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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

Engine complaints

163 reports
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105,000 miles · Aug 3, 2015
Engine

GETTING OFF THE FREEWAY I LET GO OF THE GAS PEDAL TO COAST TO A COMPLETE STOP. WITHOUT WARNING THE TRUCK SHUT OFF IN THE MIDDLE OF THE OFF RAMP. STARTS RIGHT UP BUT MAKES A NOISE AS IF YOU WERE STARTING A COLD DIESEL ENGINE. IT'S HAPPENED 5 TIMES IN THE LAST 2 MONTHS AND THE DEALER COULD FIND OR FIX THE ISSUE.

NHTSA ODI #10745941

18,000 miles · Jul 13, 2015
Electrical SystemEngineFuel/propulsion System

AT ABOUT 18000 MILES ON VEHICLE IT SUDDENLY STALLED. THROTTLE BODY CONTROL LIGHT CAME ON, RPM DROPPED TO ALMOST ZERO. PUMPING GAS PEDAL HAD NO EFFECT. CONDITION LASTED ABOUT 15 TO 25 SECONDS. TOOK TRUCK TO DEALER AND WAS INFORMED IT NEEDED A THROTTLE BODY SOFTWARE UPDATE. THIS WAS DONE. ALSO WAS PERFORMED AGAIN LATER. THE STALLI…

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AT ABOUT 18000 MILES ON VEHICLE IT SUDDENLY STALLED. THROTTLE BODY CONTROL LIGHT CAME ON, RPM DROPPED TO ALMOST ZERO. PUMPING GAS PEDAL HAD NO EFFECT. CONDITION LASTED ABOUT 15 TO 25 SECONDS. TOOK TRUCK TO DEALER AND WAS INFORMED IT NEEDED A THROTTLE BODY SOFTWARE UPDATE. THIS WAS DONE. ALSO WAS PERFORMED AGAIN LATER. THE STALLING IS INTERMITTENT SOME TIMES NOT HAPPENING FOR WEEKS THEN AGAIN IT WILL HAPPEN UP TO 3 TIMES IN A WEEK.BIT ONCE STALLED ON MY LADY AS SHE WAS CROSSING AN INTERSECTION . VEHICLE NOW HAS 77000 MILES ON ODOMETER . I THOUGHT THIS JUST A HASSLE UNTIL ABOUT THREE WEEKS AGO. AS I WAS MERGING ON TO THE INTERSTATE AT ABOUT 65 MPH IN FRONT OF A BIG TRUCK THE VEHICLE STALLED FOR A LONG PERIOD. THE BIG RIG WAS WITHIN A VERY FEW FEET OF MY VEHICLE BEFORE ENGINE STARTED RUNNING AGAIN. NEEDLESS TO SAY THIS SCARED ME BIG TIME. THIS WAS WHEN I STARTED TO LOOK FOR SOMEONE TO BE IN MY CORNER ON THIS VEHICLE HAS BEEN SERVICED BY DODGE DEALERSHIP REGULARLY SINCE NEW. EACH TIME I HAVE REPORTED STALLS AND AT ONE TIME HAD A CASE OPENED WITH CHRYSLER. I AM TOLD THEY FIND NOTHING AND THEY ONLY HAVE MY WORD THIS IS HAPPENING. THIS FROM DEALER AND CHRYSLER

NHTSA ODI #10733679

Mileage unknown · May 18, 2015
EngineEngine And Engine CoolingFuel System, Diesel

TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 14V635000 (ENGINE AND ENGINE COOLING, FUEL SYSTEM, DIESEL) HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTUR…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 14V635000 (ENGINE AND ENGINE COOLING, FUEL SYSTEM, DIESEL) HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. UPDATED 8/27/15*CN

NHTSA ODI #10717147

Mileage unknown · May 5, 2015
EngineFuel/propulsion System

TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 14V635000 (ENGINE AND ENGINE COOLING, FUEL SYSTEM, DIESEL); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTU…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 14V635000 (ENGINE AND ENGINE COOLING, FUEL SYSTEM, DIESEL); HOWEVER, THE PART TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE.

NHTSA ODI #10714623

Mileage unknown · May 1, 2015
EngineFuel/propulsion System

TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 14V635000 (ENGINE AND ENGINE COOLING, FUEL SYSTEM, DIESEL) HOWEVER, THE PART NEEDED TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MAN…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 14V635000 (ENGINE AND ENGINE COOLING, FUEL SYSTEM, DIESEL) HOWEVER, THE PART NEEDED TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE.

