NHTSA owner reports · September 18, 2026 snapshot.
Service Brakes complaints
14 reportsClear category filterMileage unknown · Jun 8, 2021
Electrical SystemExterior LightingService Brakes
While pulling a trailer, integrated trailer brake controller stopped working and disabled the trailer brakes. All trailer lights worked, just no brakes. Showed red warning in dash and "CF" on brake controller after failure. No warning before failure. Checked connections and tested with another trailer. Even with no trailer,…
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While pulling a trailer, integrated trailer brake controller stopped working and disabled the trailer brakes. All trailer lights worked, just no brakes. Showed red warning in dash and "CF" on brake controller after failure. No warning before failure. Checked connections and tested with another trailer. Even with no trailer, warning is on and trailer brakes are not functional. Created hazard to driver and other motorists by spontaneous loss of brakes. Online forums indicate this is not an isolated incident. More recently, now the trailer running lights have failed. Brake and turn signal lights work, but no running lights. No police report of inspections. Not yet repaired. Available for inspection.
NHTSA ODI #11420194
5,000 miles · Jan 14, 2021
Electrical SystemPower TrainService Brakes
THE INTEGRATED BRAKE CONTROLLER IS INTERMITTENT AT BEST. I PURCHASED A TRAILER AND IT HOOKED UP FINE. WORKED FINE TOWING UNTIL I DISCONNECTED THE TRAILER AND SEVEN PIN CONNECTOR. NOW THE CONTROLLER TELLS ME THERE IS NO TRAILER ON THE CONTROLLER AND THE DASH ALERTS. UPON PULLING THE TRAILER AGAIN THE CONTROLLER TELLS ME I'M NOT T…
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THE INTEGRATED BRAKE CONTROLLER IS INTERMITTENT AT BEST. I PURCHASED A TRAILER AND IT HOOKED UP FINE. WORKED FINE TOWING UNTIL I DISCONNECTED THE TRAILER AND SEVEN PIN CONNECTOR. NOW THE CONTROLLER TELLS ME THERE IS NO TRAILER ON THE CONTROLLER AND THE DASH ALERTS. UPON PULLING THE TRAILER AGAIN THE CONTROLLER TELLS ME I'M NOT TOWING WHEN I AM. ??
NHTSA ODI #11388248
105,000 miles · Jul 18, 2019
Service Brakes
WHILE IN MOTION MY FOOT BRAKE DOES NOT SEND ENOUGH VOLTAGE TO THE ELECTRIC BRAKES ON MY TOY HAULER 5TH WHEEL TRAILER. I HAVE TO USE THE HAND BRAKE LEVER TO SAFELY STOP THE TRAILER.. WHILE STOPPED MY FOOT BRAKE SENDS 3.4 VOLTS TO THE TRAILER WHILE THE HAND BRAKE SENDS 12 VOLTS (THE GAIN IS TURNED TO ITS HIGHEST). WITH THE IGNI…
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WHILE IN MOTION MY FOOT BRAKE DOES NOT SEND ENOUGH VOLTAGE TO THE ELECTRIC BRAKES ON MY TOY HAULER 5TH WHEEL TRAILER. I HAVE TO USE THE HAND BRAKE LEVER TO SAFELY STOP THE TRAILER.. WHILE STOPPED MY FOOT BRAKE SENDS 3.4 VOLTS TO THE TRAILER WHILE THE HAND BRAKE SENDS 12 VOLTS (THE GAIN IS TURNED TO ITS HIGHEST). WITH THE IGNITION OFF, THE BRAKE LIGHTS ON THE TRUCK TO DO NOT ACTIVATE WITH THE FOOT BRAKE PEDAL. MY LOCAL RAM DEALER DOES NOT KNOW WHAT THE PROBLEM IS, NOR HAVE THEY HEARD FROM CHRYSLER. THE APPOINTMENT WIT THE RAM DEALER WAS ON JULY 10, 2019.
