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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

What owners actually said

697 reports
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…

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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 · Feb 5, 2015
Engine And Engine CoolingFuel System, Diesel

TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 14V63500 (ENGINE AND ENGINE COOLING, FUEL SYSTEM, DIESEL); HOWEVER, THE PART NEEDED TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MAN…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 1500. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 14V63500 (ENGINE AND ENGINE COOLING, FUEL SYSTEM, DIESEL); HOWEVER, THE PART NEEDED TO DO THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF THE DELAY. THE CONTACT HAD NOT EXPERIENCED A FAILURE.

NHTSA ODI #10681595

30,000 miles · Feb 1, 2015
Service Brakes

FRONT BRAKES LOCKED UP AT 60 MPH. *TR

NHTSA ODI #10680306

49,000 miles · Jan 22, 2015
Exterior Lighting

THE DRIVER'S SIDE HEADLIGHT WOULD GO OFF AND ON IN INTERVALS AND THEN FINALLY WENT OUT COMPLETELY. I PURCHASED A STOCK BULB FROM A DODGE DEALERSHIP AND HAD THE BULB INSTALLED BY A DIFFERENT DODGE DEALERSHIP. AFTER HAVING THE BULB CHANGED AT FIELD'S CHRYSLER DODGE JEEP, THEY PULLED MY TRUCK AROUND FOR ME TO PICK UP AND I NOTICE…

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THE DRIVER'S SIDE HEADLIGHT WOULD GO OFF AND ON IN INTERVALS AND THEN FINALLY WENT OUT COMPLETELY. I PURCHASED A STOCK BULB FROM A DODGE DEALERSHIP AND HAD THE BULB INSTALLED BY A DIFFERENT DODGE DEALERSHIP. AFTER HAVING THE BULB CHANGED AT FIELD'S CHRYSLER DODGE JEEP, THEY PULLED MY TRUCK AROUND FOR ME TO PICK UP AND I NOTICED THAT IT STILL WASN'T WORKING, SO THEY TOOK IT BACK INTO THE SHOP AND WORKED ON IT SOME MORE AND FINALLY GOT THE HEADLIGHT WORKING. WITHIN A FEW DAYS AFTER THE BULB REPLACEMENT, THE LIGHT STOPPED WORKING AGAIN. I TOOK THE TRUCK BACK TO THE DEALERSHIP AND THEY TOLD ME THERE WAS A PART THAT THEY HAD TO ORDER, BUT USED A SECURITY TIE FOR THIS PART TO KEEP CONTINUITY UNTIL THE NEW PART ARRIVED. WHEN THE PART ARRIVED, I TOOK MY TRUCK BACK TO THE DEALERSHIP TO HAVE THE PART REPLACED. I RENTED A VEHICLE FOR THE DAY AND PICKED UP MY TRUCK THE FOLLOWING DAY. ABOUT 5 DAYS AFTER THIS REPAIR, THE HEADLIGHT WENT OUT AGAIN. NOW, I HAVE TO TAKE THE TRUCK BACK TO THE DEALERSHIP YET AGAIN AND SPEND MORE MONEY, TIME, MISSED WORK DUE TO THEIR DEFECTIVE PART AND DESIGN. I HAVE HAD SO MANY OTHER PROBLEMS WITH THIS TRUCK THAT IT IS MIND BOGGLING. I WAS JUST PULLED OVER BY THE POLICE LAST NIGHT FOR THE LIGHT BEING OUT. I CONSTANTLY WORRY ABOUT GETTING PULLED OVER WHEN DRIVING AT NIGHT AND THIS HAS BEEN EXTREMELY AGGRAVATING AND STRESSFUL. THIS HAS LIMITED MY DRIVING AT NIGHT SIGNIFICANTLY. I HAVE PERFORMED AN INTERNET SEARCH FOR THIS ISSUE WITH THIS TRUCK AND APPARENTLY THIS IS A COMMON SAFETY DEFECT. THUS FAR, I HAVE INCURRED AT LEAST $400.00 IN EXPENSES BUT DOES NOT ACCOUNT FOR MY TIME AND MISSED WORK. PLEASE HELP. *TR

NHTSA ODI #10678440

2,000 miles · Jan 13, 2015
Power Train

WHEN ON A40 TO45 PERCENT GRADE MY TRUCK TRANSMISSION WON'T ENGAGE UNLESS I REV TO 2000 TO 2500 RPM AND WHEN IT DOES IT BANGS INTO GEAR. THE DEALERSHIP SAYS THEY CAN NOT RECREATE THE PROBLEM BUT IT HAPPENS EVERY TIME I PUT MY BOAT IN OR TAKE IT OUT OF THE WATER. *TR

NHTSA ODI #10672281

27,591 miles · Jan 7, 2015
Service Brakes

BRAKES MUSHY, GO ALL WAY TO FLOOR, WHEN TRYING TO PUMP BRAKES TRUCK TAKES OFF KNOCKING 79 YEAR OLD WOMAN TO THE GROUND HURTING HER. TOOK TO DODGE DEALERSHIP THEY COULDN'T FIND ANYTHING. IT DID IT AGAIN TOOK IT TO ANOTHER DODGE DEALERSHIP, THEY SUGGESTED TO TAKE IT BACK TO THE ORIGINAL DODGE DEALERSHIP. TOTAL TIMES OF IT HAPPENIN…

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BRAKES MUSHY, GO ALL WAY TO FLOOR, WHEN TRYING TO PUMP BRAKES TRUCK TAKES OFF KNOCKING 79 YEAR OLD WOMAN TO THE GROUND HURTING HER. TOOK TO DODGE DEALERSHIP THEY COULDN'T FIND ANYTHING. IT DID IT AGAIN TOOK IT TO ANOTHER DODGE DEALERSHIP, THEY SUGGESTED TO TAKE IT BACK TO THE ORIGINAL DODGE DEALERSHIP. TOTAL TIMES OF IT HAPPENING 6 TIMES WITH THE LAST TIME TRUCK SHUTTING ITSELF OFF IN THE MIDDLE OF THE ROAD. BACKUP DISPLAY IS FREEZING UP AND TELLING TO GET OUT TO LOOK WHEN NOTHING IS THERE. DEALERSHIP JAMES HODGE MOTOR CO. THINKS IT THE COMPUTER BOARD BUT THEY DON'T WANT TO DO ANYTHING ABOUT IT, BECAUSE THERE'S NO RECALL FOR WHAT'S HAPPENING. I DID SOME RESEARCH AND FOUND SOMETHING ON THE BRAKES, WHEN I WENT BACK TO PRINT IT OUT, THE ARTICLE WAS NOT THERE ANYMORE. REIMERS, PARIS, TEXAS ANY OTHERS THAT THIS IS HAPPENING TO PLEASE REPORT FOR SAFETY. *TR

NHTSA ODI #10670748

30,000 miles · Jan 3, 2015
Exterior Lighting

THE HEADLIGHTS TURN OFF AND STAY OFF INDEFINITELY. TOGGLING THE HEADLIGHT SWITCH CAN SOMETIMES GET THEM TO COME BACK ON, BUT NOT ALWAYS. *TR

NHTSA ODI #10669884

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 …

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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

2,700 miles · Nov 20, 2014
EngineService Brakes

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

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

NHTSA ODI #10659822

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

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

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

NHTSA ODI #10653582

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.