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2012 Dodge RAM 2500

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2012 Dodge RAM 2500 do not stand out strongly from the model-year median of 275.

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When problems were reported

Mileage at the reported incident

179 reports with mileage · 104 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.

  • Steering. Review the 109 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 51 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine. Review the 44 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

8 crash reports12 fire reports4 injury reports

Suspension complaints

22 reports
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Mileage unknown · Oct 7, 2022
Suspension

When driving at highway speed, if I hit the seam between the road and a bridge and it is not smooth my truck goes into a, "Death wobble." The steering wheel and the whole truck shakes uncontrollably. I can barely keep it in the road. It will only stop when the vehicle slows below 30mph. This problem started about 48,000 miles, I…

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When driving at highway speed, if I hit the seam between the road and a bridge and it is not smooth my truck goes into a, "Death wobble." The steering wheel and the whole truck shakes uncontrollably. I can barely keep it in the road. It will only stop when the vehicle slows below 30mph. This problem started about 48,000 miles, I only have a little over 56,000 now. I have changed the stabilizer, got new tires and an alignment. I will be taking it to a mechanic on the 17th but I really believe the manufacture should have a recall on this vehicle. It is very dangerous. I am not the only person to own one of these trucks and this happens to.

NHTSA ODI #11488389

135,000 miles · Feb 19, 2020
Suspension

TL* THE CONTACT OWNS A 2012 RAM 2500. THE CONTACT STATED WHILE DRIVING AT AN UNKNOWN SPEED THE TRACK BAR BUSHING FELL APART AND CAUSED EXCESSIVE SHAKING WITHOUT WARNING. THE CONTACT HAD TO PULL THE VEHICLE TO THE SIDE OF THE ROAD FOR SEVERAL MINUTES. THE CONTACT DROVE THE VEHICLE TO THE RESIDENCE. THE VEHICLE WAS NOT TAKEN TO A …

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TL* THE CONTACT OWNS A 2012 RAM 2500. THE CONTACT STATED WHILE DRIVING AT AN UNKNOWN SPEED THE TRACK BAR BUSHING FELL APART AND CAUSED EXCESSIVE SHAKING WITHOUT WARNING. THE CONTACT HAD TO PULL THE VEHICLE TO THE SIDE OF THE ROAD FOR SEVERAL MINUTES. THE CONTACT DROVE THE VEHICLE TO THE RESIDENCE. THE VEHICLE WAS NOT TAKEN TO A DEALER FOR A DIAGNOSTIC TEST OR REPAIRS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE HOWEVER, NO ASSISTANCE WAS OFFERED. THE FAILURE MILEAGE WAS 135,000.

NHTSA ODI #11310198

50,000 miles · Apr 2, 2019
Power TrainSuspensionWheels

TL* THE CONTACT OWNS A 2012 RAM 2500. THE CONTACT STATED THAT THE REAR AXLES SEIZED AND THE REAR TIRES SLID WHILE OPERATING THE VEHICLE. THE VEHICLE SLID OFF THE ROAD DUE TO THE FAILURE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE DEALER WAS NOT CONTACTED. THE CONTACT WAS A MECHANIC AND DIAGNOSED THAT THE VEHICLE NEEDED A …

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TL* THE CONTACT OWNS A 2012 RAM 2500. THE CONTACT STATED THAT THE REAR AXLES SEIZED AND THE REAR TIRES SLID WHILE OPERATING THE VEHICLE. THE VEHICLE SLID OFF THE ROAD DUE TO THE FAILURE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE DEALER WAS NOT CONTACTED. THE CONTACT WAS A MECHANIC AND DIAGNOSED THAT THE VEHICLE NEEDED A FILL PLUG AND NEW GEAR OIL. THE VEHICLE WAS NOT REPAIRED BECAUSE THE CONTACT DID NOT HAVE THE PROPER FILL COVER FOR THE FILL PLUG. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND DID NOT ASSIST. THE DEALER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 50,000. THE VIN WAS UNKNOWN.

