NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
150 reports146,000 miles · Sep 18, 2024
Air Bags
The contact owns a 2010 Dodge Ram 3500. The contact stated while driving approximately 30 MPH, the air bag warning light illuminated. The contact stated that the vehicle was taken to an independent mechanic who diagnosed the vehicle and determined that the driver's side air bag needed to be replaced. The mechanic informed the co…
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The contact owns a 2010 Dodge Ram 3500. The contact stated while driving approximately 30 MPH, the air bag warning light illuminated. The contact stated that the vehicle was taken to an independent mechanic who diagnosed the vehicle and determined that the driver's side air bag needed to be replaced. The mechanic informed the contact of NHTSA Campaign Number: 16V947000 (Air Bags). The contact called a dealer and was informed that the VIN was not included. The manufacturer was not made aware of the failure. The failure mileage was approximately 146,000.
NHTSA ODI #11615152
270,000 miles · Dec 5, 2023
Electrical System
The contact owns a 2010 Dodge Ram 3500. The contact stated that while driving at various speeds, the vehicle shut off without warning. The contact stated that the failure occurred after driving over a bump in the roadway. The contact stated that occasionally, while wiggling the ignition key the engine would turn on before shutti…
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The contact owns a 2010 Dodge Ram 3500. The contact stated that while driving at various speeds, the vehicle shut off without warning. The contact stated that the failure occurred after driving over a bump in the roadway. The contact stated that occasionally, while wiggling the ignition key the engine would turn on before shutting off. The vehicle was taken to the local dealer who determined that the ignition switch was faulty and needed to be replaced. The manufacturer was notified of the failure, but no assistance was offered. The contact was informed that the VIN was not included in the NHTSA Campaign Number: 14V373000 (Electrical System). The contact stated that the vehicle had experienced the failure listed in the recall. The failure mileage was 270,000.
NHTSA ODI #11558508
Mileage unknown · Jun 12, 2022
Electrical SystemSteeringVehicle Speed Control
Fobik key ignition vibrates causing switching from (RUN) position to (ACC) position, shutting off the engine and making it almost impossible to steer a 3000kg machine without power steering increasing the risk for accidents.
NHTSA ODI #11468887
Mileage unknown · Nov 22, 2021
Electrical SystemEngineFuel/propulsion SystemFire
Truck totally destroyed by spontaneous fire, suspected to be related to short in radio or dashboard. Assessment done by fire department and truck paid off by Progressive Insurance but no compensation for contents of truck. Truck in driveway, not running and fire damaged adjacent vehicle at cost of $7000 paid by vehicle owner and…
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Truck totally destroyed by spontaneous fire, suspected to be related to short in radio or dashboard. Assessment done by fire department and truck paid off by Progressive Insurance but no compensation for contents of truck. Truck in driveway, not running and fire damaged adjacent vehicle at cost of $7000 paid by vehicle owner and USAA insurance.
NHTSA ODI #11441379
Mileage unknown · Jul 30, 2021
Power Train
My husband, our son, and I were traveling down the highway at about 60-65mph when we started hearing a low winding sound. Seconds later, before my husband could get the truck over to the shoulder of the road, there was a loud banging sound coming from underneath the truck that sounded like something was coming through the floorb…
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My husband, our son, and I were traveling down the highway at about 60-65mph when we started hearing a low winding sound. Seconds later, before my husband could get the truck over to the shoulder of the road, there was a loud banging sound coming from underneath the truck that sounded like something was coming through the floorboard. He was finally able to get the truck pulled to the shoulder of the road but wasn't able to put the truck in the park position. He had to use the park brake to get the truck to completely stop. Once the tow truck safely lifted the truck, you could clearly see gears hanging amd what looked to be remains of the transfer case. The truck was towed to a body shop where several codes were discovered, which all pertained to the truck going into 4wd by itself without any warning and unknowing to the driver. This glitch is what appears to have caused the transfer case to grenade, further causing damage to the drive shaft and smashing the fuel line. We, as owners, had the transfer case serviced and fluids flushed just two weeks prior to this happening After further investigation and conversations with the local Dodge dealer, it appears that this has happened in several situations yet no safety recalls have been issued. There is a national backorder for transfer cases for our particular year which is a red flag. We're now left with an over $8100.00 bill and everyone pointing the finger at each other. This could have ended tragically had there been more traffic on the road when the truck began stalling on the busy interstate.
