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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.

About this comparison →

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

What owners actually said

697 reports
Mileage unknown · Oct 6, 2015
Air Bags

TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED A NOTIFICATION OF NHTSA CAMPAIGN NUMBER: AIR BAGS (15V459000) HOWEVER, THE RECALL PART WAS NOT AVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOT NOTIFIED OF THE ISSUE. THE CONTAC…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED A NOTIFICATION OF NHTSA CAMPAIGN NUMBER: AIR BAGS (15V459000) HOWEVER, THE RECALL PART WAS NOT AVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOT NOTIFIED OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE.

NHTSA ODI #10780165

40,000 miles · Oct 6, 2015
Electrical SystemExterior LightingFuel/propulsion System

MY 2012 RAM 1500 HAS BEEN IN THE SHOP SEVEN TIMES IN THE PAST YEAR FOR ELECTRICAL PROBLEMS. THE ORIGINAL PROBLEMS WERE RELATED TO THE PCM WHICH WOULD SHORT OUT AND CAUSE MY VEHICLE TO OPERATE IN ONLY ONE GEAR. THIS PROBLEM WAS FIXED FINALLY BY REPLACING THE PCM AND VARIOUS OTHER PARTS. MY TRUCK RECENTLY HAD THE ENGINE TEMPER…

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MY 2012 RAM 1500 HAS BEEN IN THE SHOP SEVEN TIMES IN THE PAST YEAR FOR ELECTRICAL PROBLEMS. THE ORIGINAL PROBLEMS WERE RELATED TO THE PCM WHICH WOULD SHORT OUT AND CAUSE MY VEHICLE TO OPERATE IN ONLY ONE GEAR. THIS PROBLEM WAS FIXED FINALLY BY REPLACING THE PCM AND VARIOUS OTHER PARTS. MY TRUCK RECENTLY HAD THE ENGINE TEMPERATURE SENSOR, RIGHT HEADLIGHT, AND FUEL PUMP CONTROL GO OUT ALL AROUND THE SAME TIME WHICH MADE IT DIFFICULT FOR MY TRUCK TO START AND WHEN IT DID START IT SOUNDED ANEMIC AND WOULD OFTEN HAVE ALERTS GOING OFF. THE DEALERSHIP CLAIMED THAT THE TIPM WAS THE CAUSE OF THE FUEL PUMP PROBLEMS AND NOW I AM WONDERING IF IT IS THE ROUTE OF ALL THE OTHER PROBLEMS. THIS MOST RECENT REPAIR COST ME $1000 DOLLARS AND WELL OVER $100 IN ALTERNATIVE TRANSPORTATION ARRANGEMENTS. MY TRUCK IS ONLY TWO AND A HALF YEARS OLD WITH 50K MILES ON IT. I SHOULD NOT BE HAVING THIS MANY PROBLEMS WITH THIS NEW OF A VEHICLE. CHRYSLER AND RAM HAVE A WELL DOCUMENTED HISTORY OF RECENT PROBLEMS WITH THE TIPM ACROSS VARIOUS VEHICLES AND AN INVESTIGATION NEEDS TO BE CONDUCTED AND CUSTOMERS NEED TO BE COMPENSATED FOR THE PROBLEMS THIS PART HAS CAUSED.

NHTSA ODI #10780136

Mileage unknown · Oct 6, 2015
Air Bags

TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V459000 (AIR BAGS) AND STATED THAT THE PART WAS NOT AVAILABLE WITHIN A REASONABLE TIME FRAME TO SCHEDULE THE RECALL REPAIR. THE DEALER STATED THAT THE PART MAY BE AVAILABLE AFTER NOVEMBER 16, 2015. THE MANUFACTURER COULD NOT…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 15V459000 (AIR BAGS) AND STATED THAT THE PART WAS NOT AVAILABLE WITHIN A REASONABLE TIME FRAME TO SCHEDULE THE RECALL REPAIR. THE DEALER STATED THAT THE PART MAY BE AVAILABLE AFTER NOVEMBER 16, 2015. THE MANUFACTURER COULD NOT PROVIDE AN ESTIMATED DATE FOR WHEN THE VEHICLE WOULD RECEIVE THE RECALL REPAIR. THE CONTACT WAS NOT EXPERIENCING A FAILURE. UPDATED 12/03/15*LJ THE CONSUMER STATED THE VEHICLE WAS REPAIRED UNDER THE RECALL ON 11/18/2015. *JS