NHTSA ODI #11233161
Mileage unknown · Jul 17, 2019
Service Brakes
BRAKE TRANSMISSION SHIFT INTERLOCK RECALL, NHTSA RECALL #17V-821, RECALL DATE 01/04/2018. I HAVE CONTACTED THE LOCAL DEALERSHIP-SERVICE DEPARTMENT ON NUMEROUS ATTEMPTS AND I AM BEING TOLD PARTS ARE NOT AVAILABLE AT THE TIME FOR SAID RECALL.
NHTSA ODI #11232708
107,000 miles · Jun 21, 2019
Service Brakes
WHEN STEPPING ON THE BRAKES WHILE PULLING MY 40 FT TOY HAULER POWER IS NOT BEING SUPPLIED TO THE ELECTRIC BRAKES. IF THE ELECTRIC BRAKES ARE APPLIED BY HAND THEN POWER IS SUPPLIED. ALSO, THE BRAKE LIGHTS TO DO NOT COME ON ON THE TRUCK WHEN THE FOOT BRAKE IS APPLIED UNLESS THE ENGINE IS RUNNING. THIS TRUCK HAS THE FACTORY INST…
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WHEN STEPPING ON THE BRAKES WHILE PULLING MY 40 FT TOY HAULER POWER IS NOT BEING SUPPLIED TO THE ELECTRIC BRAKES. IF THE ELECTRIC BRAKES ARE APPLIED BY HAND THEN POWER IS SUPPLIED. ALSO, THE BRAKE LIGHTS TO DO NOT COME ON ON THE TRUCK WHEN THE FOOT BRAKE IS APPLIED UNLESS THE ENGINE IS RUNNING. THIS TRUCK HAS THE FACTORY INSTALLED INTEGRATED BRAKE CONTROLLER. THE FUSE FOR FEEDING POWER TO THE TRAILER BRAKE IS GOOD.
NHTSA ODI #11221785
195,000 miles · Mar 4, 2019
Electrical SystemService BrakesSteering
WIN MODULES AND/OR IGNITION SWITCH RANDOMLY TURNS ENGINE OFF AND ALL ELECTRONICS INCLUDING TRAILER BRAKE CONTROLS. VEHICLE LOSS OF POWER BRAKES AND POWER STEERING. LOSS OF TRAILER BRAKE CONTROLS. I WAS DRIVING PULLING A 10,000LBS. TRAILER AND TRUCK WAS NEAR IMPOSSIBLE TO STOP. I WAS DRIVING DOWN THE HIGHWAY. GLAD I WASN'T DRIVI…
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WIN MODULES AND/OR IGNITION SWITCH RANDOMLY TURNS ENGINE OFF AND ALL ELECTRONICS INCLUDING TRAILER BRAKE CONTROLS. VEHICLE LOSS OF POWER BRAKES AND POWER STEERING. LOSS OF TRAILER BRAKE CONTROLS. I WAS DRIVING PULLING A 10,000LBS. TRAILER AND TRUCK WAS NEAR IMPOSSIBLE TO STOP. I WAS DRIVING DOWN THE HIGHWAY. GLAD I WASN'T DRIVING AROUND PEDESTRIANS, AND NO TRAFFIC, OR DRIVING INTO A CITY RUSH HOUR LIKE I USUALLY AM. NOW I DON'T PULL A TRAILER ANYMORE WITH THIS TRUCK BECAUSE I'M SCARED OF SMASHING SOMEONE OR SOMETHING. A LOT OF PEOPLE USE THESE TRUCKS AS COMMERCIAL VEHICLES AND TOWING AND THIS NEEDS ADDRESSES BEFORE SOMEONE GETS HURT OR KILLED. *DT*JB *DT*JB
NHTSA ODI #11183861
96,000 miles · Nov 29, 2017
Service BrakesSteering
HISSING NOISE COMING FROM HYDROBOOST AREA. WHILE DRIVING AND WHEN STOPPED WITH ENGINE RUNNING THERE IS A HISSING NOISE UNDER THE DASH. DEPRESSING THE BRAKES, THE NOISE QUIETS. WHEN TURNING THE STEERING WHEEL, THE NOISE QUIETS. UPON FURTHER INVESTIGATION THE NOISE IS COMING FROM THE HYDROBOOST AREA.
