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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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110,000 miles · Dec 5, 2019
Electrical SystemEngine

WHILE DRIVING THE VEHICLE ON THE HIGHWAY, IT LOST POWER AND SHUT OFF. HAD IT TOWED TO A MECHANIC AND THEY SAID MY VALVES, LIFTERS, AND CAMSHAFT WERE DAMAGED. THE TRUCK ONLY HAS 110,000 MILES ON IT. WHEN THE TRUCK LOST POWER, IT WOULD HAVE CAUSED AN ACCIDENT, LUCKY THOUGH I WAS ABLE TO PULL OVER IN ENOUGH TIME, BEFORE ANOTHER VE…

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WHILE DRIVING THE VEHICLE ON THE HIGHWAY, IT LOST POWER AND SHUT OFF. HAD IT TOWED TO A MECHANIC AND THEY SAID MY VALVES, LIFTERS, AND CAMSHAFT WERE DAMAGED. THE TRUCK ONLY HAS 110,000 MILES ON IT. WHEN THE TRUCK LOST POWER, IT WOULD HAVE CAUSED AN ACCIDENT, LUCKY THOUGH I WAS ABLE TO PULL OVER IN ENOUGH TIME, BEFORE ANOTHER VEHICLE COULD HIT ME. THIS SEEMS TO BE A COMMON THING, WITH THESE TRUCKS, THE MECHANIC CAN'T REPLACE THE PIECES BECAUSE OF OUT OF STOCK, SO HE WANTS TO REPLACE THE WHOLE ENGINE. THIS ISSUE NEEDS TO BE INVESTIGATED, BEFORE SOMEONE DOES GET INTO AN ACCIDENT.

NHTSA ODI #11287172

148,000 miles · Dec 2, 2019
Engine

CYLINDER MISFIRE AT HIGH RPM. ROLLER LIFTERS GETTING STUCK OR WEARING AND CAUSING GROOVES OR EXCESSIVE CAMSHAFT WEAR. RANDOM CYLINDERS AND LIFTERS BECOMING STUCK OR BEARINGS ON LIFTERS FAILING CAUSING EXCESSIVE AND PREMATURE CAMSHAFT WEAR OR FAILURE OF LOBES ON CAMSHAFT. 2012 HEMI 5.7L ENGINE. HAPPENS WHEN ENGINE PUT UNDER A LOA…

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CYLINDER MISFIRE AT HIGH RPM. ROLLER LIFTERS GETTING STUCK OR WEARING AND CAUSING GROOVES OR EXCESSIVE CAMSHAFT WEAR. RANDOM CYLINDERS AND LIFTERS BECOMING STUCK OR BEARINGS ON LIFTERS FAILING CAUSING EXCESSIVE AND PREMATURE CAMSHAFT WEAR OR FAILURE OF LOBES ON CAMSHAFT. 2012 HEMI 5.7L ENGINE. HAPPENS WHEN ENGINE PUT UNDER A LOAD SUCH AS GETTING ONTO HIGHWAY OR PASSING A SLOWER MOVING VEHICLE. UNDER LOAD OR HIGHER RPM ENGINE FAULT LIGHT ILLUMINATES AND WILL BLINK ON AND OFF FOR A FEW SECONDS. PURCHASED ON 11/16/19 AS USED VEHICLE. ODOMETER 147514.

NHTSA ODI #11286333

92,000 miles · Sep 17, 2019
Engine

TL* THE CONTACT OWNS A 2012 RAM 1500. WHILE DRIVING APPROXIMATELY 40 MPH, THE VEHICLE SUDDENLY STALLED AND WAS TOWED TO STALLING DODGE (1245 38TH BLVD NE, CAIRO, GA). THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 92,000.

