WHEEL STUD FAILURE - REAR WHEELS. WHEEL STUDS SHOW EXCESSIVE WEAR, STRETCHING AND COMPRESSION.
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.
About this comparison →How this year compares
Owner complaints by model year
Compare all RAM 1500 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
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.
Wheels complaints
10 reportsTL* THE CONTACT OWNS A 2012 RAM 1500. WHILE DRIVING 25 MPH AND ATTEMPTING TO OVERTAKE ANOTHER VEHICLE, THE ACCELERATOR PEDAL WAS DEPRESSED AND THE REAR PASSENGER WHEEL VIOLENTLY SPUN. ALL THE OTHER WHEELS FUNCTIONED NORMALLY. THE CONTACT STATED THAT THE FAILURE ONLY OCCURRED WHEN THE ROAD SURFACE WAS WET. THE CONTACT WAS CONCERN…
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TL* THE CONTACT OWNS A 2012 RAM 1500. WHILE DRIVING 25 MPH AND ATTEMPTING TO OVERTAKE ANOTHER VEHICLE, THE ACCELERATOR PEDAL WAS DEPRESSED AND THE REAR PASSENGER WHEEL VIOLENTLY SPUN. ALL THE OTHER WHEELS FUNCTIONED NORMALLY. THE CONTACT STATED THAT THE FAILURE ONLY OCCURRED WHEN THE ROAD SURFACE WAS WET. THE CONTACT WAS CONCERNED THAT THERE WAS A DISCREPANCY BETWEEN THE INFORMATION PROVIDED BY THE MANUFACTURER AND THE DEALER. THE CONTACT WAS INFORMED BY THE DEALER THAT THE VEHICLE OPERATED AS INTENDED; HOWEVER, THE MANUFACTURER STATED OTHERWISE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 22,000.
WE EXPERIENCED A BLOW OUT OF OUR GOODYEAR P275/60R20 LEFT FRONT TIRE WHILE DRIVING OUR 2012 DODGE RAM 1500 PICKUP. WE WERE DRIVING AT 70 MPH ON DIVIDED HIGHWAY AND WERE WATCHING ROAD WHEN BLOW UP HAPPENED WITH NO DEBRIS PRESENT. AIR PRESSURE WAS NORMAL (39PSI) JUST BEFORE ACCIDENT. THE BLOW OUT WAS FROM RIM TO RIM.
TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. WHILE DRIVING 20 MPH IN 4 WHEEL DRIVE, THE STEERING COLUMN AND WHEELS VIBRATED AND MADE AN ABNORMAL NOISE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE USUALLY OCCURRED WHILE DRIVING AT LOW SPEEDS. THE CONTACT BELIEVED THE SYMPTOM…
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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. WHILE DRIVING 20 MPH IN 4 WHEEL DRIVE, THE STEERING COLUMN AND WHEELS VIBRATED AND MADE AN ABNORMAL NOISE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE USUALLY OCCURRED WHILE DRIVING AT LOW SPEEDS. THE CONTACT BELIEVED THE SYMPTOMS WERE RELATED TO NHTSA CAMPAIGN NUMBER: 13V038000 (POWER TRAIN), BUT THE VIN WAS EXCLUDED. THE MANUFACTURER WAS NOT MADE AWARE OF THE ISSUE. THE FAILURE MILEAGE WAS 18,000.
DRIVING ALONG HIGHWAY AND ALL OF A SUDDEN TRUCK STARTS TO FISHTAIL OUT OF CONTROL FROM THE REAR, CAUSING ME TO GO INTO THE DITCH IN ONE SIDE OF THE HIGHWAY THEN COMING OUT TO GO ACROSS THE INTERSTATE THEN LAND IN THE MEDIAN DITCH. FORTUNATELY I HIT NO ONE AND NO ONE WAS INJURED EXCEPT SCARING ME TILL I DON'T LIKE DRIVING MUCH AN…
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DRIVING ALONG HIGHWAY AND ALL OF A SUDDEN TRUCK STARTS TO FISHTAIL OUT OF CONTROL FROM THE REAR, CAUSING ME TO GO INTO THE DITCH IN ONE SIDE OF THE HIGHWAY THEN COMING OUT TO GO ACROSS THE INTERSTATE THEN LAND IN THE MEDIAN DITCH. FORTUNATELY I HIT NO ONE AND NO ONE WAS INJURED EXCEPT SCARING ME TILL I DON'T LIKE DRIVING MUCH ANYMORE. THE DAMAGES WERE MINOR LOSS OF THE INSERTS TO THE LOCKED RIMS WHICH WERE BROCKEN OFF.