NHTSA ODI #11427230
Mileage unknown · Jul 21, 2021
Power Train
My family and I were traveling down the interstate about 60-65mph in 2 wheel drive when out of nowhere we started hearing a whining/roaring noise that quickly got louder. Seconds later, there was a loud rumbling noise that sounded like something was coming through the floorboard of the truck. Luckily, I was able to steer the tru…
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My family and I were traveling down the interstate about 60-65mph in 2 wheel drive when out of nowhere we started hearing a whining/roaring noise that quickly got louder. Seconds later, there was a loud rumbling noise that sounded like something was coming through the floorboard of the truck. Luckily, I was able to steer the truck to the shoulder of the road and get it to stop, but the truck would not go into park. I had to use the park brake to make sure that it wouldn't roll. After the tow truck arrived and safely jacked the truck up, we immediately noticed that it was the transfer case that had exploded. Gears were hanging out in plain site and it caused a bend in my front driveshaft. There were no warning signs and I had just had the transfer case and my transmission serviced and flushed 2 weeks prior. This put my family's and other lives in danger because had there been more traffic on the road at the time this happened, I wouldn't have had time or room to maneuver my truck safely to get it off the road. We could have been rear ended or had broken parts fly off the truck, that would have been out of my control. The truck was towed to the shop where I had the transfer case serviced, but as of now there's a national backorder on transfer cases for this truck. In speaking with the dealer and doing my own research, I've also learned that there has been a recall on the transfer cases of 2016 and newer Ram 3500 trucks. This needs to be looked into asap. Codes pulled from the truck at the auto shop where the truck currently is are c1404, c1405, c140d stating that the transfer case motor puts the system in 4wd by itself while driving without any warning.
NHTSA ODI #11425835
Mileage unknown · Jul 13, 2021
Electrical System
WIN ignition module has slowly been causing difficult starting problems. Now, over even slight bumps, the sloppiness in the connection between the key and the WIN module allows the key to move and the vehicle to shut off while driving. This is becoming more and more common and is very dangerous. Just on my 10 minute drive home f…
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WIN ignition module has slowly been causing difficult starting problems. Now, over even slight bumps, the sloppiness in the connection between the key and the WIN module allows the key to move and the vehicle to shut off while driving. This is becoming more and more common and is very dangerous. Just on my 10 minute drive home from work today, it occurred 4 times. One time, I had just turned right on a red light (with plenty of space between me and oncoming traffic) and the truck shut off completely. Without the key being in the exact right position, I had difficulty restarting the truck and could have been very dangerous to me and the vehicle coming toward me.
NHTSA ODI #11424690
259,300 miles · Mar 29, 2021
Electrical SystemService BrakesSteering
WHILE DRIVING, THE TRUCK JUST SHUTS OFF. RESULTING IN LOSS OF STEERING, LIGHTS AND POWER BREAKS.
NHTSA ODI #11405433
100,000 miles · Feb 23, 2021
Fuel/propulsion System
DURING FUELING WITH THE VEHICLE STATIONARY, FUEL WILL SPILL OUT OF SPOUT WHEN TANK IS FULL AS FUEL DISPENSER SHUTS OFF. THIS HAPPENS ANY TIME VEHICLE IS FUELED.
NHTSA ODI #11397637
36,662 miles · Oct 24, 2020
Fuel/propulsion System
WHILE TRAVELING ON THE HIGHWAY AT APPROXIMATELY 75 MPH WITH A LOAD IN THE BED OF THE TRUCK AND TOWING A TRAILER, THE VEHICLE ENGINE STOPPED, ELIMINATING POWER STEERING AND POWER BRAKES. AFTE HAVING THE VEHICLE TOWED TO THE DEALER FOR DIAGNOSIS, IT WAS DETERMINED THAT THE CP$ HIGH PRESSURE FUEL PUMP HAD DISCINTEGRATED.
NHTSA ODI #11366248
Official recalls
9Jan 15, 2019
Chrysler (FCA US LLC) is recalling certain 2010 Dodge Ram 3500, Ram 4500/5500, 2010-2011 Dodge Dakota, 2010-2014 Dodge Challenger, 2010-2015 Dodge Challenger, Chrysler 300, and 2010-2016 Jeep Wrangler vehicles. Upon deployment of the driver's frontal air bag, excessive internal pressure may cause the inflator to explode.
