NHTSA owner reports · September 18, 2026 snapshot.
Steering complaints
47 reportsClear category filterMileage unknown · Jul 29, 2015
Steering
WHEN DRIVING OR DIPS OR SMALL HOLES ON THE ROAD THE TRUCK SHIFTS HARD TO RIGHT AND LEFT EVERY TIME.HAD FRONT WHEEL ALIGNMENT DONE PROBLEM STILL OCCURS .CAN'T BELIEVE OUT OF 600,000 VEHICLES NO RECALL OR BY BACK ON MY 2012 RAM.WHEN THEY SPECIFICALLY LISTED 2012 AS ONE OF THE YEARS THAT GOT RECALLED.I EXPECT A RECALL AND ACCOMM…
Read full complaint
WHEN DRIVING OR DIPS OR SMALL HOLES ON THE ROAD THE TRUCK SHIFTS HARD TO RIGHT AND LEFT EVERY TIME.HAD FRONT WHEEL ALIGNMENT DONE PROBLEM STILL OCCURS .CAN'T BELIEVE OUT OF 600,000 VEHICLES NO RECALL OR BY BACK ON MY 2012 RAM.WHEN THEY SPECIFICALLY LISTED 2012 AS ONE OF THE YEARS THAT GOT RECALLED.I EXPECT A RECALL AND ACCOMMODATION.
NHTSA ODI #10744539
Mileage unknown · Jul 28, 2015
Steering
MAKES A POPPING SOUND ON THE FRONT LEFT SIDE.
NHTSA ODI #10744181
Mileage unknown · Jul 27, 2015
Steering
HAVE HAD ISSUES ON STEERING STRAIGHT AND VIBRATION AT HIGHWAY SPEEDS. THE STEERING WHEEL HAS NOT BEEN IN ALIGNMENT SINCE BEFORE THE DEALER ALIGNMENT WAS DONE. TIRES SQUEAL AT TURNS AT SLOW SPEED, I HAVE HAD THE TIRES BALANCED ROTATED, I HAVE HAD THE TRUCK ALIGNED BY THE DEALER WITH NO EFFECTIVE DIFFERENCE IN THE STEERING OR THE …
Read full complaint
HAVE HAD ISSUES ON STEERING STRAIGHT AND VIBRATION AT HIGHWAY SPEEDS. THE STEERING WHEEL HAS NOT BEEN IN ALIGNMENT SINCE BEFORE THE DEALER ALIGNMENT WAS DONE. TIRES SQUEAL AT TURNS AT SLOW SPEED, I HAVE HAD THE TIRES BALANCED ROTATED, I HAVE HAD THE TRUCK ALIGNED BY THE DEALER WITH NO EFFECTIVE DIFFERENCE IN THE STEERING OR THE WEAR ON THE TIRES.
NHTSA ODI #10743908
32,000 miles · Jul 27, 2015
Air BagsSteering
MY AIRBAG LIGHT COMES ON THE DASHBOARD AND STAYS ON FOR A WHILE SOMETIMES GOES OFF THEN COMES RIGHT BACK ON. MY WINDSHIELD WASHER FLUID MESSAGE COMES ON EVEN WHITH A FULL TANK OF FLUID. MY DRIVER SIDE WINDOW GOES UP AND DOWN ON ITS OWN SOMETIMES. MY MAIN CONCERN IS THE "DEATH WOBBLE" COMING FROM THE FRONT END WHEN TRAVELING AT H…
Read full complaint
MY AIRBAG LIGHT COMES ON THE DASHBOARD AND STAYS ON FOR A WHILE SOMETIMES GOES OFF THEN COMES RIGHT BACK ON. MY WINDSHIELD WASHER FLUID MESSAGE COMES ON EVEN WHITH A FULL TANK OF FLUID. MY DRIVER SIDE WINDOW GOES UP AND DOWN ON ITS OWN SOMETIMES. MY MAIN CONCERN IS THE "DEATH WOBBLE" COMING FROM THE FRONT END WHEN TRAVELING AT HIGHWAY SPEEDS. IF YOU GUYS COULD ENLIGHTEN ME ON ALL OF THIS THAT WOULD BE GREAT BECAUSE I SEARCHED MY VIN NUMBER AND NO RECALLS CAME UP. I DON'T WANT TO BE DRIVING DOWN THE FREEWAY AND MY STEERING SUDDENLY GOES. ALSO GOD FOR BID I GET INTO AN ACCIDENT I WANT TO MAKE SURE MY AIRBAGS WILL DEPLOY.