NHTSA ODI #10714045

64,913 miles · Mar 1, 2015
EngineFuel/propulsion SystemVehicle Speed Control

UPON SELECTING TRANSMISSION "D" OPTION INSTRUMENT PANEL INDICATED "6", DROVE TO BARN FOR HORSE FEED. NEEDING TO BACK UP TO FENCE, TO DISPERSE FEED, TRANSMISSON SELECTION OF "R" WAS NECESSARY. USING THE BRAKE PEDAL TO REGULATE SPEED AND NO USAGE OF ACCELERATOR PEDAL (AS AUTOMATIC TRANSMISSON VEHICLES WILL GENERALLY MOTIVATE WHEN …

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UPON SELECTING TRANSMISSION "D" OPTION INSTRUMENT PANEL INDICATED "6", DROVE TO BARN FOR HORSE FEED. NEEDING TO BACK UP TO FENCE, TO DISPERSE FEED, TRANSMISSON SELECTION OF "R" WAS NECESSARY. USING THE BRAKE PEDAL TO REGULATE SPEED AND NO USAGE OF ACCELERATOR PEDAL (AS AUTOMATIC TRANSMISSON VEHICLES WILL GENERALLY MOTIVATE WHEN GEAR SELECTION IS INITIATED) "SUDDEN ACCELERATION" OCCURRED CAUSING DAMAGE TO TAILGATE WHICH WAS DOWN. BRAKE PEDAL WAS PRESSED AND VEHICLE WAS STOPPED. WITH BRAKE PEDAL DEPRESSED TRANSMISSON SELECTION "D" WAS INITIATED, IN ORDER TO INVESTIGATE DAMAGE, AND ONCE AGAIN WITH BRAKE PEDAL USED TO REGULATE SPEED AND NO USAGE OF ACCELERATOR PEDAL "SUDDEN ACCELERATION" WAS AGAIN ENCOUNTERED. BRAKE PEDAL WAS AGAIN DEPRESSED WHICH STOPPED VEHICLE. NO FURTHER OCCURRANCES WERE ENCOUNTERED THAT DAY. WEATHER WAS SUNNY AND COOL, HIGH 40'S, WITH DRY CONDITIONS. *TR

NHTSA ODI #10691307

2,700 miles · Nov 20, 2014
EngineService Brakes

BRAKES MUSHY, GO ALL WAY TO FLOOR, NEED TO BE PUMPED BEFORE EACH STOP. BAD COLD START ENGINE NOISE COULD MAKE ENGINE STOP WORKING ACCORDING TO CHRYSLER REPAIR BULLETIN. CHRYSLER REFUSED TO REPAIR EITHER DEFECT - BRAKE LIGHT FLASHES AND STAYS ON MUCH LONGER DUE TO PUMPING AND NEED FOR CONSTANT PEDAL ACTION. ACCORDING TO ON-LINE…

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BRAKES MUSHY, GO ALL WAY TO FLOOR, NEED TO BE PUMPED BEFORE EACH STOP. BAD COLD START ENGINE NOISE COULD MAKE ENGINE STOP WORKING ACCORDING TO CHRYSLER REPAIR BULLETIN. CHRYSLER REFUSED TO REPAIR EITHER DEFECT - BRAKE LIGHT FLASHES AND STAYS ON MUCH LONGER DUE TO PUMPING AND NEED FOR CONSTANT PEDAL ACTION. ACCORDING TO ON-LINE SEARCH THE ABOVE DEFECTS ARE COMMON IN DODGE RAMS - CHRYSLER REFUSING TO REPAIR - CLAIMS "BRAKES WORKING NORMALLY" - PLEASE ADVISE WHAT TO DO. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10659822

83,000 miles · Nov 8, 2014
EngineFuel/propulsion System

TRIED TO START TRUCK - DEAD JUMPED BATTERY - WENT AND BOUGHT A NEW BATTERY TRUCK RAN FINE DURING THE DAY - WENT OUT NEXT MORNING - TRUCK WOULD TRY TO TURN OVER BUT WOULDN'T START- TOOK IT TO DEALER- DEALER SAID TO DIAGNOSE WOULD BE $ 130 DOLLARS PAID FOR THAT- THEY SAID THAT THE BATTERY WAS NOT HOOKED UP CORRECTLY THEY FIXED I…

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TRIED TO START TRUCK - DEAD JUMPED BATTERY - WENT AND BOUGHT A NEW BATTERY TRUCK RAN FINE DURING THE DAY - WENT OUT NEXT MORNING - TRUCK WOULD TRY TO TURN OVER BUT WOULDN'T START- TOOK IT TO DEALER- DEALER SAID TO DIAGNOSE WOULD BE $ 130 DOLLARS PAID FOR THAT- THEY SAID THAT THE BATTERY WAS NOT HOOKED UP CORRECTLY THEY FIXED IT- TOOK TRUCK HOME- TRIED TO START IT THE NEXT MORNING.. SAME THING WON'T TURN OVER- WILL CRANK BUT WON'T TURN OVER- CALLED DEALER HE SAID BRING IT IN - NOW THEY SAY THAT THE SENDING UNIT IN THE GAS TANK IS BAD - $ 750 TO FIX - INSTALLED NEW UNIT PAID THE BILL BROUGHT TRUCK HOME LAST NIGHT THIS MORNING TRUCK WON'T START- TRIED CALLING DEALER NO ANSWER-LEFT MESSAGE-NO CALL BACK... *TR