I HAVE TRIED CONTACTING DODGE. I HAVE NOT RECIEVED ANY LETTERS OR A WRITTEN NOTICE ON MY RAM 1500 PICKUP. I AM STATIONED IN KOREA AND PURCHASED MY VEHICLE FROM A DEALER IN HUNTSVILLE ALABAMA. I HAVE THE TRUCK WITH ME. WHAT SHOULD I DO WHEN I GET NO ANSWERS FROM THE MAKER. I DO NOT WANT TO BE DRIVING A VEHICLE HERE THAT HAS …
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I HAVE TRIED CONTACTING DODGE. I HAVE NOT RECIEVED ANY LETTERS OR A WRITTEN NOTICE ON MY RAM 1500 PICKUP. I AM STATIONED IN KOREA AND PURCHASED MY VEHICLE FROM A DEALER IN HUNTSVILLE ALABAMA. I HAVE THE TRUCK WITH ME. WHAT SHOULD I DO WHEN I GET NO ANSWERS FROM THE MAKER. I DO NOT WANT TO BE DRIVING A VEHICLE HERE THAT HAS A PROBLEM FOR WHICH I CANNOT GET IT FIXED AND MAY KILL ME OR SOMEONE ELSE IN KOREA. THE NEW CAR SALES PEOPLE HERE IN THE PX ARE NO HELP AND ALL THEY WANT TO DO IS SELL YOU A NEW CAR.
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…
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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
AFTER HAVING A BREAKDOWN, DUE TO ROAD DEBRIS DAMAGING A WHEEL / TIRE, I WAS LEFT STRANDED ON THE SIDE OF THE ROAD, AS I WAS UNABLE TO REMOVE MY SPARE TIRE AND CHANGE THE WHEEL AS MY EMERGENCY ROADSIDE JACK AND TOOLS TO LOWER THE SPARE TIRE WERE MISSING. I CONTACTED CUSTOMER SERVICE AND ADVISED THEM OF WHAT WAS GOING ON. THEY…
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AFTER HAVING A BREAKDOWN, DUE TO ROAD DEBRIS DAMAGING A WHEEL / TIRE, I WAS LEFT STRANDED ON THE SIDE OF THE ROAD, AS I WAS UNABLE TO REMOVE MY SPARE TIRE AND CHANGE THE WHEEL AS MY EMERGENCY ROADSIDE JACK AND TOOLS TO LOWER THE SPARE TIRE WERE MISSING. I CONTACTED CUSTOMER SERVICE AND ADVISED THEM OF WHAT WAS GOING ON. THEY DECLINED TO HELP ME, AND FURTHER STATED THAT MOST VEHICLE DO NOT COME WITH SUCH ITEMS AS I HAVE ROADSIDE ASSISTANCE. I LET THE REPRESENTATIVE KNOW HE WAS INCORRECT IN MAKING SUCH A STATEMENT AS IT IS A REQUIREMENT AS FAR AS I WAS CONCERNED, MY MANUAL STATES I HAVE ONE, AS WELL AS THERE IS A PLACE FOR ONE TO GO, HOWEVER THE PACK IT'S SELF IS NOT THERE. HE THEN TOLD ME I SHOULD HAVE REPORTED THE PROBLEM SOONER. AFTER ASKING HIM HOW I WOULD HAVE KNOWN ABOUT IT UNTIL I HAD AN EMERGENCY, HE TOLD ME I SHOULD HAVE INSPECTED THE EQUIPMENT BEFORE PURCHASING THE VEHICLE. HE STATES SOMEONE MAY HAVE TAKEN IT, IF I LOANED OUT THE VEHICLE. AS THE CALL PROGRESSED AND HE WAS ABSOLUTELY SET ON NOT HELPING ME, I ASKED HIM WHEN HE LAST CHECKED ON HIS EMERGENCY EQUIPMENT, HE IN RETURN STATED WE WERE TALKING ABOUT MY VEHICLE AND WHAT I SHOULD HAVE DONE, NOT HIS OR WHAT OTHER PEOPLE DO. *TR
DODGE RAM LARAMIE1500 4X4 CREW CAB BUILT IN JUNE 2012 HAS FACTORY 20X9 ALUMINUM CHROME CLAD WHEELS WITH GOODYEAR WRANGLER HP P275/60R20 TIRES. PROBLEM WITH THIS IS THE SPARE TIRE & THE FACTORY JACK. HAD A REAR PASSENGER SIDE TIRE BLOW OUT AND HAD TO JACK THE TRUCK TO FIX THE FLAT. FIRST, THE SPARE TIRE SIZE IS P235/85R17, MY WH…
