closed with the FCA extended warranty program.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist, and the Agency reserves the right to take additional action if warranted by new circumstances. To review a complete closing summary, please the attached closing report. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

Seats:front Assembly:head Restraint

The Office of Defects Investigation (ODI) opened PE19014 on September 9, 2019, to investigate 128 consumer complaints alleging that the Active Head Rest (AHR) inadvertently deployed without the occurrence of a crash or other rear impact event in model year (MY) 2014 Jeep Grand Cherokee and Dodge Durango vehicles.When ODI opened the investigation, ODI was aware of thirteen alleged injuries.A small number of Early Warning Reports identified driver and/or passenger front seat AHR inadvertent deployments without a rear impact event.Reported safety consequences resulting from the AHR deployments include concussions, headaches, soft tissue injuries, disorientation, nausea, vomiting and/or loss of vehicle control as a result of being surprised and distracted by being struck in the head by the inadvertent AHR deployment. On September 24, 2019, ODI sent an Information Request (IR) letter to Fiat Chrysler Automobiles (FCA).ODI requested certain detailed information from FCA related to the following subject vehicles: MY 2010-2014 Dodge Avenger 200, MY 2010-2014 Dodge Calber, MY 2010-2014 Chrysler Sebring, MY 2013-2015 Ram Tradesman, MY 2012 Ram Van, MY 2010-2019 Dodge Grand Caravan, MY 2010-2016 Chrysler Town and Country, MY 2010-2017 Jeep Compass, MY 2011-2020 Dodge Durango, MY 2011-2020 Jeep Grand Cherokee, MY 2010-2019 Dodge Journey, MY 2010-2012 Jeep Liberty, MY 2010-2011 Jeep Nitro, and MY 2010-2011 Jeep Patriot vehicles.On December 2, 2019, ODI received a response from FCA that included vehicle production data, consumer complaints, field reports, warranty claims, manufacturer actions, production changes, and other data related to the alleged defect from the start of production (2010) through September 24, 2019.On January 27, 2020, ODI received an update to the December 2, 2019, IR response from FCA.On September 22, 2020, ODI requested additional subject vehicle AHR information from FCA.ODI received FCA's response on October 21, 2020.ODI subsequently received an update to FCA's October 21, 2020, response on February 16, 2021.During the investigation, ODI requested updates to certain IR questions on two occasions.FCA provided updates to question #2 on March 5, 2021, and questions #2 and #5 on May 26, 2023. FCA’s IR response data identified approximately 7.5 million subject vehicles (with approximately 15 million AHR assemblies).Due to the large number of vehicles and failure reports, ODI focused its analysis on the FCA vehicle model with the highest failure rate to represent the worst-case scenario.For this purpose, ODI focused on MY 2012-2015 Jeep Grand Cherokee vehicles for its analysis.This population includes 710,890 vehicles that FCA manufactured between August 19, 2011, and August 8, 2015.ODI identified 2,839 alleged AHR failures within this limited population.ODI identified 263 alleged injuries that were caused by AHR failures in MY 2012-2015 Grand Cherokees vehicles.Of these alleged injuries, ODI categorized them as eighty-two (82) soft tissue (neck/whiplash, bruise) injuries, four (4) concussions, fifty-nine (59) headaches, and one hundred eighteen (118) without a specific injury description.Although complainants have alleged injuries, ODI has been unable to obtain evidence to substantiate or validate any injuries where medical treatment was required.Consumer outreach was conducted by ODI, where sixty-three (63) FCA complainants with alleged injuries were contacted.Twelve of the sixty-three FCA consumers responded and were interviewed by ODI.ODI requested medical records, however, only one response was provided. Attorneys representing the responding complainant provided a synopsis that indicated they had experienced prior neck-related injuries dating to the mid-1990s.ODI also contacted one hundred (100) consumers who submitted Vehicle Owner Questionnaires (VOQ) in an attempt to validate alleged injuries. Despite the efforts of ODI, the office has been unsuccessful at obtaining substantive documentation/evidence supporting complaints that allege serious injuries (where pre-existing medical conditions did not already exist). In addition to the low severity of alleged injuries caused by AHR deployments, there have been eleven alleged crashes and two alleged lane departures within the entire subject vehicle population that has been in the field up to sixteen years (with over 8,500 AHR inadvertent deployments).ODI was not able to validate that the alleged crashes were the result of inadvertent head rest deployments, and the crashes were minor in nature. ODI has conducted a thorough investigation of the alleged safety defect and with up to sixteen years of exposure for some vehicles and over 8,500 inadvertent AHR deployments, no serious crashes or injuries could be validated in the sub-population of focus.The lack of serious injuries validated by ODI with such large period of field exposure is consistent with thework done by NHTSA’s Human Injury Research Division and the Biodynamic Research Corporation, which support that an inadvertent AHR deployment is not likely to cause serious injury.In addition to the low risk of injury, FCA released an extended warranty program that covers inadvertent AHR deployment for ten years / unlimited mileage from the vehicle's in-service date. PE19014 is closed with the FCA extended warranty program.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist, and the Agency reserves the right to take additional action if warranted by new circumstances. To review a complete closing summary, please the attached closing report. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

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.