NHTSA ODI #10653582

15,333 miles · Oct 6, 2014
EngineFuel/propulsion System

ENGINE IDLE SPIKED AND DROPPED IN RUSH HOUR STOP AND GO TRAFFIC UNTIL THE TRUCK EVENTUALLY STALLED. I PLACED THE TRUCK IN PARK AND TRIED RESTARTING. THE "ELECTRONIC THROTTLE CONTROL" LIGHT ILLUMINATED IN THE DASH. I TURNED THE TRUCK OFF AND TRIED RESTARTING. THE STARTER TURNED OVER BUT THE TRUCK ACTED AS IF AN ELEMENT NEEDED FOR…

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ENGINE IDLE SPIKED AND DROPPED IN RUSH HOUR STOP AND GO TRAFFIC UNTIL THE TRUCK EVENTUALLY STALLED. I PLACED THE TRUCK IN PARK AND TRIED RESTARTING. THE "ELECTRONIC THROTTLE CONTROL" LIGHT ILLUMINATED IN THE DASH. I TURNED THE TRUCK OFF AND TRIED RESTARTING. THE STARTER TURNED OVER BUT THE TRUCK ACTED AS IF AN ELEMENT NEEDED FOR COMBUSTION WAS MISSING. I TURNED MY HAZARDS ON--AS TRAFFIC WAS CLEARING AROUND ME. I TRIED STARTING THE TRUCK A DOZEN TIMES BEFORE CALLING 911 (SINCE I WAS IN THE MIDDLE OF AN INTERSTATE HWY). I TEXTED A FRIEND WHO SAID TRY STARTING WITH THE ACCELERATOR PEDAL FULLY DEPRESSED--THE TRUCK STARTED, BUT THEN WENT RIGHT BACK TO SPIKING IDLE AND THE ENGINE DIED AGAIN. AT THIS TIME TRAFFIC WAS SPEEDING BY SO FAST ON BOTH SIDES THAT I COULD NOT EXIT THE VEHICLE. STATE PATROL CAME TO PUSH ME TO THE SHOULDER. TRUCK STARTED AGAIN ON THE SHOULDER AFTER SEVERAL ATTEMPTS AND I MANAGED TO MOVE IT ABOUT 50 FEET BEFORE IT DIED AGAIN. HAD TRUCK TOWED TO NEAREST DEALERSHIP WHERE THEY INFORMED ME IT MAY TAKE UP TO 2 WEEKS BEFORE THEY CAN DIAGNOSE MY TRUCK. STILL UNDER WARRANTY. SECOND TIME THIS HAS HAPPENED WITH THIS VEHICLE IN 6 WEEKS. FIRST TIME DEALERSHIP DROVE TRUCK 84 MILES AND RETURNED IT WITH A NOTE SAYING THEY COULD NOT REPLICATE THE PROBLEM. *TR

NHTSA ODI #10641893

57,890 miles · Mar 25, 2014
Engine

TL* THE CONTACT OWNS 2012 DODGE RAM 1500. THE CONTACT STATED THAT DRIVER'S SIDE ENGINE EXHAUST MANIFOLD MADE A LOUD TICKING NOISE WHILE DRIVING AT VARIOUS SPEEDS. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION WHERE IT WAS ADVISED THAT THE DRIVER SIDE MANIFOLD BOLT WAS FRACTURED. THE DRIVER'S SIDE MANIFOLD BOLT WAS REPLACED…

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TL* THE CONTACT OWNS 2012 DODGE RAM 1500. THE CONTACT STATED THAT DRIVER'S SIDE ENGINE EXHAUST MANIFOLD MADE A LOUD TICKING NOISE WHILE DRIVING AT VARIOUS SPEEDS. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION WHERE IT WAS ADVISED THAT THE DRIVER SIDE MANIFOLD BOLT WAS FRACTURED. THE DRIVER'S SIDE MANIFOLD BOLT WAS REPLACED HOWEVER THE PASSENGER'S SIDE MANIFOLD BOLT LATER EXHIBITED THE SAME FAILURE. THE PASSENGER SIDE MANIFOLD BOLT WAS NOT REPLACED. THE MANUFACTURER ADVISED THE CONTACT THAT THE WARRANTY WAS EXPIRED AND DENIED ASSISTANCE WITH THE REPAIR. THE FAILURE AND CURRENT MILEAGE WAS 57,890.

NHTSA ODI #10574728

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.