NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes, Hydraulic complaints
13 reportsClear category filter80,000 miles · Aug 10, 2026
Service Brakes, Hydraulic
The contact owns a 2016 Jeep Wrangler. The contact stated that while driving at an undisclosed speed, the vehicle experienced an ABS module failure. The ABS and traction control warning lights were illuminated. The dealer was contacted and diagnosed the vehicle with ABS control module failure; however, the part to repair the veh…
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The contact owns a 2016 Jeep Wrangler. The contact stated that while driving at an undisclosed speed, the vehicle experienced an ABS module failure. The ABS and traction control warning lights were illuminated. The dealer was contacted and diagnosed the vehicle with ABS control module failure; however, the part to repair the vehicle was not available. The vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time to provide the parts for the repair. The manufacturer was made aware of the failure but was unable to determine when parts for the repair would be available. The failure mileage was approximately 80,000.
NHTSA ODI #11755958
76,000 miles · May 22, 2026
Service Brakes, Hydraulic
The contact owns a 2016 Jeep Wrangler. The contact stated while the vehicle was parked, the antilock brake system warning light was illuminated. The vehicle was taken to an independent mechanic where it was diagnosed that the antilock brake system needed to replaced however, the dealer recommended that the vehicle be taken to a …
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The contact owns a 2016 Jeep Wrangler. The contact stated while the vehicle was parked, the antilock brake system warning light was illuminated. The vehicle was taken to an independent mechanic where it was diagnosed that the antilock brake system needed to replaced however, the dealer recommended that the vehicle be taken to a dealer. The vehicle was not repaired. The vehicle was taken to a dealer where it was diagnosed once again that the antilock brake system needed to be replaced however, the parts were not available. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 76,000.
NHTSA ODI #11739541
67,108 miles · May 5, 2026
Service Brakes, Hydraulic
The contact owns a 2016 Jeep Wrangler. The contact stated while driving at an undisclosed speed, the ABS and traction control warning lights illuminated. The vehicle was taken to an independent mechanic where it was diagnosed with a failed ABS module. The contact was informed that the ABS module needed to be replaced. The vehicl…
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The contact owns a 2016 Jeep Wrangler. The contact stated while driving at an undisclosed speed, the ABS and traction control warning lights illuminated. The vehicle was taken to an independent mechanic where it was diagnosed with a failed ABS module. The contact was informed that the ABS module needed to be replaced. The vehicle was not repaired. In addition, the contact was informed that the parts were in back order indefinitely. The contact was advised that she could drive the vehicle at her own risk. The manufacturer was not made aware of the failure. The failure mileage was approximately 67,108.
NHTSA ODI #11735902
77,000 miles · Feb 9, 2026
Service Brakes, Hydraulic
The contact owns a 2016 Jeep Wrangler. The contact stated that while driving at an undisclosed speed, the vehicle jerked with an abnormal sound coming from the vehicle. The contact stopped the vehicle, and there was an unknown warning light illuminated. The vehicle was turned off and restarted; however, while driving, the failur…
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The contact owns a 2016 Jeep Wrangler. The contact stated that while driving at an undisclosed speed, the vehicle jerked with an abnormal sound coming from the vehicle. The contact stopped the vehicle, and there was an unknown warning light illuminated. The vehicle was turned off and restarted; however, while driving, the failure reoccurred with several unknown warning lights illuminated. The vehicle was towed to a private dealer, where it was diagnosed with ABS control module failure. The dealer informed the contact that the part to do the repair was not available. The vehicle remained with the dealer unrepaired. The contact related the failure to NHTS Campaign number: 22V426000 (SERVICE BRAKES, HYDRAULIC); however, the VIN was not included. The manufacturer was made aware of the failure. The failure mileage was approximately 77,000.
NHTSA ODI #11716848
150,000 miles · Dec 8, 2025
Service Brakes, Hydraulic
The contact owns a 2016 Jeep Wrangler. The contact stated that while driving on wet roads, the vehicle lost traction, failed to accelerate as intended, and caused the tires to spin before accelerating. While depressing the brake pedal, the wheels locked up, and the vehicle failed to come to a gradual stop. The ABS control module…
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The contact owns a 2016 Jeep Wrangler. The contact stated that while driving on wet roads, the vehicle lost traction, failed to accelerate as intended, and caused the tires to spin before accelerating. While depressing the brake pedal, the wheels locked up, and the vehicle failed to come to a gradual stop. The ABS control module displayed DTC: C2200 (Internal ABS Module Failure). The vehicle was taken to the dealer, who confirmed the fault code. The vehicle was not repaired because the Part Number 68259556AD was on back order. The manufacturer was notified of the failure and informed the contact that the part was still under engineering review, and that a remedy had not yet been found. The failure mileage was approximately 150,000.