NHTSA ODI #11051367
22,000 miles · Jul 8, 2016
Service Brakes
THE OEM TRAILER BRAKE CONTROLLER WILL SHOW A "TRAILER BRAKES DISCONNECTED", "CHECK TRAILER BRAKES" THIS IS A RANDOM MESSAGE AND CHECKING THE WIRING SHOWS NO PROBLEMS. THE DEALERS APPEAR TO BE CLUELESS ABOUT THE ISSUE AND BLAME THE OWNERS TRAILER. THE WARNING ON THE DASH DISPLAY AND ON THE OEM TRAILER BRAKE WILL DISPLAY AT A…
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THE OEM TRAILER BRAKE CONTROLLER WILL SHOW A "TRAILER BRAKES DISCONNECTED", "CHECK TRAILER BRAKES" THIS IS A RANDOM MESSAGE AND CHECKING THE WIRING SHOWS NO PROBLEMS. THE DEALERS APPEAR TO BE CLUELESS ABOUT THE ISSUE AND BLAME THE OWNERS TRAILER. THE WARNING ON THE DASH DISPLAY AND ON THE OEM TRAILER BRAKE WILL DISPLAY AT ANY SPEED AND WITHOUT BRAKE APPLICATION. THERE ARE REPEATED POSTS ON THE VARIOUS INTERNET FORUMS WITH NO CORRECTION AVAILABLE, AND SINCE IT IS A INTERMITTENT PROBLEM, VERY HARD TO DIAGNOSE.
NHTSA ODI #10883526
124,000 miles · Nov 5, 2014
Fuel/propulsion SystemPower TrainService Brakes
MY DRIVER WAS TRAVELING AT 80 MPH IN CRUISE CONTROL WHEN HE STARTED TO NOTICE A VIBRATION FROM THE TRUCK THAT WAS SHAKING THE MIRRORS. HE TOOK THE VEHICLE OUT OF CRUISE CONTROL AND STARTED TO DECELERATE. AT APPROXIMATELY 70 MPH A LARGE BANG WAS HEARD FROM BENEATH THE VEHICLE AND THE FRONT END OF THE TRUCK WAS LIFTED OFF OF THE P…
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MY DRIVER WAS TRAVELING AT 80 MPH IN CRUISE CONTROL WHEN HE STARTED TO NOTICE A VIBRATION FROM THE TRUCK THAT WAS SHAKING THE MIRRORS. HE TOOK THE VEHICLE OUT OF CRUISE CONTROL AND STARTED TO DECELERATE. AT APPROXIMATELY 70 MPH A LARGE BANG WAS HEARD FROM BENEATH THE VEHICLE AND THE FRONT END OF THE TRUCK WAS LIFTED OFF OF THE PAVEMENT. THIS CAUSED THE VEHICLE TO BE TURNED SLIGHTLY SIDEWAYS WHEN IT CAME BACK DOWN INTO CONTACT WITH THE PAVEMENT WHILE TRAVELING AT 70 MPH! THANKFULLY MY DRIVER WAS ABLE TO CORRECT THE VEHICLE STRAIGHT BUT WHEN HE PUSHED ON THE BRAKE PEDAL IT WENT ALL THE WAY TO THE FLOOR. HE WAS ABLE TO COAST THE VEHICLE TO THE SIDE OF THE ROAD AND EVENTUALLY BRING IT TO A STOP. PARTS FROM THE TRUCK HAD BEEN STREWN DOWN THE INTERSTATE OVER APPROXIMATELY 200 YDS. THERE WAS A VEHICLE TRAVELING BEHIND MY DRIVER AT THE TIME OF THE INCIDENT BUT LUCKILY THEY WERE FAR ENOUGH BEHIND THAT THEY WERE ABLE TO TAKE EVASIVE ACTIONS TO AVOID ANY FLYING DEBRIS. THANKFULLY THERE WERE NO INJURIES OR AFTER INCIDENT ACCIDENTS THAT OCCURRED THOUGH I WOULD ATTRIBUTE THIS TO THE ALERT AND RESPONSIVE DRIVING OF BOTH MY DRIVER AND THE DRIVER OF THE VEHICLE BEHIND HIM. HAD THERE BEEN A VEHICLE DIRECTLY BEHIND OR TO THE SIDE OF HIM THERE COULD HAVE BEEN A MAJOR ACCIDENT POSSIBLY RESULTING IN INJURIES OR DEATH. THIS VEHICLE WAS TOWED TO A DODGE RAM DEALER WHERE WE WERE INFORMED THAT THE FRONT DRIVE SHAFT WAS THE PART