NHTSA ODI #10743864
29,000 miles · Jun 8, 2015
Power TrainSteeringWheels
TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT STATED THAT THE DRIVER SIDE TIE ROD WAS WORN PREMATURELY, WHICH CAUSED THE TIRES TO BE WORN. IN ADDITION, THREE SECURITY LOCKS AND THE STUDS AND BOLTS FRACTURED ON THE FRONT DRIVER SIDE TIRE WITHOUT WARNING. THE SUSPENSION ON THE DRIVER AND PASSENGER SIDE TIRES WAS UNSTABLE…
Read full complaint
TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT STATED THAT THE DRIVER SIDE TIE ROD WAS WORN PREMATURELY, WHICH CAUSED THE TIRES TO BE WORN. IN ADDITION, THREE SECURITY LOCKS AND THE STUDS AND BOLTS FRACTURED ON THE FRONT DRIVER SIDE TIRE WITHOUT WARNING. THE SUSPENSION ON THE DRIVER AND PASSENGER SIDE TIRES WAS UNSTABLE AND THE STEERING WHEEL WAS EXTREMELY LOOSE. THE CONTACT ALSO INDICATED THAT THE WHEELS WERE LOCKING IN THE REAR, WHICH INDICATED A DRIVE TRAIN FAILURE BECAUSE THE BOLTS ALSO FRACTURED IN THE REAR. THE VEHICLE WAS TAKEN TO THREE DIFFERENT DEALERS FOR INSPECTION AND DIAGNOSTIC TESTING. THE CONTACT WAS PROVIDED WITH CONFLICTING INFORMATION FROM THE DEALERS AND WAS WAITING TO DETERMINE HOW THE MANUFACTURER WAS GOING TO REMEDY THE FAILURE. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBERS: 13V038000 (POWER TRAIN), 12V474000 (POWER TRAIN), 13V528000 (STEERING), 11V350000 (STE/ERING) AND 10E040000 (WHEELS). THE MANUFACTURER WAS NOTIFIED OF THE FAILURES AND PROVIDED NO REMEDY. THE APPROXIMATE FAILURE MILEAGE WAS 29,000. UPDATED 11/12/15*LJ UPDATED 10/19/2017*CN
NHTSA ODI #10724024
Mileage unknown · Feb 12, 2015
Engine And Engine CoolingFuel System, DieselSteering
TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED A NOTIFICATION FOR NHTSA CAMPAIGN NUMBERS: 14V635000 (ENGINE AND ENGINE COOLING, FUEL SYSTEM, DIESEL) AND 13V527000 (STEERING) AND STATED THAT THE PARTS NEEDED WERE UNAVAILABLE TO REPAIR THE VEHICLE. THE DEALER WAS UNABLE TO INFORM WHEN THE PARTS WOULD BECOME AVAIL…
Read full complaint
TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED A NOTIFICATION FOR NHTSA CAMPAIGN NUMBERS: 14V635000 (ENGINE AND ENGINE COOLING, FUEL SYSTEM, DIESEL) AND 13V527000 (STEERING) AND STATED THAT THE PARTS NEEDED WERE UNAVAILABLE TO REPAIR THE VEHICLE. THE DEALER WAS UNABLE TO INFORM WHEN THE PARTS WOULD BECOME AVAILABLE. THE MANUFACTURER WAS NOT NOTIFIED OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. THE VIN WAS NOT AVAILABLE.
NHTSA ODI #10682954
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…
Read full complaint
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
Mileage unknown · Dec 10, 2014
Fuel System, DieselPower TrainSteering
THE WEEK OF MARCH 9TH OF THIS YEAR, WE TOOK THE TRUCK IN FOR TRANSMISSION PROBLEM AND WHEEL ALIGNMENT TO THE LOCAL DEALER: FRONTIER DODGE CHRYSLER JEEP 5801 SPUR 327 LUBBOCK, TX 79424 THE TRANSMISSION WAS REPAIRED. THE SERVICE ADVISOR TOLD US THAT THEY WILL ONLY FIX THE ALIGNMENT AFTER THEY RECEIVE THE RECALL PART# N49. DUE …
Read full complaint
THE WEEK OF MARCH 9TH OF THIS YEAR, WE TOOK THE TRUCK IN FOR TRANSMISSION PROBLEM AND WHEEL ALIGNMENT TO THE LOCAL DEALER: FRONTIER DODGE CHRYSLER JEEP 5801 SPUR 327 LUBBOCK, TX 79424 THE TRANSMISSION WAS REPAIRED. THE SERVICE ADVISOR TOLD US THAT THEY WILL ONLY FIX THE ALIGNMENT AFTER THEY RECEIVE THE RECALL PART# N49. DUE TO THEM HAVING TO REALIGN IT AGAIN AFTER THEY REPAIR N49. THE STEERING WHEEL'S POSITION IS OFF. THE LOGO IS TILTED TO THE RIGHT. WITH THAT SAID, ITS NOW DECEMBER AND WE HAVE NOT RECEIVED ANY CALLS FROM THE DEALER. THEY