NHTSA ODI #11703685
60,000 miles · Apr 4, 2025
Service Brakes, HydraulicTraction Control System
The contact owns a 2016 Jeep Wrangler. The contact stated that the ABS, traction control, and service brake warning lights were illuminated. The ABS and cruise control were inoperable. The traction control was inoperable while driving in the mountains and in snow. The local dealer was contacted, who informed the contact that the…
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The contact owns a 2016 Jeep Wrangler. The contact stated that the ABS, traction control, and service brake warning lights were illuminated. The ABS and cruise control were inoperable. The traction control was inoperable while driving in the mountains and in snow. The local dealer was contacted, who informed the contact that the parts were on backorder to repair the vehicle. The vehicle was not diagnosed or repaired. The contact called another local dealer, AJ Dohmann Chrysler Dodge Jeep Ram (24945 LA-1 S, Plaquemine, LA 70764), who confirmed that the parts were on backorder. The manufacturer was contacted, but no assistance was provided. The failure mileage was approximately 60,000.
NHTSA ODI #11652819
92,239 miles · Mar 20, 2025
Service Brakes, Hydraulic
The contact owns a 2016 Jeep Wrangler. The contact stated that while driving at an undisclosed speed, the ABS warning light illuminated. The vehicle was taken to the dealer, who determined that the ABS module had malfunctioned and needed to be replaced; however, the contact was informed that replacement parts were under engineer…
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The contact owns a 2016 Jeep Wrangler. The contact stated that while driving at an undisclosed speed, the ABS warning light illuminated. The vehicle was taken to the dealer, who determined that the ABS module had malfunctioned and needed to be replaced; however, the contact was informed that replacement parts were under engineering review and not yet available. The vehicle was not repaired. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 92,239.
NHTSA ODI #11649417
96,000 miles · Feb 21, 2025
Service Brakes, Hydraulic
The contact owns a 2016 Jeep Wrangler. The contact stated while driving at an undisclosed speed, the brake pedal was depressed, and went to the floorboard. No warning light was illuminated. The vehicle failed to stop until the contact applied the parking brake. The vehicle was towed to an independent mechanic, who diagnosed that…
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The contact owns a 2016 Jeep Wrangler. The contact stated while driving at an undisclosed speed, the brake pedal was depressed, and went to the floorboard. No warning light was illuminated. The vehicle failed to stop until the contact applied the parking brake. The vehicle was towed to an independent mechanic, who diagnosed that the ABS module and pump had failed and needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 96,000.
NHTSA ODI #11644119
89,000 miles · Jan 28, 2025
Service Brakes, Hydraulic
The contact owns a 2016 Jeep Wrangler. The contact stated that while her husband driving 65 MPH, the ABS warning light and the brake warning light illuminated. The vehicle was taken to Joe Hudson's Collision Center, where the mechanic used a Code Reader to retrieve DTC: C2200 (ABS Module Failure). The dealer was notified of the …
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The contact owns a 2016 Jeep Wrangler. The contact stated that while her husband driving 65 MPH, the ABS warning light and the brake warning light illuminated. The vehicle was taken to Joe Hudson's Collision Center, where the mechanic used a Code Reader to retrieve DTC: C2200 (ABS Module Failure). The dealer was notified of the failure and informed the contact that the ABS module was on backorder. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 89,000.
NHTSA ODI #11639132
60,700 miles · Nov 25, 2024
Service Brakes, Hydraulic
The contact owns a 2016 Jeep Wrangler. The contact stated that while driving at various speeds, the traction control, Brake, and ABS warning lights illuminated. In addition, the contact stated that the Hill Assist warning light was occasionally illuminated. The contact inspected the vehicle and became aware that the speed sensor…
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The contact owns a 2016 Jeep Wrangler. The contact stated that while driving at various speeds, the traction control, Brake, and ABS warning lights illuminated. In addition, the contact stated that the Hill Assist warning light was occasionally illuminated. The contact inspected the vehicle and became aware that the speed sensor and battery needed to be replaced. The vehicle was repaired by the contact; however, the failure persisted. The local dealer was contacted; however, the contact was informed that the VIN was not under recall. The manufacturer was made aware of the failure. The failure mileage was approximately 60,700.
NHTSA ODI #11627199
Official recalls
5Mar 14, 2024
Chrysler (FCA US, LLC) (Stellantis) is recalling certain right hand drive 2016 Jeep Wrangler vehicles. Debris contamination may cause the clockspring to fail, preventing the driver's air bag from deploying in a crash.
Consequence & remedy
Consequence: An air bag that does not deploy in a crash can increase the risk of injury.
Remedy: Dealers will replace the clockspring, steering wheel back cover, and steering column shrouds, free of charge. Owner notification letters were mailed April 4, 2024. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC's number for this recall is 27B.
Sep 26, 2019
Chrysler (FCA US LLC) is recalling certain 2011-2018 Jeep Wrangler right hand drive vehicles. The driver's seat belt buckle mounting strap may fracture and separate from the seat frame.
Consequence & remedy
Consequence: A separated or severed seat belt buckle strap will result in an inoperable seat belt, increasing the risk of injury in the event of a crash.
