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2012 Dodge RAM 1500

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2012 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

472 reports with mileage · 225 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 175 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 163 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel/propulsion System. Review the 92 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

32 crash reports10 fire reports20 injury reports

Electrical System complaints

175 reports
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60,000 miles · Jun 1, 2015
Air BagsElectrical System

TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. WHILE DRIVING 20 MPH, THE AIR BAG WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE WIRING HARNESS WAS DEFECTIVE AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED DUE TO THE PART NOT BEING AVAILABLE. THE MANUFACTURER WAS NOTIFIED. T…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. WHILE DRIVING 20 MPH, THE AIR BAG WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE WIRING HARNESS WAS DEFECTIVE AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED DUE TO THE PART NOT BEING AVAILABLE. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 60,000.

NHTSA ODI #10722675

109,000 miles · May 23, 2015
Electrical System

THE VEHICLE HAS SHUT OFF NUMEROUS TIMES WHILE DRIVING DUE TO A FAULTY IGNITION SWITCH.

NHTSA ODI #10721107

68,000 miles · Feb 18, 2015
Air BagsElectrical SystemPower Train

TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. WHILE DRIVING 35 MPH AND MAKING A TURN, THERE WAS A DELAYED RESPONSE WHEN THE ACCELERATOR PEDAL WAS ENGAGED. THE TRACTION CONTROL WARNING LIGHT ILLUMINATED CONTINUOUSLY DURING THE FAILURE. ON NUMEROUS OCCASIONS, THE KEY BECAME STUCK IN THE IGNITION SWITCH UNTIL AFTER REPEATED ATTEMPTS.…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. WHILE DRIVING 35 MPH AND MAKING A TURN, THERE WAS A DELAYED RESPONSE WHEN THE ACCELERATOR PEDAL WAS ENGAGED. THE TRACTION CONTROL WARNING LIGHT ILLUMINATED CONTINUOUSLY DURING THE FAILURE. ON NUMEROUS OCCASIONS, THE KEY BECAME STUCK IN THE IGNITION SWITCH UNTIL AFTER REPEATED ATTEMPTS. IN ADDITION, THE GEAR SHIFTER MOVED OUT OF GEAR WHEN SLIGHTLY TOUCHED WHEN DRIVING. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE CLOCK SPRING WOULD NEED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE ISSUE. THE APPROXIMATE FAILURE MILEAGE WAS 68,000.

NHTSA ODI #10683982

45,015 miles · Feb 10, 2015
Electrical SystemService BrakesSteering

WHILE TRAVELING DOWN ROAD THE VEHICLE JUST SHUT OFF LOSING STEERING AND BRAKING WAS ABLE TO PUT IN NEUTRAL AND GET STARTED AFTER SEVERAL TRIES OF STARTING AND IT WOULD SHUT RIGHT BACK OFF BEFORE IT WOULD START AND STAY RUNNING, IT HAS DONE THIS NUMEROUS TIMES SOMETIMES WHEN FIRST STARTING VEHICLE SOMETIMES RIGHT AFTER STARTING…

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WHILE TRAVELING DOWN ROAD THE VEHICLE JUST SHUT OFF LOSING STEERING AND BRAKING WAS ABLE TO PUT IN NEUTRAL AND GET STARTED AFTER SEVERAL TRIES OF STARTING AND IT WOULD SHUT RIGHT BACK OFF BEFORE IT WOULD START AND STAY RUNNING, IT HAS DONE THIS NUMEROUS TIMES SOMETIMES WHEN FIRST STARTING VEHICLE SOMETIMES RIGHT AFTER STARTING AND DRIVING OFF, IT HAS DID THIS SEVERAL TIMES PULLING OUT OF MY DRIVEWAY ONTO BUSY HIGHWAY ALMOST RESULTING IS AN ACCIDENT. IT HAPPENED TO MY WIFE A COUPLE OF TIMES THE FIRST TIME SHE COULD NOT GET IT TO START AND STAY RUNNING TO GET IT OUT OF THE ROADWAY AND HAD TO PUT THE EMERGENCY FLASHERS ON AND LEAVE IT SETTING ACROSS THE SOUTH BOUND LANE OF THE HIGHWAY TO COME BACK INSIDE TO GET ME TO TRY TO GET IT OUT OF THE ROAD. AFTER THAT INCIDENT SHE WAS AFRAID TO DRIVE IT,TOOK TO DEALERSHIP 02/09/15 GOT BACK TODAY 02/10/15 THEY HAD TO REPLACE IGNITION SWITCH MODULE AT A COST OF $286.75 THIS WAS A SERIOUS SAFETY ISSUE AND NEEDS TO BE LOOKED INTO AND THERE SHOULD BE A RECALL ISSUED FOR THIS PROBLEM BEFORE THERE IS A SERIOUS ACCIDENT RESULTING IN SERIOUS INJURY OR A FATALITY. THERE WAS A RECALL ISSUED FOR THE SAME PROBLEM ON THE DODGE CARAVAN'S AND DODGE JOURNEY'S WITH THE SAME TYPE WIN (WIRELESS IGNITION NODE) IGNITION SWITCH. *TR

