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2011 Dodge RAM 1500

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2011 Dodge RAM 1500 do not stand out strongly from the model-year median of 520.

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When problems were reported

Mileage at the reported incident

491 reports with mileage · 197 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.

  • Electrical System. Review the 214 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 175 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 151 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

28 crash reports7 fire reports17 injury reports

What owners actually said

688 reports
Mileage unknown · Apr 2, 2016
Fuel/propulsion System

WHEN REFUELING THE VEHICLE AT A TYPICAL GAS STATION, AND THE STATION'S FUEL PUMP SHUTS OFF AUTOMATICALLY, FUEL COMES UP THE FUEL FILLER NECK AND WASHES DOWN THE SIDE OF THE VEHICLE AND ONTO THE GROUND. THIS DOES NOT HAPPEN EVERY TIME, BUT DOES HAPPEN MOST OF THE TIME, AND AT VARIOUS STATION LOCATIONS AND VARIOUS STATION COMPA…

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WHEN REFUELING THE VEHICLE AT A TYPICAL GAS STATION, AND THE STATION'S FUEL PUMP SHUTS OFF AUTOMATICALLY, FUEL COMES UP THE FUEL FILLER NECK AND WASHES DOWN THE SIDE OF THE VEHICLE AND ONTO THE GROUND. THIS DOES NOT HAPPEN EVERY TIME, BUT DOES HAPPEN MOST OF THE TIME, AND AT VARIOUS STATION LOCATIONS AND VARIOUS STATION COMPANIES. I'VE READ OTHER REPORTS THAT INDICATE THIS IS AN ISSUE THAT HAS AFFECTED OTHER OWNERS OF SIMILAR VEHICLES. AS SOON AS I DESCRIBED THE PROBLEM TO THE SERVICE MANAGER AT THE LOCAL DODGE DEALER, HE WAS FAMILIAR WITH THE PROBLEM. PER THE SERVICE MANAGER, THIS ISSUE HAS ONLY BEEN ADDRESSED WITH REGARD TO A FEW VEHICLE MODELS AND YEARS, AND THIS ONE IS NOT COVERED. WORKING WITH DODGE CUSTOMER SERVICE, A CASE NUMBER HAS BEEN OPENED. THE DODGE CUSTOMER SERVICE REP SPOKE WITH THE SERVICE MANAGER AT THE LOCAL DODGE DEALER, AND THEY WERE ABLE TO LOWER THE COST OF THE LABOR TO REPLACE THE FUEL TANK FILLER TUBE, HOWEVER WE WILL BE EXPECTED TO PAY FOR THE PART AND THE REPAIR FOR A KNOWN DEFECT. PLEASE NOTE THAT THE 'WHEN DID THIS HAPPEN' AND THE "ABOUT HOW MANY MILES WERE ON YOUR VEHICLE AT THE TIME OF THE INCIDENT' FIELDS DON'T REALLY APPLY, AS THIS IS AN ONGOING ISSUE, AND CAN HAPPEN ANY TIME I GO THE THE GAS STATION TO FILL UP THE VEHICLE. THE DATE I PROVIDED FOR THE 'WHEN DID THIS HAPPEN' FIELD IS THE DATE THAT I VISITED THE LOCAL DODGE DEALER AND SPOKE WITH DODGE CUSTOMER SERVICE.

NHTSA ODI #10853123

55,074 miles · Mar 25, 2016
Power Train

TL* THE CONTACT OWNS A 2011 RAM 1500. THE CONTACT STATED THAT THE VEHICLE SHIFTED INDEPENDENTLY INTO NEUTRAL. AFTER THE FAILURE OCCURRED, THE VEHICLE WOULD NOT SHIFT INTO PARK UNTIL AFTER THE VEHICLE WAS RESTARTED. THE FAILURE OCCURRED EVERYDAY. THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED NOR RE…

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TL* THE CONTACT OWNS A 2011 RAM 1500. THE CONTACT STATED THAT THE VEHICLE SHIFTED INDEPENDENTLY INTO NEUTRAL. AFTER THE FAILURE OCCURRED, THE VEHICLE WOULD NOT SHIFT INTO PARK UNTIL AFTER THE VEHICLE WAS RESTARTED. THE FAILURE OCCURRED EVERYDAY. THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 55,074.