THAT FAILED. WE WERE INFORMED BY DEALER PERSONNEL THAT THIS DRIVE SHAFT HAS A JOINT THAT IS NON-SERVICEABLE NOR EASILY INSPECTED AND THAT THIS WAS THE ROOT CAUSE OF THE FAILURE. OTHER PARTS THAT WERE EFFECTED WERE THE TRANSFER CASE (THE CASE WAS BROKEN IN TWO PIECES AND THE INTERNALS WERE BLOWN OUT), TRANSMISSION CRACKED BEYOND REPAIR, BRAKE LINES HAD BEEN SEVERED, FUEL LINES HAD BEEN SEVERED AND A HOLE WAS PUNCHED THROUGH THE CAB BOTTOM INTO THE PASSENGER AREA. *TR
NHTSA ODI #10652823
Mileage unknown · Aug 25, 2014
Service Brakes
TL* THE CONTACT OWNS A 2012 DODGE RAM 3500. THE CONTACT RECEIVED A RECALL NOTIFICATION FOR NHTSA CAMPAIGN NUMBER: 14V154000 (SERVICE BRAKES, HYDRAULIC); HOWEVER, THE PART NEEDED FOR THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WA…
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TL* THE CONTACT OWNS A 2012 DODGE RAM 3500. THE CONTACT RECEIVED A RECALL NOTIFICATION FOR NHTSA CAMPAIGN NUMBER: 14V154000 (SERVICE BRAKES, HYDRAULIC); HOWEVER, THE PART NEEDED FOR THE REPAIR WAS UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS NOTIFIED. THE CONTACT HAD NOT EXPERIENCED A FAILURE.
NHTSA ODI #10628039
Official recalls
8May 27, 2021
Chrysler (FCA US, LLC) is recalling certain 2012-2021 RAM 3500, 3500 Cab Chassis, 4500 Cab Chassis, and 5500 Cab Chassis vehicles. Incorrect information in the Service and Owner's Manuals may cause the flanged lug nuts to be over-tightened, which could result in a broken wheel stud and possible wheel separation.
Consequence & remedy
Consequence: Wheel separation can cause a vehicle crash.
Remedy: Dealers will update the torque specification in the owner's manual and other published service documents. Dealers will also inspect the vehicle's wheel studs, replacing them if necessary, free of charge. Owner notification letters were mailed on November 30, 2021. Campaign Y36 owner notification letters were mailed on November 30, 2021. Campaign Y26 owner notification letters were mailed on December 1, 2021. Owners may contact FCA US customer service at 1-800-853-1403. FCA US's numbers for this recall are Y26 and Y36.
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.
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.
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.
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.
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.
Aug 6, 2013
Chrysler Group LLC (Chrysler) is recalling certain model year 2012 RAM 3500 trucks manufactured May 4, 2012, through August 7, 2012; and model year 2012 RAM 4500 and 5500 trucks manufactured May 3, 2012, through August 7, 2012. Due to a loose snap ring inside the transmission, there may be a loss of power transfer through the transmission to the wheels.
Consequence & remedy
Consequence: An unexpected loss of power transfer may increase the risk of a crash.