NHTSA ODI #11256090

94,000 miles · Jul 11, 2019
Engine

LOUD TICKING NOISE CAUSED BY LIFTER/CAMSHAFT MALFUNCTION. TRUCK LOSES POWER. WHILE DRIVING ON HIGHWAY, TRUCK STARTED MISFIRING (CYLINDER 3). HAD TO PUT ON HAZARD FLASHERS AND DRIVE AT SEVERELY REDUCED SPEEDS FOR 125 MILES TO GET HOME. THIS IS A MAJOR PROBLEM WITH THE HEMI ENGINE. CANNOT GET LIFTERS DUE TO SUPPLY AND DEMAND IS…

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LOUD TICKING NOISE CAUSED BY LIFTER/CAMSHAFT MALFUNCTION. TRUCK LOSES POWER. WHILE DRIVING ON HIGHWAY, TRUCK STARTED MISFIRING (CYLINDER 3). HAD TO PUT ON HAZARD FLASHERS AND DRIVE AT SEVERELY REDUCED SPEEDS FOR 125 MILES TO GET HOME. THIS IS A MAJOR PROBLEM WITH THE HEMI ENGINE. CANNOT GET LIFTERS DUE TO SUPPLY AND DEMAND ISSUES. IF YOU CAN FIND LIFTERS, THE PRICES ARE OUTRAGEOUS. DODGE DEALER.STATES THERE ARE MORE THAN 10,000 LIFTERS ON BACK ORDER. PLEASE, PLEASE, PLEASE INVESTIGATE. WE MAY HAVE TO LET OUR TRUCK GO BACK TO THE BANK AS WE CANNOT DRIVE IT BUT STILL OWE 20K!!! PLEASE FOR THE SAKE OF THOUSANDS OF AFFECTED DODGE OWNERS, DO SOMETHING!!!

NHTSA ODI #11230986

73,000 miles · Jul 1, 2019
Engine

2012 DODGE RAM 1500 SPORT 5.7 HEMI 73000 MILES AND WITHOUT WARNING WHILE DRIVING THE VALVE SPRING BREAKS DID NOT EVEN GENERATE A CHECK ENGINE LIGHT COME TO FIND OUT THAT SEVERAL OTHER RAM HEMI OWNERS HAVE HAD THE SAM ISSUE AND DODGE APPARENTLY IS AWARE OF THIS AND WILL NOT!!!!!!!!!!!! STAND BEHIND THEIR PRODUCT SO I WILL NEVER!!…

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2012 DODGE RAM 1500 SPORT 5.7 HEMI 73000 MILES AND WITHOUT WARNING WHILE DRIVING THE VALVE SPRING BREAKS DID NOT EVEN GENERATE A CHECK ENGINE LIGHT COME TO FIND OUT THAT SEVERAL OTHER RAM HEMI OWNERS HAVE HAD THE SAM ISSUE AND DODGE APPARENTLY IS AWARE OF THIS AND WILL NOT!!!!!!!!!!!! STAND BEHIND THEIR PRODUCT SO I WILL NEVER!!!!!!!!!!!!!!!!!!!!!!!!!!! OWN OR RECOMMEND TO ANYONE I KNOW TO OWN ONE OF THESE P.O.S. RAMS NOT WORTH THE MONEY OR THE TROUBLE!!!!!!!!!!!!!!!!!! DODGE SHOULD BE SUED AND THEY SHOULD BE ASHAMED OF THE THIER LACK OF CUSTOMER CARE!!!!!!!!!!!! I CONTACTED THE DODGE HQ AND WAS TOLD THAT I WOULD RECEIVE A FOLLOW-UP PHONE CALL WITHIN 24 HRS GOT NOTHING AGAIN THEY DON'T CARE

NHTSA ODI #11228648

112,000 miles · Jun 10, 2019
Engine

TL* THE CONTACT OWNS A 2012 RAM 1500. WHILE DRIVING AT ANY SPEED, THE VEHICLE SHOOK, THE ENGINE MADE ABNORMAL NOISES, AND THE CHECK ENGINE INDICATOR REMAINED ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE LIFTERS IN THE ENGINE CYLINDER NEEDED TO BE REPLACED. THE CONTACT CALLED VILLAGE MOTORS…

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TL* THE CONTACT OWNS A 2012 RAM 1500. WHILE DRIVING AT ANY SPEED, THE VEHICLE SHOOK, THE ENGINE MADE ABNORMAL NOISES, AND THE CHECK ENGINE INDICATOR REMAINED ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE LIFTERS IN THE ENGINE CYLINDER NEEDED TO BE REPLACED. THE CONTACT CALLED VILLAGE MOTORS AT 330-674-2055 (LOCATED AT 784 WOOSTER RD, MILLERSBURG, OH 44654) WHERE IT WAS DETERMINED THAT THERE WAS NO RECALL. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND THE CONTACT WAS PROVIDED A FAKE PHONE NUMBER. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 112,000.