NHTSA ODI #10682656

47,000 miles · Oct 30, 2014
Electrical System

TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 55 MPH, THE ENGINE STALLED WITHOUT WARNING. THE VEHICLE WAS ABLE TO BE RESTARTED. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE KEY WAS LOOSE AND CAUSING THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUF…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 55 MPH, THE ENGINE STALLED WITHOUT WARNING. THE VEHICLE WAS ABLE TO BE RESTARTED. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE KEY WAS LOOSE AND CAUSING THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 47,000. UPDATED 12/17/14*LJ THE CONSUMER STATED THE VEHICLE WAS REPAIRED BY REPLACING THE ELECTRONIC MODULE. UPDATED 9/29/2015 *JS

NHTSA ODI #10651330

21,000 miles · Oct 8, 2014
Electrical System

TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT STATED THAT THE VEHICLE HESITATED TO START AFTER SEVERAL ATTEMPTS. THE FAILURE OCCURRED ON MULTIPLE OCCASIONS. THE VEHICLE WAS TOWED TO A DEALER WHO STATED THAT THE TIPM MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED. THE MANUFACTURER WAS N…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT STATED THAT THE VEHICLE HESITATED TO START AFTER SEVERAL ATTEMPTS. THE FAILURE OCCURRED ON MULTIPLE OCCASIONS. THE VEHICLE WAS TOWED TO A DEALER WHO STATED THAT THE TIPM MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 21,000.

NHTSA ODI #10643403

45,000 miles · Aug 13, 2014
Electrical SystemFire

ON JULY 8, 2014 MY 2012 RAM 1500 CAUGHT FIRE WHILE PARKED IN MY DRIVEWAY AT HOME. THE VEHICLE WAS LAST OPERATED ON THE EVENING OF JULY 7, 2014. AT APPROXIMATELY NOON ON JULY 8, 2014 WHILE WORKING ON MY COMPUTER INSIDE MY HOUSE I DETECTED THE ODOR OF BURNING PLASTIC. I ASSUME IT WAS INITIALLY ORIGINATING FROM INSIDE MY HOUSE. AFT…

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ON JULY 8, 2014 MY 2012 RAM 1500 CAUGHT FIRE WHILE PARKED IN MY DRIVEWAY AT HOME. THE VEHICLE WAS LAST OPERATED ON THE EVENING OF JULY 7, 2014. AT APPROXIMATELY NOON ON JULY 8, 2014 WHILE WORKING ON MY COMPUTER INSIDE MY HOUSE I DETECTED THE ODOR OF BURNING PLASTIC. I ASSUME IT WAS INITIALLY ORIGINATING FROM INSIDE MY HOUSE. AFTER INVESTIGATING I WALKED OUTSIDE AND FOUND THAT THE INTERIOR OF MY TRUCK WAS ON FIRE. I PUT OUT THE FIRE AND IMMEDIATELY CALLED THE LOCAL FIRE DEPARTMENT WHO RESPONDED TO ENSURE THAT THE FIRE WAS COMPLETELY OUT. I IMMEDIATELY CONTACTED MY INSURANCE COMPANY IN ADDITION TO THE LOCAL DEALER, JEFF D'AMBORSIO AUTO GROUP, I SPOKE WITH THE SERVICE MANAGER WHO IN TURN CONTACTED HIS REGIONAL MANAGER FOR GUIDANCE. I RECEIVED A LETTER DATE JULY 10, 2014 FROM THE CHRYSLER CUSTOMER CLAIMS RESOLUTION GROUP ADVISING THEY WERE IN THE PROCESS OF REVIEWING MY FILE. I WAS CONTACTED BY THE RESOLUTION GROUP AND ADVISED THE FILE WAS BEING TURNED OVER TO A GROUP, ISG, FOR FURTHER INVESTIGATION IN RESOLUTION. CHRYSLER ARRANGED TO HAVE THE VEHICLE TOWED ON JULY 12, 2014 TO THE JEFF D' AMBROSIO DEALERSHIP WHERE A REPRESENTATIVE FROM CHRYSLER WAS TO INSPECT THE VEHICLE. THAT INSPECTION TOOK PLACE ON TUESDAY, JULY 15TH. THE ORIGIN OF THE FIRE ACCORDING TO THE INSURANCE COMPANY FIRE INVESTIGATOR ORIGINATED IN THE PASSENGER SIDE DOOR PANEL AND RESULTED IN TOTAL DAMAGES OF $23,000 WHICH THE INSURANCE COMPANY DEEMED A TOTAL LOSS. MY INSURANCE COMPANY SETTLED A CLAIM BY PAYING OFF THE LOAN BALANCE OF $19,500 AND SUBMITTED A CHECK TO ME FOR THE EXCESS TO COVER THE VALUE OF THE VEHICLE. UNFORTUNATELY I AM NOT PROVIDED RESULTS OF THE INVESTIGATION PERFORMED AT THE DEALERSHIP BY THE REPRESENTATIVE FROM CHRYSLER. THE CASE NUMBER ASSIGNED BY CHRYSLER [XXX]. AS OF TODAY, AUGUST 13 I HAVE NO RESOLUTION DIRECTLY FROM CHRYSLER. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10621930