Consequence & remedy
Consequence: In the event of a crash necessitating deployment of the passenger's frontal air bag, the inflator could explode with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. The recall began February 4, 2019. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is V01.
Jan 9, 2018
Chrysler (FCA US LLC) is recalling certain 2009-2013 Jeep Wrangler, Chrysler 300, Dodge Challenger and Dodge Charger vehicles, and 2009-2011 Dodge Dakota vehicles sold, or ever registered, in the states of Alabama, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, South Carolina, Texas, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands or "Zone A." Additionally, Chrysler is recalling certain 2009-2010 RAM 4500 Cab Chassis, RAM 5500 Cab Chassis, RAM 3500 Cab Chassis, Jeep Wrangler, Chrysler 300, Dodge Dakota, Dodge Challenger, and Dodge Charger vehicles ever registered in the states of Arizona, Arkansas, Delaware, District of Columbia, Illinois, Indiana, Kansas, Kentucky, Maryland, Missouri, Nebraska, Nevada, New Jersey, New Mexico, North Carolina, Ohio, Oklahoma, Pennsylvania, Tennessee, Virginia, and West Virginia or "Zone B." Chrysler is also recalling certain 2009 RAM 3500, RAM 2500, RAM 4500 Cab Chassis, RAM 5500 Cab Chassis, Dodge Durango, Chrysler Aspen, RAM 3500 Cab Chassis, Jeep Wrangler, Chrysler 300, Dodge Dakota, Dodge Challenger, and Dodge Charger vehicles ever registered in the states of Alaska, Colorado, Connecticut, Idaho, Iowa, Maine, Massachusetts, Michigan, Minnesota, Montana, New Hampshire, New York, North Dakota, Oregon, Rhode Island, South Dakota, Utah, Vermont, Washington, Wisconsin, and Wyoming. In the event of a crash necessitating deployment of the passenger frontal air bag, these passenger air bag inflator may explode due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling.
Consequence & remedy
Consequence: An inflator explosion may result in sharp metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler will notify owners, and dealers will replace the passenger frontal air bag inflator, free of charge. The recall began February 28, 2018. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is U03.
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.
Dec 22, 2016
Chrysler (FCA US LLC) is recalling certain model year 2009 Dodge Durango and Chrysler Aspen vehicles manufactured January 17, 2007, to December 18, 2008, and 2010 RAM 3500 cab chassis manufactured September 25, 2009, to February 1, 2010. The affected vehicles are equipped with a dual-stage driver frontal air bag that may be susceptible to moisture intrusion which, over time, could cause the inflator to rupture.
Consequence & remedy
Consequence: In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could rupture with metal fragments striking the driver or other occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler has notified owners, and dealers will replace the driver's frontal air bag inflator, free of charge. The recall began January 11, 2017. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is S92. Note: This recall covers vehicles that were accidentally excluded from recall 15V-313.
Oct 13, 2016
Chrysler (FCA US LLC) is recalling certain model year 2011-2014 Dodge Charger Police vehicles, 2007-2013 RAM 3500 Cab Chassis, 2008-2013 RAM 4500 and 5500 Cab Chassis, and 2013 RAM 2500 and 3500 vehicles. The affected vehicles have a 220 amp alternator that may suddenly fail.
Consequence & remedy
Consequence: If the alternator fails, the vehicle may stall without warning, increasing the risk of a crash. There is also the possibility that the alternator may short circuit, increasing the risk of a fire.
Remedy: Chrysler will notify owners, and dealers will replace the alternator with a revised alternator, free of charge. The recall began on December 23, 2016. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is S68.