NHTSA ODI #11219089

Mileage unknown · May 31, 2019
EngineUnknown Or Other

I BOUGHT 2012 RAM 1500 IN AUGUST 2018, I MAKE PAYMENT. THIS PAST APRIL VIBRATION AND HESITATION GOT WORSE, I HAD PLUGS REPLACED , DIDN'T HELP. FOUND OUT THAT LIFTERS NEEDED REPLACED AND CAMSHAFT. I SPENT $217 ON PLUG REPLACEMENT AND ADDITIONAL $4500 TO REPLACE LIFTERS CAMSHAFT. ENGINE LIGHT COMES ON NOW IT'S SAYING VAPORATION …

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I BOUGHT 2012 RAM 1500 IN AUGUST 2018, I MAKE PAYMENT. THIS PAST APRIL VIBRATION AND HESITATION GOT WORSE, I HAD PLUGS REPLACED , DIDN'T HELP. FOUND OUT THAT LIFTERS NEEDED REPLACED AND CAMSHAFT. I SPENT $217 ON PLUG REPLACEMENT AND ADDITIONAL $4500 TO REPLACE LIFTERS CAMSHAFT. ENGINE LIGHT COMES ON NOW IT'S SAYING VAPORATION LEAK. I HAVE READ THAT THOUSANDS AND THOUSANDS OF CUSTOMERS HAVE HAD THIS PROBLEM AND NO RECALL FROM CHRYSLER. THIS IS MY FIRST DODGE, THIS WILL BE MY LAST DODGE UNLESS I GET COMPENSATION FROM CHRYSLER. I KNOW THIS TRUCK IS NOT UNDER WARRANTY, BUT CHRYSLER HAS TO KNOW THAT THIS IS A PROBLEM WITH THE HEMI , I WAS TOLD AT A DEALER THIS WAS COMMON IN HEMI , NO ONE TOLD ME THAT WHEN I BROUGHT I STILL OWE ON THIS TRUCK , PLUS I'M OUT $4667 THAT I CAN'T GET BACK IF I TRADED, ONLY HAD 8 MONTHS WHEN THIS HAPPENED. THIS DOESN'T INCLUDE THE THE VAP PROBLEM ON THE COST.

NHTSA ODI #11217192

79,000 miles · May 30, 2019
Electrical SystemEngineFuel/propulsion System

I STARTED TO HAVE TROUBLE WITH THE TRUCK AS IT WOULD NOT START IN THE MORNINGS WHEN I WAS TRYING TO GO TO WORK. I REPLACED THE FUEL PUMP AND IT DID NOT SOLVE THE PROBLEM. SHORTLY AFTER THAT, MY BATTERY WOULD BE DEAD MOST MORNINGS. I REPLACED THE BATTERY, BUT STILL THE PROBLEMS CONTINUED. THE TRUCK STARTED TO LOSE POWER WHILE I W…