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DODGE RAM LARAMIE1500 4X4 CREW CAB BUILT IN JUNE 2012 HAS FACTORY 20X9 ALUMINUM CHROME CLAD WHEELS WITH GOODYEAR WRANGLER HP P275/60R20 TIRES. PROBLEM WITH THIS IS THE SPARE TIRE & THE FACTORY JACK. HAD A REAR PASSENGER SIDE TIRE BLOW OUT AND HAD TO JACK THE TRUCK TO FIX THE FLAT. FIRST, THE SPARE TIRE SIZE IS P235/85R17, MY WHEELS ARE 20" RIMS AND 1-1/4 HIGHER OVER ALL. THIS TRUCK HAS THE ELECTRONIC STABILITY CONTROL (ESC) WHICH STATES TO HAVE THE PROPER SIZE RIMS & TIRES AS THIS SYSTEM MAY NOT FUNCTION PROPERLY IF THEY ARE DIFFERENT SIZES. SECONDLY, THE JACK DODGE PROVIDES CAN'T HOLD THE WEIGHT OF THESE TRUCKS. THIS JACK COLLAPSED SOON AFTER RAISING THE FLAT TRUCK TIRE 1-2" OFF THE GROUND, THE WORM GEAR LOOKS LIKE A U-BOLT. CALLED BOTH THE DEALER I PURCHASED THE TRUCK FROM IN DECEMBER 2012 AND DODGE. NEITHER IS WILLING TO HELP REMEDY THESE PROBLEMS. DODGE DID HAVE A RECALL 12V192000 JAN 5TH 6TH 2012 FOR THE SPARE TIRE NOT BEING SIZED CORRECTLY. IS THIS NOT THE SAME CASE? *TR
I WAS ON VACATION IN SMOKES GOING UP A HILL. I WAS BEHIND A SLOW MOVING CAR ABOUT 25 TO 35 MPH. WHEN ALL THE SUDDEN MY TRUCK STARTS SLUGGING. IT WAS LIKE IT DIDN'T KNOW WHAT GEAR TO GET IN. IT WOULD GO HIGH AND START JERKING THEN LOW. THEIR WAS A CAR BEHIND ME SO FINALLY I JUST STOPPED IN THE ROAD TO LET THE ONE IN FRONT GO ON. …
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I WAS ON VACATION IN SMOKES GOING UP A HILL. I WAS BEHIND A SLOW MOVING CAR ABOUT 25 TO 35 MPH. WHEN ALL THE SUDDEN MY TRUCK STARTS SLUGGING. IT WAS LIKE IT DIDN'T KNOW WHAT GEAR TO GET IN. IT WOULD GO HIGH AND START JERKING THEN LOW. THEIR WAS A CAR BEHIND ME SO FINALLY I JUST STOPPED IN THE ROAD TO LET THE ONE IN FRONT GO ON. IT FELT LIKE THE TRANSMISSION WAS GOING FALL OUT OF THE TRUCK. NOW IT DOES IT JUST GOING DOWN THE ROAD . I CAN PUSH THE PEDDLE 1/4 WAY DOWN AND IT DOES NOT RESPOND . IT SHIFTS IN TO A HIGHER GEAR TO SOON THIS TRANSMISSION IN THESE TRUCK NEED TO BE RECALLED BEFORE SOMEONE GET HURT OR KILLED. YOU NEVER KNOW WHAT THEY GOING TO DO. GUESS ITS THE CAUSE OF THE VIBRATION AT 60 TO HIGHER ALSO. I TOOK IT TO DEALER TODAY AND THEY SAID ITS ALL NORMAL . HOW CAN IT BE NORMAL WHEN IT WAS NOT DOING IT WHEN I FIRST GOT IT. GUESS THAT IS THEIR ANSWER TO EVERY PROBLEM MAKES THEIR DAY EASER. WE THE PEOPLE OF RAM OWNERS NEED HELP .CAN ANYBODY HELP US WE PAY TO MUCH FOR THOSE TRUCKS FOR THEM TO RIDE LIKE THAT. AND FOR OUR PEACE OF MIND KNOWING THAT WE ARE CONTROLLING THE TRUCK NOT THE TRANSMISSION . DON'T WAIT TO HAVE IT RECALLED BECAUSE IT MIGHT BE YOU THAT GETS HIT BY A DEFAULTED TRUCK OR EVEN WORSE YOUR KID THAT IS WALKING INTO A STORE. ASKING FOR HELP BEFORE SOMETHING BAD HAPPENS. THANK FOR YOUR HELP!! *TR
Official recalls
618V160000 · 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
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.
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