NHTSA ODI #10851552

72,000 miles · Mar 24, 2016
EngineService BrakesSteering

WHILE DRIVING ON A 2 LANE ROAD AT 50 MPH APPROX SPEED, THE ENGINE SHUT OFF. POWER STEERING AND POWER BRAKES BECAME EXTREMELY STIFF, BUT I WAS ABLE TO MUSCLE TRUCK TO SHOULDER. AFTER STOPPING, I PUT IT IN PARK, THE KEY WAS STILL IN ON POSITION; TURNED KEY AND ENGINE STARTED. I HAVE OWNED THIS TRUCK FOR 45 DAYS AND THIS HAS HAP…

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WHILE DRIVING ON A 2 LANE ROAD AT 50 MPH APPROX SPEED, THE ENGINE SHUT OFF. POWER STEERING AND POWER BRAKES BECAME EXTREMELY STIFF, BUT I WAS ABLE TO MUSCLE TRUCK TO SHOULDER. AFTER STOPPING, I PUT IT IN PARK, THE KEY WAS STILL IN ON POSITION; TURNED KEY AND ENGINE STARTED. I HAVE OWNED THIS TRUCK FOR 45 DAYS AND THIS HAS HAPPENED TWICE AT TOTALLY RANDOM TIMES. I AM VERY FORTUNATE I WAS ON A ROAD WITHOUT MUCH TRAFFIC. HAD I BEEN IN A STEERING, PASSING OR OTHER SITUATION, I COULD HAVE BEEN IN A SERIOUS ACCIDENT I LEARNED FROM INTERNET THAT THIS IS A FREQUENT COMPLAINT OF RAM OWNERS AND OTHER CHRYSLER PRODUCT VEHICLE OWNERS, AND THAT A RECALL HAS BEEN ISSUED FOR CERTAIN CHRYSLER VEHICLES ALREADY. THE FAULTY PART WAS THE TIPM MODULE. THERE IS ALSO A CLASS ACTION LAWSUIT IN PROCESS INVOLVING OTHER CHRYSLER VEHICLES NOT YET RECALLED, INCLUDING THE MODEL I OWN. I TOOK THE VEHICLE INTO THE DEALER, AND THEY COULD NOT POSITIVELY IDENTIFY THE CAUSE. THEY WOULD NOT AGREE TO REPLACE TIPM EVEN THOUGH I'M UNDER WARRANTY, BUT INSTEAD WANTED TO DO SOFTWARE UPDATES ON SEVERAL "MODULES" AND SAID IF IT HAPPENED AGAIN, I SHOULD BRING IT BACK. TOTALLY UNACCEPTABLE!!! I CALLED RAM CUSTOMER CARE AND EXPLAINED THAT THE VEHICLE IS DANGEROUS AND THAT I CANNOT ACCEPT A SOFTWARE UPDATE IN THE HOPE IT FIXES IT GIVEN THE TIPM HISTORY OF THESE VEHICLES. THEY ADVISED THAT THERE WERE NO DIAGNOSTIC "CODES" PRESENT, SO THEY WOULD NOT REPLACE THE TIPM. THEY THEN ADMITTED THAT A FAULTY TIPM WOULD NOT PRODUCE ANY CODES, BUT AGAIN SAID THEY NEEDED TO RULE OUT A SOFTWARE ISSUE FIRST BY TRIAL AND ERROR AND REFUSED TO REPLACE THE TIPM EVEN THOUGH THERE WAS NO WAY TO DIAGNOSE IF IT WAS FAULTY. MY SON IS DRIVING THIS TRUCK TO COLLEGE, AND I AM NOT ABOUT TO RISK HIM BEING KILLED IN THIS VEHICLE SO I WAS FORCED TO PAY $1,350 FOR A NEW TIPM. RAM NEEDS TO RECALL THESE IMMEDIATELY.