NHTSA ODI #10780053

Mileage unknown · Oct 6, 2015
Air BagsVehicle Speed ControlCrash

TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. WHILE THE VEHICLE WAS IN THE PARK POSITION, IT ACCELERATED INDEPENDENTLY AND CRASHED INTO A BUILDING. THE AIR BAGS FAILED TO DEPLOY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THERE WERE NO INJURIES AND A POLICE REPORT WAS FILED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VI…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. WHILE THE VEHICLE WAS IN THE PARK POSITION, IT ACCELERATED INDEPENDENTLY AND CRASHED INTO A BUILDING. THE AIR BAGS FAILED TO DEPLOY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THERE WERE NO INJURIES AND A POLICE REPORT WAS FILED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 13V038000 (POWER TRAIN). THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ODI #10780026

9,000 miles · Oct 5, 2015
Electrical SystemEngine

TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT STATED THAT WHILE DRIVING AT 10 MPH, THE VEHICLE LOST ALL POWER AND THE VEHICLE BEGAN COASTING. THE CONTACT STATED THAT ONCE THE VEHICLE CAME TO A COMPLETE STOP THE VEHICLE WAS ABLE TO RESTART AFTER ABOUT THIRTY MINUTES. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT COULD NOT …

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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT STATED THAT WHILE DRIVING AT 10 MPH, THE VEHICLE LOST ALL POWER AND THE VEHICLE BEGAN COASTING. THE CONTACT STATED THAT ONCE THE VEHICLE CAME TO A COMPLETE STOP THE VEHICLE WAS ABLE TO RESTART AFTER ABOUT THIRTY MINUTES. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT COULD NOT BE DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 9,000.

NHTSA ODI #10779895

33,564 miles · Sep 20, 2015
Service Brakes

WHEN APPLYING BRAKES THE PEDAL GOES TO THE FLOOR WITH LITTLE OR NO BRAKING. UPON RELEASING BRAKE PEADAL AND DEPRESSING AGAIN THE BRAKES THEN WORK NORMALLY. OCCURS INTERMITTENTLY AND RANDOMLY. HAS OCCURED 4 TIMES BETWEEN 9/3/15 AN 9/20/15. BRAKES OPERATE NORMALLY OTHER THAN THE 4 RANDOM OCCURENCES. NO OTHER SIGNS OR SYMPTO…

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WHEN APPLYING BRAKES THE PEDAL GOES TO THE FLOOR WITH LITTLE OR NO BRAKING. UPON RELEASING BRAKE PEADAL AND DEPRESSING AGAIN THE BRAKES THEN WORK NORMALLY. OCCURS INTERMITTENTLY AND RANDOMLY. HAS OCCURED 4 TIMES BETWEEN 9/3/15 AN 9/20/15. BRAKES OPERATE NORMALLY OTHER THAN THE 4 RANDOM OCCURENCES. NO OTHER SIGNS OR SYMPTOMS. BRAKE SYSTEM ON VEHICLE HAS NOT BEEN SERVICED PRIOR TO THIS, IT IS AS DELIVERED NEW.

NHTSA ODI #10766227

18,000 miles · Sep 15, 2015
Power TrainSteeringWheels

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.

NHTSA ODI #10763966

5,000 miles · Sep 11, 2015
Power TrainUnknown Or Other

THE RAM1500 WAS BEING STARTED AND PUT IN REVERSE THEN DRIVE AND IT MAKES A GRINDING NOISE. STARTED GETTING WORSE AND FAMILY MEMBERS WOULD NOTICE THE NOISE WHEN LEAVING THEIR HOMES. THEN ABOUT 3 MONTHS AGO (JUNE 2015) WE TOOK IT IN TO DODGE AND THEY HEARD THE PROBLEM AND SAID THEY HAD CONTACTED THE ENGINEERS AND JUST KEEP AN EYE …

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THE RAM1500 WAS BEING STARTED AND PUT IN REVERSE THEN DRIVE AND IT MAKES A GRINDING NOISE. STARTED GETTING WORSE AND FAMILY MEMBERS WOULD NOTICE THE NOISE WHEN LEAVING THEIR HOMES. THEN ABOUT 3 MONTHS AGO (JUNE 2015) WE TOOK IT IN TO DODGE AND THEY HEARD THE PROBLEM AND SAID THEY HAD CONTACTED THE ENGINEERS AND JUST KEEP AN EYE ON IT. NO FIXING OF ANY KIND. NOW EVERY ONCE IN A WHILE, AS IT SHIFTS GEARS IT CLONKS INTO GEAR. THE TRANSMISSION DOES NOT ALWAYS SHIFT PROPERLY. IT STAYS IN A GEAR LONGER THAN IT SHOULD. YOU CAN HEAR THE GEARS NOT PROPERLY SHIFTING. THE BRAKES ON THE TRUCK DONT SEEM TO STOP FAST ENOUGH. TAKING TRUCK IN FOR THAT NEXT WEEK.