NHTSA ODI #11193335

38,000 miles · Sep 12, 2017
Suspension

AT APPRX.38,000 MI,ON A FREEWAY AT 65 MPH, RAN OVER A SMALL BUMP IN THE ROAD THE TRUCK BEGAN SHAKING VIOLENTLY, AS IF IT WAS GOING TO FLY APART.TOOK FOOT OF THE GAS, HIT THE BRAKES UNTIL SLOWED TO APPROX.. 40 MPH. I'M A SMALL FEMALE IT WAS ALL I COULD DO TO GET THE VEHICLE TO THE OFF RAMP. THIS WAS NOT A NORMAL TIRE OUT OF BALAN…

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AT APPRX.38,000 MI,ON A FREEWAY AT 65 MPH, RAN OVER A SMALL BUMP IN THE ROAD THE TRUCK BEGAN SHAKING VIOLENTLY, AS IF IT WAS GOING TO FLY APART.TOOK FOOT OF THE GAS, HIT THE BRAKES UNTIL SLOWED TO APPROX.. 40 MPH. I'M A SMALL FEMALE IT WAS ALL I COULD DO TO GET THE VEHICLE TO THE OFF RAMP. THIS WAS NOT A NORMAL TIRE OUT OF BALANCE SITUATION.IF SO IT WOULD DO THAT CONSISTENTLY. A FEW WEEKS LATER IT OCCURRED WHILE MY HUSBAND WAS DRIVING IT.HE'S DEFINITION IS LIKE A BUCKING BRONCO. WE PURCHASED AN EXTENDED WARRANTY FROM THE DEALERSHIP LAKE NORMAN CHRYSLER DODGE. TOOK THE TRUCK IN WE THOROUGHLY EXPLAINED TO THE SERVICE WRITER HOW DANGEROUS THIS IS, IT'S A SAFETY ISSUE. HE WROTE IT UP AS A VERY BAD VIBRATION. THEIR FINDINGS WAS A STEERING STABALIZER AND REPLACED IT. MILEAGE WAS 42722. IT DOESN'T DO THIS WITH EVERY BUMP YOU HIT. THIS VEHICLE IS NOT DRIVEN OFTEN. NOW ONLY A FEW HUNDRED MILES LATER IT HAPPENED AGAIN TWICE. BOTH TIMES WHILE TRAVELING ON THE FREEWAY 60 TO 65 MPH. WHEN YOU'RE ON A FREEWAY AND A TRACTOR TRAILER TRUCK IS BEHIND YOU, IT IS LIFE THREATENING TO TAKE YOUR FOOT OFF THE GAS AND HIT THE BRAKES. THE TRUCK IS BACK AT THE DEALERSHIP HAS BEEN THERE FOR 1 1/2 WEEKS. THEY CAN'T FIND ANYTHING WRONG. WE HAVE DISCOVERED THIS IS CALLED THE DEATH WOBBLE AND DODGE HAS HAD THIS PROBLEM FOR YEARS AND HAS NEVER SOLVED THE PROBLEM.THIS HAS BEEN A MAJOR PROBLEM ON THE DODGE RAM 2500 AND JEEP WRANGLERS. NORMALLY IT OCCURS WHEN THE VEHICLE HAS 150,000 MILES ON IT OR BETTER WHEN PARTS HAVE WORN OUT, NOT AT 40,000.IF THE DEALER SAYS THAT ALL THE PARTS AND BUSHINGS ARE GOOD, IF SO, THEN THIS IS A DODGE RAM DESIGN FLAW. THERE ARE REPORTS ALL OVER THE INTERNET OF OTHER OWNERS WHO HAVE THIS SAME PROBLEM AND HOW DANGEROUS IT IS. WE PAID A LOT OF MONEY TO PURCHASE THIS VEHICLE AND NOW CAN'T EVEN DRIVE IT.