NHTSA ODI #10851512

12,500 miles · Mar 13, 2016
Fuel/propulsion SystemVisibility/wiper

MY TIPM FUSE BOX . MY FUEL PUMP STAY ON WHEN I TURN OFF THE PICK UP AND WHEN IM DRIVING ON THE HIGHWAY IT WILL JUST SHUT DOWN NOW IT WILL NOT START WHEN COLD.(DEALERSHIP) SEZ IT A BAD FUEL PUMP RELAY THAT IS INTERGRATED TO THE FUSE BOX. MY WIPERS WILL SHUT OFF WHILE DRIVING IN THE RAIN. (DEALERSHIP) SEZ IT'S THE FUSE BOX AND HA…

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MY TIPM FUSE BOX . MY FUEL PUMP STAY ON WHEN I TURN OFF THE PICK UP AND WHEN IM DRIVING ON THE HIGHWAY IT WILL JUST SHUT DOWN NOW IT WILL NOT START WHEN COLD.(DEALERSHIP) SEZ IT A BAD FUEL PUMP RELAY THAT IS INTERGRATED TO THE FUSE BOX. MY WIPERS WILL SHUT OFF WHILE DRIVING IN THE RAIN. (DEALERSHIP) SEZ IT'S THE FUSE BOX AND HAS TO BE REPLACED FOR $1,000 MY TRUCK ONLY HAS 12,500 MILES ON IT AND IS 5YRS OLD. DEALERSHIP TELLS ME IT IS A PROBLEM WITH THESE VEHICLES.

NHTSA ODI #10846316

61,000 miles · Mar 9, 2016
Service BrakesSteeringCrashInjury

TL* THE CONTACT OWNS A 2011 RAM 1500. WHILE DRIVING APPROXIMATELY 25 MPH MAKING A RIGHT TURN, THE VEHICLE SHOOK HARD WITHOUT WARNING. THE BRAKE PEDAL TRAVELED TO THE FLOOR WHEN IT WAS DEPRESSED. THE CONTACT HAD NO CONTROL OVER THE STEERING AND THE WHEEL WOULD NOT MOVE. THE CONTACT CRASHED INTO ANOTHER VEHICLE AND THE BRAKES RETU…

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TL* THE CONTACT OWNS A 2011 RAM 1500. WHILE DRIVING APPROXIMATELY 25 MPH MAKING A RIGHT TURN, THE VEHICLE SHOOK HARD WITHOUT WARNING. THE BRAKE PEDAL TRAVELED TO THE FLOOR WHEN IT WAS DEPRESSED. THE CONTACT HAD NO CONTROL OVER THE STEERING AND THE WHEEL WOULD NOT MOVE. THE CONTACT CRASHED INTO ANOTHER VEHICLE AND THE BRAKES RETURNED TO NORMAL. THE CONTACT SUSTAINED INJURIES TO THE NECK AND A KNOT ON THE LEFT SIDE. MEDICAL ATTENTION WAS NOT REQUIRED. A POLICE REPORT WAS FILED. THE CONTACT WAS ABLE TO DRIVE THE VEHICLE TO HIS RESIDENCE. THE APPROXIMATE FAILURE MILEAGE WAS 61,000.