May 24, 2016
Chrysler (FCA US LLC) expanded the affected population to include 73,712 2005-2009 RAM 2500 trucks produced at the St. Louis North Assembly Plant. With this change, Chrysler is recalling certain model year 2004-2008 RAM 1500, 2005-2009 RAM 2500, 2006-2009 RAM 3500, 2007-2010 RAM 3500 Cab Chassis, 2008-2010 RAM 4500 and 5500 Cab Chassis, 2004-2009 Dodge Durango, 2007-2009 Chrysler Aspen, 2007-2012 Jeep Wrangler, 2008-2012 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2012 Chrysler 300, 2006-2012 Dodge Charger, 2005-2011 Dodge Dakota, and 2006-2009 Mitsubishi Raider vehicles originally sold, or ever registered, in AL, CA, FL, GA, HI, LA, MS, SC, TX, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Chrysler is also recalling 2004-2008 RAM 1500, 2005-2009 RAM 2500, 2006-2009 RAM 3500, 2007-2009 RAM 3500 Cab Chassis, 2008-2009 RAM 4500 and 5500 Cab Chassis, 2004-2009 Dodge Durango, 2007-2009 Chrysler Aspen, 2007-2009 Jeep Wrangler, 2008-2009 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2009 Chrysler 300, 2006-2009 Dodge Charger, 2005-2009 Dodge Dakota and 2006-2009 Mitsubishi Raider vehicles originally sold, or ever registered, in AZ, AR, DE, Washington D.C., IL, IN, KS, KY, MD, MO, NE, NV, NJ, NM, NC, OH, OK, PA, TN, VA, and WV, or "Zone B." Lastly, unless included in "Zone A" or "Zone B" above, Chrysler is recalling certain 2005-2008 RAM 2500, 2006-2008 RAM 3500, 2007-2008 RAM 3500 Cab Chassis, 2008 RAM 4500 and 5500 Cab Chassis, 2004-2008 Dodge Durango, 2007-2008 Chrysler Aspen, 2007-2008 Jeep Wrangler, 2008 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2008 Chrysler 300, 2006-2008 Dodge Charger, 2005-2008 Dodge Dakota, and 2006-2008 Mitsubishi Raider vehicles originally sold, or registered, in AK, CO, CT, ID, IA, ME, MA, MI, MN, MT, NH, NY, ND, OR, RI, SD, UT, VT, WA, WI, and WY.
Consequence & remedy
Consequence: These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. These inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling. An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.
Remedy: Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler will notify the Chrysler, Dodge, Jeep and RAM owners. Mitsubishi owners will be notified by their company. Dealers will replace the passenger frontal air bag inflator, free of charge. The recall began on March 27, 2017. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is S43. Note: This recall supersedes recall 14V-7700.
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.
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.
Jul 6, 2011
CHRYSLER IS RECALLING CERTAIN MODEL YEAR 2008-2011 DODGE RAM 2500/3500 4X4, MANUFACTURED FROM FEBRUARY 14, 2008, THROUGH MARCH 28, 2011; MODEL YEAR 2008-2011 DODGE RAM 3500 CAB CHASSIS 4X2, MANUFACTURED FROM FEBRUARY 14, 2008, THROUGH MARCH 28, 2011; AND MODEL YEAR 2008 DODGE RAM 1500 MEGA CAB 4X4, MANUFACTURED FROM FEBRUARY 14, 2008, THROUGH AUGUST 15, 2008, BECAUSE THE LEFT TIE ROD BALL STUD MAY FRACTURE. THIS CONDITION TENDS TO OCCUR DURING LOW SPEED PARKING LOT TYPE MANEUVERS WHEN THE CUSTOMER IS MAKING A TIGHT TURN. ADDITIONALLY, MODEL YEAR 2003-2008 DODGE RAM 2500/3500 VEHICLES MAY HAVE RECEIVED THE AFFECTED TIE ROD ASSEMBLY AS A REPLACEMENT PART DURING NORMAL SERVICE.
Consequence & remedy
Consequence: THIS CONDITION COULD RESULT IN THE POTENTIAL LOSS OF DIRECTIONAL STABILITY IN THE LEFT HAND FRONT WHEEL, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE TIE ROD ENDS FOR RELATIVE ORIENTATION AND REPLACE THE LEFT OUTER TIE ROD AS REQUIRED AND PERFORM A FRONT END TOE ALIGNMENT AS NEEDED. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 3, 2011. OWNERS MAY 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
2EA21002 · Desiccated Air Bag Inflator Rupture
Opened Sep 17, 2021 · No close date supplied
Status: open (inferred from source dates) · Air Bags:frontal:driver Side:inflator Module; Air Bags:frontal:passenger Side:inflator Module
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.
Additional source detail variants (2)
Air Bags:frontal:driver Side:inflator Module
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.
Air Bags:frontal:passenger Side:inflator Module
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.
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.
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