NHTSA ODI #11022939

31,000 miles · Apr 12, 2016
Power TrainService BrakesSuspension

THE TRANSFER CASE OF THE TRUCK BROKE SUDDENLY AND SINCE I WAS DRIVING AT 75 MILES, THE ROTATION OF THE METAL PARTS KEEP GOING AND BROKE MAYOR PARTS UNDER THE RUCKS SUCH AS TRANSMITION, SUSPENSION, OIL LINES, DIESEL LINES, AND MUCH AND MUCH MORE EVEN MADE A HOLE UNDER THE CABIN. THE PART UNDER THE TRUCK JUST LOOK LIKE SOMETHING E…

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THE TRANSFER CASE OF THE TRUCK BROKE SUDDENLY AND SINCE I WAS DRIVING AT 75 MILES, THE ROTATION OF THE METAL PARTS KEEP GOING AND BROKE MAYOR PARTS UNDER THE RUCKS SUCH AS TRANSMITION, SUSPENSION, OIL LINES, DIESEL LINES, AND MUCH AND MUCH MORE EVEN MADE A HOLE UNDER THE CABIN. THE PART UNDER THE TRUCK JUST LOOK LIKE SOMETHING EXPLODED BECAUSE THE DAMAGE IS TOO BIG. EVEN BEYOND REPAIR FOR ME.

NHTSA ODI #10855119

44,000 miles · Dec 22, 2015
SuspensionCrash

TL* THE CONTACT OWNS A 2012 RAM 2500. THE CONTACT STATED THAT WHILE DRIVING AT 60 MPH, THE FRONT END OF THE VEHICLE BEGAN TO SHAKE UNCONTROLLABLY WITHOUT WARNING. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE UPPER AND LOWER BALL JOINTS HAD FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BUT THE FA…

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TL* THE CONTACT OWNS A 2012 RAM 2500. THE CONTACT STATED THAT WHILE DRIVING AT 60 MPH, THE FRONT END OF THE VEHICLE BEGAN TO SHAKE UNCONTROLLABLY WITHOUT WARNING. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE UPPER AND LOWER BALL JOINTS HAD FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. ON ANOTHER OCCASION, THE VEHICLE SHOOK UNCONTROLLABLY WHICH CAUSED THE CONTACT TO CRASH INTO A DITCH. THE VEHICLE WAS ABLE TO BE DRIVEN AFTER THE CRASH. THE VEHICLE WAS NOT TAKEN BACK TO THE DEALER TO BE DIAGNOSED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 44,000. UPDATED 02/10/16*LJ THE CONSUMER WAS INFORMED THE TORSION BAR NEEDED TO BE REPLACED. UPDATED 02/18/16.*JB

NHTSA ODI #10811783

Mileage unknown · Nov 17, 2015
SteeringSuspension

MY VEHICLE IS PART OF THE RAM TRUCK REPURCHASE UNDER RECALL N49. FCA US SENT ME AN OFFER FOR MY TRUCK THAT I RECEIVED OCTOBER 26. I FILLED OUT THE PAPERWORK AND E-MAILED IT TO THE LISTED ADDRESS. I CALLED THE NEXT DAY, OCTOBER 27 AND FCA US VERIFIED THEY HAD RECIEVED MY DOCUMENTATION. THEY SAID A CHECK FOR THE REPURCHASE HAD BE…