NHTSA ODI #10845834

97,000 miles · Mar 8, 2016
Electrical SystemFuel/propulsion System

"TAKATA RECALL" MY 2011 RAM 1500 STOPED IN THE MIDDLE OF THE CITY STREET AND STEERING WHEEL GOT HARD AND IT WAS HARD TO START UP. SO I TOOK IT TO GET FIXED THEY SAID IT WAS THE FUEL PUMP SO WE REPLACED IT,THEN I WOULD TURN THE KEY AND IT WOULD STAY STUCK TRYING TO TURN ON KILLED MY BATTERY BOUGHT ANOTHER ONE CHANGED THE FUEL PU…

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"TAKATA RECALL" MY 2011 RAM 1500 STOPED IN THE MIDDLE OF THE CITY STREET AND STEERING WHEEL GOT HARD AND IT WAS HARD TO START UP. SO I TOOK IT TO GET FIXED THEY SAID IT WAS THE FUEL PUMP SO WE REPLACED IT,THEN I WOULD TURN THE KEY AND IT WOULD STAY STUCK TRYING TO TURN ON KILLED MY BATTERY BOUGHT ANOTHER ONE CHANGED THE FUEL PUMP AGAIN NOW THE FUEL PUMP WILL NOT TURN OFF UNTIL I PULL THE FUSE NOW THE SAY IT'S THE TIPM I CALLED THE DEALER AND SAID NO RECALL BUT I'M HAVING ALL THE PROBLEMS AS THE CARS THAT DO! I PUT ALL THAT I HAD TO GET A RELIABLE TRUCK FOR MY KIDS AND I AND THIS HAPPENS.

NHTSA ODI #10845638

Mileage unknown · Mar 3, 2016
Steering

2011 RAM 2500. ATTORNEY REPRESENTING CONSUMER WRITES IN REGARDS TO LEFT TIE ROD STUD RECALL NOTICE AND OPTION 2 REPURCHASE ISSUES. *LD THE CONSUMER WANTED CHRYSLER TO PURCHASE THE VEHICLE BACK FROM HIM. THE DEALER INFORMED THE CONSUMER, THEY DID NOT HAVE ANY INFORMATION ON THE BUY BACK. EVENTUALLY, THE REPAIRS WERE DONE. THE…

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2011 RAM 2500. ATTORNEY REPRESENTING CONSUMER WRITES IN REGARDS TO LEFT TIE ROD STUD RECALL NOTICE AND OPTION 2 REPURCHASE ISSUES. *LD THE CONSUMER WANTED CHRYSLER TO PURCHASE THE VEHICLE BACK FROM HIM. THE DEALER INFORMED THE CONSUMER, THEY DID NOT HAVE ANY INFORMATION ON THE BUY BACK. EVENTUALLY, THE REPAIRS WERE DONE. THE CONSUMER WAS INFORMED THE OPTION OF BUYING THE VEHICLE BACK WAS NO LONGER AN OPTION. *JB

NHTSA ODI #10838417

62,000 miles · Mar 2, 2016
Exterior Lighting

TL* THE CONTACT OWNS A 2011 RAM 1500. WHILE THE VEHICLE WAS PARKED, THE PASSENGER SIDE LOW AND HIGH BEAM HEADLAMPS FAILED TO ILLUMINATE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO WAS UNABLE TO DIAGNOSE OR REPAIR THE VEHICLE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 62,000. UPDATED 04/21/…

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TL* THE CONTACT OWNS A 2011 RAM 1500. WHILE THE VEHICLE WAS PARKED, THE PASSENGER SIDE LOW AND HIGH BEAM HEADLAMPS FAILED TO ILLUMINATE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO WAS UNABLE TO DIAGNOSE OR REPAIR THE VEHICLE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 62,000. UPDATED 04/21/2016*LJ THE CONSUMER TOOK THE VEHICLE TO AN INDEPENDENT MECHANIC, WHO THEN CONTACTED THE DEALER. THEY STATED THE PROBLEM WAS POWER TRAIN CONTROL MODULE AND ONLY THEY COULD REPLACE IT. UPDATED 09/07/16.*JB

NHTSA ODI #10839386

40,000 miles · Feb 25, 2016
Electrical SystemService BrakesVehicle Speed ControlCrash