56,000 miles · Jun 9, 2014
Electrical SystemStructure

EVERYTHING WAS ALRIGHT, WE PARKED THE TRUCK CAME OUT AND IT WOULDN'T OPEN THE DOOR, SO WE MANUALLY OPENED THE DOOR. IT WAS JUST DEAD. WE HAD IT TOWED TO A DODGE DEALER IN PRICE, UTAH. WE HAVE ONLY HAD THIS VEHICLE FOR ABOUT A YEAR AND A HALF. THE COMPUTER OFF THE KEY IGNITION WAS GONE. IT COSTS US $924.00. *TR

NHTSA ODI #10597137

43,200 miles · May 15, 2014
Electrical SystemExterior Lighting

I HAD BOTH THE HIGH AND LOW BEAM ON THE PASSENGER SIDE OUT ON MAY 9TH. I TOOK IT TO THE DEALER AND TOLD THEM THAT IT SEEMED STRANGE BOTH BULBS WOULD GO OUT AT THE SAME TIME. THE DEALER PULLED THE FRONT END APART AND CHANGED BOTH BULBS ON THE PASSENGER SIDE AND TOLD ME THEY WERE BURNED OUT AND ARE NOW FIXED. MAY 10TH AT 6:30AM I …

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I HAD BOTH THE HIGH AND LOW BEAM ON THE PASSENGER SIDE OUT ON MAY 9TH. I TOOK IT TO THE DEALER AND TOLD THEM THAT IT SEEMED STRANGE BOTH BULBS WOULD GO OUT AT THE SAME TIME. THE DEALER PULLED THE FRONT END APART AND CHANGED BOTH BULBS ON THE PASSENGER SIDE AND TOLD ME THEY WERE BURNED OUT AND ARE NOW FIXED. MAY 10TH AT 6:30AM I GOT UP AND STARTED MY TRUCK AND ONCE AGAIN THE PASSENGER SIDE HIGH AND LOW BEAM LIGHT WAS OUT. THE DEALER TOLD ME THE TECHNICIAN ACTUALLY MADE SURE IT WAS ONLY THE BULB NO WIRING OR CONNECTION PROBLEM AND DOES NOT KNOW WHY IT IS OUT AGAIN. IT IS VERY DANGEROUS AND ALSO A VIOLATION TO BE DRIVING WITH A HEADLIGHT OUT IN THE STATE OF MARYLAND. SEVERAL OTHER PEOPLE HAVE REPORTED THIS PROBLEM WITH THE FAULTY ELECTRICAL CONNECTION TO THE HEADLIGHTS AND SOMETHING SHOULD BE DONE BEFORE THEIR IS AN ACCIDENT OR WORSE. IT IS NOW IN THE SAME DEALER AGAIN TO SEE WHAT EXCUSE OTHER THAN A BULB ISSUE THEY CAN COME UP WITH TO CHARGE ME AGAIN. I WOULD HIGHLY RECOMMEND DODGE LOOK INTO THIS AND FIX IT IMMEDIATELY. *TR