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MY VEHICLE IS PART OF THE RAM TRUCK REPURCHASE UNDER RECALL N49. FCA US SENT ME AN OFFER FOR MY TRUCK THAT I RECEIVED OCTOBER 26. I FILLED OUT THE PAPERWORK AND E-MAILED IT TO THE LISTED ADDRESS. I CALLED THE NEXT DAY, OCTOBER 27 AND FCA US VERIFIED THEY HAD RECIEVED MY DOCUMENTATION. THEY SAID A CHECK FOR THE REPURCHASE HAD BEEN REQUESTED. I WAS INFORMED THIS WOULD ONLY TAKE 2-3 DAYS TO ISSUE A CHECK. I CALLED BACK ON NOVEMBER 17 BECAUSE I HAVE NOT HEARD FROM FCA US FOR THREE WEEKS. AT THIS POINT FCA US CLAIMED THEY WERE WAITING ON MY DOCUMENTS. I TOLD THEM THEY HAD ALREADY VERIFIED RECEIPT OF SAID DOCUMENTATION ON OCTOBER 27. THE REPRESENTATIVE SAID " LET ME LOOK" AND AFTER LOOKING VERIFIED FCA US DID HAVE THE DOCUMENTATION AND STATED THEY WOULD REQUEST A CHECK FOR THE REPURCHASE. I ASKED HOW LONG UNTIL I COULD EXPECT TO HERE FROM THEM AND I WAS INFORMED THAT THEY ARE NOT GIVING TIMES. I QUESTIONED THE FACT THAT THEY TOLD ME 2-3 DAYS 3 WEEKS AGO AND WAS TOLD "THAT'S NOT TRUE, WE ARE NOT GIVING TIMES". IS FCA US GOING TO BE HELD ACCOUNTABLE? IT DOESN'T SEEM LIKE THEY HAVE ANY INTENT IN PAYING ME OR MY FAMILY FOR OUR UNSAFE VEHICLE. THIS RAM 2500 IS MY PRIMARY VEHICLE AND I CANNOT REPLACE IT UNTIL FCA US PAYS US WHAT IS OWED AND THIS BEING OUR PRIMARY VEHICLE WE HAVE NO CHOICE BUT CONTINUE TO DRIVE THIS UNSAFE VEHICLE WITH FAULTY STEERING THAT COULD BREAK AND CAUSE US TO CRASH.

NHTSA ODI #10794536

15,000 miles · Nov 17, 2015
SteeringSuspension

I HAVE A 2012 RAM 2500 WITH 20,000 MILES. WHENEVER YOU GO OVER A BUMP OR RAILROAD TRACK THE TRUCK STARTS TO WOBBLE UNCONTROLLABLY THAT YOU NEED TO COME TO A COMPLETE STOP. ON ONE OCCASION I WAS ON THE NEW YORK THRUWAY TRAVELING AT 70 AND HIT A BUMP AND COULDN'T EVEN SEE STRAIGHT IT WAS WOBBLING SO BAD. HAVE BROUGHT TO DEALER WH…

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I HAVE A 2012 RAM 2500 WITH 20,000 MILES. WHENEVER YOU GO OVER A BUMP OR RAILROAD TRACK THE TRUCK STARTS TO WOBBLE UNCONTROLLABLY THAT YOU NEED TO COME TO A COMPLETE STOP. ON ONE OCCASION I WAS ON THE NEW YORK THRUWAY TRAVELING AT 70 AND HIT A BUMP AND COULDN'T EVEN SEE STRAIGHT IT WAS WOBBLING SO BAD. HAVE BROUGHT TO DEALER WHEN IT FIRST HAPPENED LAST YEAR AND WAS TOLD IT WAS A BAD STEERING DAMPENER WAS REPLACED AND PROBLEM STILL EXISTS. MY WIFE WILL NOT USE THE TRUCK BECAUSE IS TERRIFIED OF THE ISSUE. I HAVE OWNED MANY RAM TRUCKS AND HAVE NEVER HAD THIS PROBLEM. AN INEXPERIENCED DRIVER COULD RESULT INTO A SERIOUS ACCIDENT.

NHTSA ODI #10794524

33,000 miles · Nov 3, 2015
Suspension

TL* THE CONTACT OWNS A 2012 DODGE RAM 2500. WHILE DRIVING 80 MPH, AN ABNORMALLY LOUD NOISE WAS HEARD UNDER THE VEHICLE. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE U-JOINT FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WA…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 2500. WHILE DRIVING 80 MPH, AN ABNORMALLY LOUD NOISE WAS HEARD UNDER THE VEHICLE. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE U-JOINT FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 33,000.