TL* THE CONTACT OWNS A 2011 RAM 1500. WHILE THE VEHICLE WAS STOPPED AT A STOP SIGN, THE VEHICLE ACCELERATED WITHOUT WARNING TO APPROXIMATELY 100 MPH. THE CONTACT ATTEMPTED TO APPLY THE BRAKES, BUT THE BRAKES FAILED. THE CONTACT TURNED THE IGNITION OFF AND THE INTERIOR LIGHTS TURNED OFF; HOWEVER, THE VEHICLE FAILED TO STOP. THE C…

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TL* THE CONTACT OWNS A 2011 RAM 1500. WHILE THE VEHICLE WAS STOPPED AT A STOP SIGN, THE VEHICLE ACCELERATED WITHOUT WARNING TO APPROXIMATELY 100 MPH. THE CONTACT ATTEMPTED TO APPLY THE BRAKES, BUT THE BRAKES FAILED. THE CONTACT TURNED THE IGNITION OFF AND THE INTERIOR LIGHTS TURNED OFF; HOWEVER, THE VEHICLE FAILED TO STOP. THE CONTACT SHIFTED INTO NEUTRAL AND THE VEHICLE RAN OFF THE ROAD. THE VEHICLE CAME TO A COMPLETE STOP. THE CONTACT ATTEMPTED TO START THE VEHICLE AND THE ENGINE REVVED EVEN THOUGH THE IGNITION WAS TURNED OFF. PRIOR TO THE FAILURE, THE VEHICLE CAME TO A ROLLING STOP WHEN IT WAS PLACED IN PARK. THE VEHICLE WAS TOWED TO THE DEALER. THE DEALER DIAGNOSED THAT THERE WAS NO FAILURE. THE VEHICLE HAD NOT BEEN REPAIRED. THE CONTACT WAS NOT INJURED AND A POLICE REPORT WAS NOT FILED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OFFERED TO SELL THE CONTACT A NEW VEHICLE. THE APPROXIMATE FAILURE MILEAGE WAS 40,000.

NHTSA ODI #10838497

Mileage unknown · Feb 25, 2016
Electrical System

TL* THE CONTACT OWNS A 2011 RAM 1500. THE CONTACT STATED THAT THERE WAS AN INTERNAL ELECTRICAL MALFUNCTION THAT DRAINED THE BATTERY VOLTAGE RANDOMLY AND THE VEHICLE STALED. THE BATTERY AND TWO FUSES WERE REPLACED BY THE CONTACT, BUT THE FAILURE RANDOMLY PROGRESSED. THE DEALER DIAGNOSED THAT THE INSTRUMENT CLUSTER/COMPUTER NEEDED…

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TL* THE CONTACT OWNS A 2011 RAM 1500. THE CONTACT STATED THAT THERE WAS AN INTERNAL ELECTRICAL MALFUNCTION THAT DRAINED THE BATTERY VOLTAGE RANDOMLY AND THE VEHICLE STALED. THE BATTERY AND TWO FUSES WERE REPLACED BY THE CONTACT, BUT THE FAILURE RANDOMLY PROGRESSED. THE DEALER DIAGNOSED THAT THE INSTRUMENT CLUSTER/COMPUTER NEEDED TO BE REPLACED. THE CONTACT INDICATED THAT THE VEHICLE CONTINUED TO HAVE A SUDDEN LOSS OF POWER AND RANDOMLY STALLED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND WAS NOT ABLE TO PROVIDE A PERMANENT REMEDY FOR THE CONDITION SO THE CONTACT WAS UNABLE TO DETERMINE WHEN THE VEHICLE WOULD BE REPAIRED. THE VIN AND FAILURE MILEAGE WERE NOT AVAILABLE.