HAVE NOT CONTACTED US WITH ANY UPDATES. WE CALLED IN JUNE AND THE SERVICE DESK AND WERE TOLD THAT THEY DIDN'T HAVE OUR PART YET. THAT WAS SAID EVEN BEFORE WE GAVE THEM OUR NAME. HOW DID THEY KNOW WHO THEY WERE TALKING TO? AFTER WE IDENTIFIED THE TRUCK, THEY SAID THAT THE PART ISN'T IN YET. THE ONLY REASON THAT WE ARE CONTACTING YOU IS DUE TO THE POOR CUSTOMER SERVICE THAT WE RECEIVED AT THE LOCAL DODGE DEALER. AND WE UNDERSTAND THAT THE RECALLS NEED TO BE DONE. THE ONLY PROBLEM IS THAT ITS NOT GETTING DON?T IN A TIMELY MATTER. THE 2ND RECALL, WITH COMPARTMENT FIRE, SOUNDS LIKE IT COULD BE A DISASTER. I DON'T EVEN FEEL COMFORTABLE DRIVING THE TRUCK ESPECIALLY HAVING MY FAMILY IN IT. I WOULD REALLY LIKE A CALL OR SOME SORT OF RESPONSE TO THE ABOVE SITUATION. *TR
NHTSA ODI #10663322
14,730 miles · Aug 28, 2014
Power TrainSteeringVehicle Speed Control
WHILE DRIVING AT 60 MPH THE TRUCK FAILED TO DOWNSHIFT FOR AN INCLINE ON THE HIGHWAY LOOSING MOMENTUM. I DEPRESSED THE ACCELERATOR PEDAL TO THE FLOOR AND NOTHING HAPPENED. AT THIS POINT I SIGNALED TO MOVE ONTO THE SHOULDER WHILE THE TRUCK CONTINUED TO LOSE MOMENTUM. WHEN I TURNED THE STEERING WHEEL, IT WAS DIFFICULT TO MOVE AS IF…
Read full complaint
WHILE DRIVING AT 60 MPH THE TRUCK FAILED TO DOWNSHIFT FOR AN INCLINE ON THE HIGHWAY LOOSING MOMENTUM. I DEPRESSED THE ACCELERATOR PEDAL TO THE FLOOR AND NOTHING HAPPENED. AT THIS POINT I SIGNALED TO MOVE ONTO THE SHOULDER WHILE THE TRUCK CONTINUED TO LOSE MOMENTUM. WHEN I TURNED THE STEERING WHEEL, IT WAS DIFFICULT TO MOVE AS IF I HAD LOST MY POWER STEERING TOO. THE BRAKES WORKED AND I STOPPED ON THE SHOULDER. I PLACED THE TRUCK IN PARK AND BACK TO DRIVE: NOTHING HAPPENED. I PLACED THE TRUCK IN PARK, TURNED IT OFF, WAITED A COUPLE MINUTES AND RESTARTED. THE TRANSMISSION AND STEERING NOW WORKED. AT NO TIME DID ANY WARNING LIGHT APPEAR ON THE DASH. I COULD HAVE CAUSED A SIGNIFICANT PILE UP ON THE FREEWAY DURING RUSH HOUR. SINCE NO WARNING LIGHTS APPEARED ON THE DASH--HOW DO I KNOW WHAT HAPPENED--OR MORE LIKELY, HOW WILL THE DEALERSHIP FIND THE ROOT CAUSE FOR THIS FAILURE. THIS BEHAVIOR IS DANGEROUS AND UNACCEPTABLE FOR A 2 YEAR OLD TRUCK WITH LESS THAN 15K MILES. I USE MY TRUCK TO SOMETIMES PULL A HORSE TRAILER. IF THIS INCIDENT HAPPENS AGAIN WHILE I AM TOWING THE OUTCOME WILL BE DISASTROUS. I AM NOW SCARED TO DRIVE MY TRUCK. *TR
NHTSA ODI #10629178
30,000 miles · Aug 12, 2014
Steering
TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED A NOTIFICATION FOR NHTSA CAMPAIGN NUMBER: 13V529000 (STEERING). THE CONTACT WAS CONCERNED ABOUT THE SAFETY RELATED ISSUE OF THE POTENTIAL FAILURE TO THE DRIVER SIDE TIE ROD ASSEMBLY, WHICH COULD POTENTIALLY LEAD TO A CRASH. THE VEHICLE WAS NOT REPAIRED AND THE MANU…
Read full complaint
TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED A NOTIFICATION FOR NHTSA CAMPAIGN NUMBER: 13V529000 (STEERING). THE CONTACT WAS CONCERNED ABOUT THE SAFETY RELATED ISSUE OF THE POTENTIAL FAILURE TO THE DRIVER SIDE TIE ROD ASSEMBLY, WHICH COULD POTENTIALLY LEAD TO A CRASH. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 30,000.
NHTSA ODI #10621675
Official recalls
6Mar 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.
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.
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.
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.
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.
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
1EA19001 · 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.