NHTSA ODI #10763168

29,303 miles · Sep 6, 2015
Electrical SystemPower TrainUnknown Or Other

I WAS DRIVING HOME FROM WORK AND THE STEERING WHEEL STARTED SHAKING AND THEN THE TRACTION LIGHT CAME ON. BEFORE I COULD PULL INTO A GAS STATION THE VEHICLE SHUT OFF ON ME. I TURNED THE KEY AND THE CAR WOULD NOT TURNOVER. I HAD THE VEHICLE TOWED TO MY HOUSE FOR THE NIGHT AND THEN TO MY MECHANIC THE NEXT MORNING. HE COULD NOT DIAG…

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I WAS DRIVING HOME FROM WORK AND THE STEERING WHEEL STARTED SHAKING AND THEN THE TRACTION LIGHT CAME ON. BEFORE I COULD PULL INTO A GAS STATION THE VEHICLE SHUT OFF ON ME. I TURNED THE KEY AND THE CAR WOULD NOT TURNOVER. I HAD THE VEHICLE TOWED TO MY HOUSE FOR THE NIGHT AND THEN TO MY MECHANIC THE NEXT MORNING. HE COULD NOT DIAGNOSE THE PROBLEM AND THAT'S WHEN I HAD IT TOWED TO THE DEALER. IT TOOK THEM 2-3 DAYS TO DIAGNOSE THE PROBLEM. WHAT THEY FOUND WAS A PROBLEM WITH THE ELECTRICAL SYSTEM. THIS IS HOW THEY STATED IT ON THE INVOICE: 29303 NO START P0688 ASD CIRCUIT FAULT, FOUND FUSE M19 BLOWN- REPLACED AND ATTEMPTED TO START- FUSE BLEW AGAIN. TRACED ASD CIRCUIT. FOUND IGNITION COIL #5 MELTED. TESTED FURTHER, FOUND #5 SPARK PLUGS FOULED AND CIRCUIT K16 SHORTED TO GROUND. REPLACED SPARK PLUGS, IGNITION INSUFFICIENT IONIZATION FAULT SET DIA AS A PCM WITH INTERNAL DRIVER FAULT CAUSED BY SHORT, REPLACED AND PROGRAMMED PCM. THIS OF COURSE HAPPENED 5 DAYS AFTER MY WARRANTY EXPIRED, GRANTED I DID NOT EVEN HAVE 30,000 MILES ON THE VEHICLE AT THE TIME.

NHTSA ODI #10761837

47,000 miles · Sep 6, 2015
Service Brakes

WHEN DRIVING AT APPROXIMATELY 25MPG DOWN A RESIDENTIAL STREET, I HEARD A SCRAPE AND A SLIGHT THUD TOWARDS THE REAR OF MY TRUCK.I IMMEDIATELY STARTED TO TRY TO SLOW DOWN AND PULL OVER BUT THERE WAS A LOSS OF BRAKES AND I HAD TO PUSH THE BRAKE ALMOST TO THE FLOOR TO GET IT TO STOP. I DID GET THE VEHICLE TO STOP AND CHECKED AROUND…

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WHEN DRIVING AT APPROXIMATELY 25MPG DOWN A RESIDENTIAL STREET, I HEARD A SCRAPE AND A SLIGHT THUD TOWARDS THE REAR OF MY TRUCK.I IMMEDIATELY STARTED TO TRY TO SLOW DOWN AND PULL OVER BUT THERE WAS A LOSS OF BRAKES AND I HAD TO PUSH THE BRAKE ALMOST TO THE FLOOR TO GET IT TO STOP. I DID GET THE VEHICLE TO STOP AND CHECKED AROUND THE CAR FOR THE PROBLEM. MY LEFT REAR BRAKE CALIPER WAS HANGING DOWN AND THE FLUID WAS LEAKING OUT. UPON CLOSE INSPECTION, BOTH OF THE CALIPER PINS WERE MISSING.

NHTSA ODI #10761827

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.