NHTSA ODI #10838460

Official recalls

4

18V160000 · Fuel System, Gasoline:storage:tank Assembly:mounting

Mar 8, 2018

Chrysler (FCA US LLC) is recalling certain 2009-2012 Dodge Ram 1500 trucks currently, or ever registered, in Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia. Exposure to environmental conditions such as water mixed with road salt may cause the front fuel tank strap frame "T-Slot" bracket to corrode, possibly causing the fuel tank to drop and make contact with the ground.

Consequence & remedy

Consequence: If the fuel tank were to drop and contact the ground, a fuel leak may result. Additionally, in the event of a crash, the fuel tank may not remain secured to the vehicle, possibly causing a fuel leak. A fuel leak in the presence in an ignition source, can increase the risk of a fire.

Remedy: Chrysler will notify owners and dealers will bolt a bracket reinforcement to the frame, free of charge. The recall began May 2, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is U04.

17V821000 · Power Train:automatic Transmission:lever And Linkage:column Shift

Dec 20, 2017

Chrysler (FCA US LLC) is recalling certain 2016-2017 Ram 3500 Cab Chassis with a Gross Vehicle Weight Rating (GVWR) of less than 10,000 lbs, 2011-2017 Ram 3500, 4500 and 5500 Cab Chassis vehicles, 2009-2017 Ram 1500 and 2010-2017 Ram 2500 and 3500 pickup trucks, all equipped with a column shifter. Pushing the brake pedal for prolonged periods when the vehicle is running and in PARK may cause the Brake Transmission Shift Interlock (BTSI) pin to stick in the open position. With the pin in the open position, the transmission can be shifted out of PARK into any gear without pushing the brake pedal or having the key in the ignition.

Consequence & remedy

Consequence: Being able to shift the transmission without pushing the brake pedal and/or without a key in the ignition can increase the risk of an unintended vehicle rollaway that may result in personal injury or a crash.

Remedy: Chrysler will notify owners, and dealers will update the vehicle software, inspect the BTSI, and, as necessary, replace it, free of charge. The recall began February 26, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is T79.

13V038000 · Power Train:driveline:differential Unit

Feb 6, 2013

Chrysler is recalling certain model year 2009-2012 Ram 1500 trucks manufactured from February 27, 2008, through June 30, 2009, and from December 1, 2009, through October 20, 2011; model year 2009-2011 Dodge Dakota trucks manufactured from February 27, 2007, through June 30, 2009, and from December 1, 2009, through September 30, 2011; model year 2009 Chrysler Aspen trucks manufactured from January 3, 2008, through December 18, 2008; and model year 2009 Dodge Durango trucks manufactured from January 3, 2008, through December 18, 2008. The rear axle pinion nut may loosen due to an undersized pinion spline that can allow relative motion between the nut and companion flange.

Consequence & remedy

Consequence: If the rear axle pinion nut loosens, the axle can lock up and cause a loss of vehicle control and/or a vehicle crash with little warning.

Remedy: On November 7, 2013 Chrysler notified owners that dealers would install a pinion nut retainer, free of charge. 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 N08.

10V656000 · Suspension:rear:axle:spindle

Dec 24, 2010

CHRYSLER IS RECALLING CERTAIN MODEL YEAR 2011 RAM 1500 TRUCKS MANUFACTURED FROM SEPTEMBER 2009 THROUGH DECEMBER 2010. SOME VEHICLES MAY HAVE EXPERIENCE A NOISE (GROWL, GRIND) COMING FROM THE REAR AXLE BEARING WHICH COULD EVENTUALLY SEIZE.

Consequence & remedy

Consequence: A FAILURE OF THE BEARING COULD CAUSE THE VEHICLE TO STALL INCREASING THE RISK OF A CRASH.

Remedy: CHRYSLER WILL NOTIFY OWNERS AND WILL INSTALL AN OIL PORT INSERT INTO THE REAR AXLE FREE OF CHARGE. THE SAFETY RECALL BEGAN ON APRIL 4, 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.