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I STARTED TO HAVE TROUBLE WITH THE TRUCK AS IT WOULD NOT START IN THE MORNINGS WHEN I WAS TRYING TO GO TO WORK. I REPLACED THE FUEL PUMP AND IT DID NOT SOLVE THE PROBLEM. SHORTLY AFTER THAT, MY BATTERY WOULD BE DEAD MOST MORNINGS. I REPLACED THE BATTERY, BUT STILL THE PROBLEMS CONTINUED. THE TRUCK STARTED TO LOSE POWER WHILE I WAS DRIVING SO I TOOK IT TO A MECHANIC. HE TOLD ME THAT THE TIPM WAS FAULTY AND NEEDED TO BE REPLACED. I HAD TO TAKE IT TO THE DEALERSHIP I PURCHASED IT FROM TO HAVE IT FIXED. I HAVE DRIVEN THE TRUCK LESS THAT 7000 MILES SINCE I PURCHASED IT. AFTER SPEAKING WITH FCA, THEY SAY THAT THEY WON'T DO ANYTHING TO HELP OUT BECAUSE THE TRUCK IS OUT OF WARRANTY. I WANT TO KNOW WHY A RECALL WAS NEVER PUT IN PLACE AND ENACTED BECAUSE I HAVE SEEN THOUSANDS OF COMPLAINTS FROM PEOPLE HAVING THE SAME PROBLEMS. I WOULD LIKE TO KNOW WHY I'M HAVING TO PAY $1794.03 OUT OF POCKET FOR THE FAULTS OF THE MANUFACTURER PF THE VEHICLE.

NHTSA ODI #11210875

35 miles · May 23, 2019
Engine

CAM AND LIFTER FAILURE UNDER 90,000MILES ON IT HAD FOR ABOUT A YEAR BOUGHT FROM DODGE DEALERSHIP THEY SAID THERE WAS NO WARRANTY OR EXTENDED WARRANTY COVERAGE ON IT THIS IS PRIME EXAMPLE OF A LEMON FOR THE LEMON LAW THIS IS APPARENTLY A COMMON ISSUE ON THESE ENGINES WITH A REPAIR COST OF 4400 DOLLARS OR MORE THIS IS UNACCEPTABLE…

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CAM AND LIFTER FAILURE UNDER 90,000MILES ON IT HAD FOR ABOUT A YEAR BOUGHT FROM DODGE DEALERSHIP THEY SAID THERE WAS NO WARRANTY OR EXTENDED WARRANTY COVERAGE ON IT THIS IS PRIME EXAMPLE OF A LEMON FOR THE LEMON LAW THIS IS APPARENTLY A COMMON ISSUE ON THESE ENGINES WITH A REPAIR COST OF 4400 DOLLARS OR MORE THIS IS UNACCEPTABLE ALSO THE DEALERSHIP HAS HAD MY TRUCK MORE THAN 3 MONTHS BECAUSE THEY CAN'T GET THE CAMSHAFT OR LIFTERS BECAUSE OF ISSUES WITH THEM AND ARE ON BACKORDER WHICH MEANS THEY HAVE BEEN PUTTING IN FAULTY PARTS INTO THE ENGINES

NHTSA ODI #11209556

136,000 miles · May 21, 2019
Engine

2012 RAM 1500 - CRANKED MY RAM TRUCK ONE MORNING AND THE ENGINE HAD A KNOCK WITH A TAPPING SOUND, TURN OFF CHECK THE OIL LEVEL WHICH WAS OK! STARTED THE ENGINE AND ONLY HEARD LIKE A MAINIFOLD LEAK. AFTER DRIVING A FEW MILES , I NOTICE THAT THE TRUCK WAS SHAKY DURING TAKE-OFF OR CLIMBING A HILL. DROP TRUCK OFF AT MY MECHANIC FOR …

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2012 RAM 1500 - CRANKED MY RAM TRUCK ONE MORNING AND THE ENGINE HAD A KNOCK WITH A TAPPING SOUND, TURN OFF CHECK THE OIL LEVEL WHICH WAS OK! STARTED THE ENGINE AND ONLY HEARD LIKE A MAINIFOLD LEAK. AFTER DRIVING A FEW MILES , I NOTICE THAT THE TRUCK WAS SHAKY DURING TAKE-OFF OR CLIMBING A HILL. DROP TRUCK OFF AT MY MECHANIC FOR A TUNE-UP AND LATER THAT DAY MY MECHANIC NOTIFIED ME THE TUNE-UP WASN'T THE PROBLEM. HE REMOVE THE CAMS/LIFTERS TO #5 LIFTER AND THAT LIFTER WASN'T MOVING LIKE 1,3 & 7. "IS WAS LIKE THE LUG ON THE CAM WERE WORE OUT."

NHTSA ODI #11208867

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.