NHTSA ODI #10787998

10,000 miles · Oct 19, 2015
Suspension

TL* THE CONTACT OWNS A 2012 DODGE RAM 2500. WHEN THE VEHICLE MADE A LEFT TURN, A POPPING NOISE WAS PRESENT NEAR THE FRONT END OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DUPLICATE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE CONTACT WAS INFORMED THAT T…

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TL* THE CONTACT OWNS A 2012 DODGE RAM 2500. WHEN THE VEHICLE MADE A LEFT TURN, A POPPING NOISE WAS PRESENT NEAR THE FRONT END OF THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHO WAS UNABLE TO DUPLICATE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 13V529000 (SUSPENSION). THE CONTACT STATED THAT THE VEHICLE EXPERIENCED THE SAME FAILURE LISTED IN THE RECALL. THE FAILURE MILEAGE WAS 10,000.

NHTSA ODI #10783222

Official recalls

4

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.

14V635000 · Engine And Engine Cooling:engine:diesel; Fuel System, Diesel

Oct 8, 2014

Chrysler Group LLC (Chrysler) is recalling certain model year 2010-2014 Ram 2500, 3500, 4500, and 5500 trucks manufactured March 27, 2009, to September 5, 2013. In the affected vehicles, the electrical connectors of the diesel fuel heater may overheat.

Consequence & remedy

Consequence: If the connectors overheat, the fuel heater may leak fuel, increasing the risk of a fire.

Remedy: Chrysler will notify owners, and dealers will replace the harness side connector with a silver plated beryllium copper terminal service kit, and inspect the fuel heater for leaks, replacing it as necessary, free of charge. Chrysler issued interim notification to owners on December 8, 2014. The recall began on April 27, 2015. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is P65.

Additional source detail variants (2)

Fuel System, Diesel

Chrysler Group LLC (Chrysler) is recalling certain model year 2010-2014 Ram 2500, 3500, 4500, and 5500 trucks manufactured March 27, 2009, to September 5, 2013. In the affected vehicles, the electrical connectors of the diesel fuel heater may overheat.

Consequence: If the connectors overheat, the fuel heater may leak fuel, increasing the risk of a fire.

Remedy: Chrysler will notify owners, and dealers will replace the harness side connector with a silver plated beryllium copper terminal service kit, and inspect the fuel heater for leaks, replacing it as necessary, free of charge. Chrysler issued interim notification to owners on December 8, 2014. The recall began on April 27, 2015. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is P65.

Engine And Engine Cooling:engine:diesel

Chrysler Group LLC (Chrysler) is recalling certain model year 2010-2014 Ram 2500, 3500, 4500, and 5500 trucks manufactured March 27, 2009, to September 5, 2013. In the affected vehicles, the electrical connectors of the diesel fuel heater may overheat.

Consequence: If the connectors overheat, the fuel heater may leak fuel, increasing the risk of a fire.

Remedy: Chrysler will notify owners, and dealers will replace the harness side connector with a silver plated beryllium copper terminal service kit, and inspect the fuel heater for leaks, replacing it as necessary, free of charge. Chrysler issued interim notification to owners on December 8, 2014. The recall began on April 27, 2015. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is P65.

13V529000 · Steering:linkages:tie Rod Assembly

Nov 6, 2013

Chrysler Group LLC (Chrysler) is recalling certain model year 2008-2012 RAM 2500 4X4 and 3500 4X4 trucks, 2008-2012 Dodge RAM 3500 4x2 Cab Chassis, and model year 2008 Dodge RAM 1500 Mega Cab 4x4. The left tie rod assembly may break.

Consequence & remedy

Consequence: A failure of the tie rod assembly may result in a loss of steering control, increasing the risk of a crash.

Remedy: Chrysler notified owners on January 16, 2014 that dealers would inspect vehicles and replace the steering linkage assembly, if necessary. On or about February 27, 2014, Chrysler ceased its recall remedy program due to parts quality concerns, and then re-initiated it on or about April 14, 2014. 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 N49.

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.