NHTSA ODI #10588648

Mileage unknown · Apr 4, 2014
Electrical System

DRIVING OUT OF HOME TO WORK, LIGHT DASH PANEL TURNED OFF AND ON, THE WINDSHIELD WIPERS CAME ON WITHOUT BEING ON, SWITCH IN THE OFF POSITION, THE RADIO TURNED OFF AND ON, AND NOW DOES NOT WORK AT ALL. HAVE LEFT VEHICLE WITH AUTO NATION DODGE IN SPRING, TX AND THEY HAVE HAD IT IN THE SERVICE CENTER FOR 2 DAYS NOW AND ARE UNABLE TO…

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DRIVING OUT OF HOME TO WORK, LIGHT DASH PANEL TURNED OFF AND ON, THE WINDSHIELD WIPERS CAME ON WITHOUT BEING ON, SWITCH IN THE OFF POSITION, THE RADIO TURNED OFF AND ON, AND NOW DOES NOT WORK AT ALL. HAVE LEFT VEHICLE WITH AUTO NATION DODGE IN SPRING, TX AND THEY HAVE HAD IT IN THE SERVICE CENTER FOR 2 DAYS NOW AND ARE UNABLE TO FIND OUT WHAT IS CAUSING THIS DANGEROUS ISSUE. *TR

NHTSA ODI #10577428

Official recalls

6

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.

17V824000 · Equipment

Dec 21, 2017

Chrysler (FCA US LLC) is recalling various Dodge, Chrysler, and RAM vehicles equipped with Kidde Plastic-Handle or Push Button 'Pindicator' Fire Extinguishers. A list of the affected trailer models is available at: https://static.nhtsa.gov/odi/rcl/2017/RMISC-17V824-0103.pdf. These extinguishers may become clogged, preventing the extinguisher from discharging as expected or requiring excessive force to activate the extinguisher. Additionally, in certain models, the nozzle may detach from the valve assembly with enough force that it could cause injury and also render the product inoperable. For a full list of the affected fire extinguisher models visit: https://static.nhtsa.gov/odi/rcl/2017/RMISC-17E062-5427.pdf

Consequence & remedy

Consequence: If the fire extinguisher does not function properly, it can increase the risk of injury in the event of a fire.

Remedy: Chrysler will notify owners instructing them to contact Kidde for a replacement fire extinguisher, free of charge. The recall began February 14, 2018. Owners may contact Chrysler customer service at 1-800-853-1403 or Kidde customer service service toll-free at 1-855-262-3540, or online at www.kidde.com and click on "Product Safety Recall" for more information. Chrysler's number for this recall is T82.

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.

15V459000 · Air Bags:frontal

Jul 22, 2015

Chrysler (FCA US LLC) is recalling certain model year 2012-2014 Ram 1500, 2500, 3500, 4500, and 5500 trucks manufactured January 18, 2011, to October 7, 2014, and equipped with the Electronic Vehicle Information Center option. The affected vehicles have a steering wheel wiring harness that may rub against the driver air bag module retainer spring.

Consequence & remedy

Consequence: This abrasion may result in an electrical short that could cause driver's frontal air bag to unexpectedly deploy. Inadvertent deployment of the air bag may increase the risk of injury and the possibility of a vehicle crash.

Remedy: Chrysler will notify owners, and dealers will inspect, repair as necessary, and secure the steering wheel wiring harness. Additionally, protective caps will be added to the air bag retainer spring ends. These repairs will be done free of charge. The recall began on September 18, 2015. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is R36.

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.

12V192000 · Equipment:other:labels

May 2, 2012

CHRYSLER IS RECALLING CERTAIN MODEL YEAR 2012 RAM 1500 TRUCKS, MANUFACTURED FROM JANUARY 5, 2012 THROUGH JANUARY 6, 2012. THE AFFECTED VEHICLES HAVE A SPARE TIRE THAT DOES NOT MATCH THE SPECIFICATIONS LISTED ON THE TIRE PLACARD. THUS, THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 110, “TIRE SELECTION AND RIMS.”

Consequence & remedy

Consequence: IF INSTALLED, THE INCORRECTLY SIZED SPARE TIRE MAY UNEXPECTEDLY ACTIVATE THE ELECTRONIC STABILITY CONTROL (ESC) SYSTEM, ALTERING THE EFFECTIVENESS OF THE ESC SYSTEM, INCREASING THE RISK OF A CRASH.

Remedy: CHRYSLER WILL NOTIFY OWNERS, AND DEALERS WILL INSPECT AND REPAIR VEHICLES AS NECCESSARY FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MAY 21, 2012. OWNERS SHOULD 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.