Remedy: FCA US will notify owners, and dealers will replace the driver's seat belt buckle, free of charge. Interim notices informing owners of the safety risk were mailed November 19, 2019. Owners will received a second letter and the recall began March 26, 2020. Owners may contact FCA customer service at 1-800-853-1403. FCA's number for this recall is VA6.
Jan 15, 2019
Chrysler (FCA US LLC) is recalling certain 2010 Dodge Ram 3500, Ram 4500/5500, 2010-2011 Dodge Dakota, 2010-2014 Dodge Challenger, 2010-2015 Dodge Challenger, Chrysler 300, and 2010-2016 Jeep Wrangler vehicles. Upon deployment of the driver's frontal air bag, excessive internal pressure may cause the inflator to explode.
Consequence & remedy
Consequence: In the event of a crash necessitating deployment of the passenger's frontal air bag, the inflator could explode with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. The recall began February 4, 2019. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is V01.
Oct 13, 2016
Chrysler (FCA US LLC) is recalling certain model year 2016-2017 Jeep Wrangler vehicles manufactured June 16, 2015, to August 14, 2016. In certain crash conditions, the front impact sensor wiring may be pulled until it detaches before a signal can be received by the Occupant Restraint Controller (ORC).
Consequence & remedy
Consequence: If the ORC module does not receive a signal from the front impact sensor, both frontal air bags and the seat belt pretensioners will not deploy in the event of a crash, increasing the risk of injury.
Remedy: Chrysler will notify owners, and dealers will reroute the front impact sensor wiring and relocate the impact sensor branch, free of charge. The recall began on November 10, 2016. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is S76.
May 11, 2016
Chrysler (FCA US LLC) is recalling certain model year 2011-2016 Right Hand Drive Jeep Wrangler vehicles manufactured February 16, 2010, to May 2, 2016. The clockspring assembly may become contaminated with dust and cause the air bag circuit to fail.
Consequence & remedy
Consequence: Failure of the air bag circuit may prevent the driver's frontal air bag from deploying in the event of a crash, increasing the risk of injury.
Remedy: Chrysler will notify owners, and dealers will replace the clockspring, wheel back cover, and column shroud, free of charge. The recall began on August 11, 2016. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is S40.
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
3EA21002 · 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.
PE19008 · Seat Belt Buckle Bracket Failure
Opened Jul 29, 2019 · Closed Dec 12, 2019
Status: closed (inferred from source dates) · Seat Belts:front:buckle Assembly
On July 17, 2019, NHTSA's Office of Defects Investigation (ODI) opened Preliminary Evaluation (PE) 19-008 after receiving three Vehicle Owner Questionnaire (VOQ) reports alleging the driver's side seat belt buckle separated from the seat frame, rendering the seat belt non-functional. The VOQs involved model year (MY) 2015 and 2016 Jeep Wrangler (JK platform) that were configured for right-hand drive (RHD) use. On August 8, 2019, ODI issued an information request (IR) letter to FCA.The scope of the IR included all JK Wrangler produced for sale in the U.S. (both left- and right-hand drive), and amongst other things, requested any reports or allegations of driver's seat belt bracket failures on these vehicles. In its review of FCA's response, ODI determined that approximately 1.7 million JK Wrangler were produced from MY 2007 to 2018, about 16,000 of which were configured for RHD. ODI notes that the RHD Wrangler are typically used for rural postal delivery which often experience a more severe duty cycle. Also RHD JK was was not produced in MY 2007.As explained in the IR response, FCA identified three distinct populations of JK Wrangler concerning the driver's seat belt bucket bracket; specifically the MY 2007-2018 LHD (~1.7M units), the MY 2008-2010 RHD (4,563 units), and the MY 2011-2018 RHD (11,463 units) populations.FCA provided details on the designs used in each of these populations, identifying specific differences deemed pertinent to the strength and durability of each unique bracket design. FCA further reviewed its analysis of the complaint and warranty data identified under the IR, and noting that it had not identified any allegations of bracket failures on the LHD population, and only one allegation on the MY 2008-2010 RHD vehicles. By comparison, FCA identified 24 allegations of bracket failure for the MY 2011-2018 RHD JK, including two reports duplicative of the VOQs. Neither the FCA nor the VOQ reports allege an injury or fatality due to bracket failure. Based on this analysis, FCA decided to conduct a safety recall for the MY 2011-2018 RHD JK population. On September 30, 2019, FCA submitted a Defect Information Report initiating NHTSA Safety Recall 19V-680 (FCA No. VA6). Under the recall action, FCA will replace the driver's seat belt bracket on MY 2011-2018 RHD Jeep JK Wrangler. The repair will be conducted free of charge.In view of FCA's recall action, and its explanations of the scope of that action, ODI is closing PE19-008. ODI will continue to monitor the non-recalled RHD, and the LHD JK Wrangler for evidence of seat belt bracket failure and will take further action if warranted.The three VOQ reports cited above can be reviewed at NHTSA.gov under the following reference numbers:11190251, 11218472, 11231639.
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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