Remedy: Chrysler will notify owners, and dealers will replace the transmission assembly free of charge. The recall began on October 17, 2013. Owners may contact Chrysler at 1-800-247-9753. Chrysler's recall campaign number is N50.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1EA19001 · Electrical Overstress
Opened Apr 19, 2019 · Closed Sep 19, 2024
Status: closed (inferred from source dates) · Air Bags: Air Bag/restraint Control Module
The Office of Defects Investigation (ODI) opened this investigation to determine if the failure of airbags to deploy during severe crashes, in certain vehicles, was the result of a safety related defect. During the investigation a complex failure was studied that can result in non-deployment of subject vehicle air bags and other restraint system devices in severe crash events. The subject vehicles may be equipped with an airbag control unit (ACU) for the supplemental restraint system (SRS) Electronic Control Unit (ECU) manufactured by ZF-TRW. The ECU receives signals from crash sensors mounted in the vehicle and deploys the vehicle air bags and seat belt pretensioners in accordance with manufacturer design specifications. The ECU in the subject vehicles contains a model DS84 application-specific integrated circuit (ASIC) which controls the communication of the crash sensor signal, firing commands (i.e., when to deploy the airbag(s) and/or pretensioners), and fault information (e.g., diagnostic trouble codes). In September 2016, FCA announced recall 16V-668 for certain model year (MY) 2010 to 2014 Chrysler, Dodge and Jeep products manufactured with the subject ZF-TRW ACU. In this recall, FCA discussed an EOS condition that resulted in a failure of the subject DS84 ASIC, which caused air bag non-deployment. FCA noted that the defect condition had only been observed in vehicles equipped with sensor harnessing routed across the front of the vehicle. Other FCA vehicles that also used the subject ACU, but were not equipped with cross-car harnessing, had not experienced EOS failures, despite similar time in service. During the course of this investigation, ODI sent two separate Information Request (IR) letters to six vehicle manufactures (including FCA, Hyundai, Honda, Kia, Mitsubishi, and Toyota) and one IR letter to ZF-TRW. These IR letters resulted in ODI receiving comprehensive data from these manufacturers and suppliers. Studies of this data found that the DS84 ASIC does not have sufficient protection against negative electrical transients or electrical overstress (“EOS”) that can be generated in certain severe crashes. An electrical transient occurs when the electrical power supplied to a circuit changes momentarily over a short duration of time. In these severe crash cases, the crash sensors and other powered wiring can be damaged and short circuited so as to create a negative electrical transient of sufficient intensity and duration (that are outside the vehicle manufacturer's specification) to damage the ASIC before the restraint device deployment signal is received by the SRS ECU. This damaged signal can lead to incomplete or nondeployment of the air bags and/or pretensioners. Airbag non-deployment and/or lack of pretensioner operation can increase the risk or severity of injury in a crash.A total of 8 fatalities and 14 injuries were associated with known EOS events. The common element in all investigated manufacturers vehicles is the SRS ECU containing a DS84 ASIC manufactured by ZF-TRW. The risk associated with the ASIC is equally shared among all OEMS involved in the investigation. The actual real-world risk can be mitigated by other factors which were assessed by ODI during this investigation. The first mitigating factor involves protections built into the ACU design which protect the DS84 ASIC from damage. There are multiple strategies and levels of protection employed by different OEMs that provide effective EOS mitigation. The two most common strategies at the ACU level are circuit protection diodes on the remote senor signal lines, and current limiting resistors that protect critical components. The second mitigating factor is found at the vehicle level and involves the location and routing of the wires leading from the crash sensors to the SRS ECU. If the wires are well protected in a crash and are not routed with other power wires carrying large currents, the risk for an EOS event is significantly reduced or eliminated. These design specific factors combine to produce a spectrum of risk for the vehicles equipped with ACUs using the DS84 ASIC. Given the many of years of field exposure, it is possible to divide the subject population into two groups; vehicles which have experienced EOS events, and vehicles which have not experienced EOS field events. Four of the six OEMs involved in this investigation have experienced EOS field events on at least one of their models equipped with a DS84 ASIC. All vehicle models (including the Toyota models identified in the Failure Report Summary of the opening resume for this investigation) with field events have been recalled. In an abundance of caution, ODI kept this investigation open five years to monitor field performance and did not identify any field events on vehicles not included in existing safety recalls. Given the spectrum of risk identified in this investigation and that all vehicles with a demonstrated unreasonable risk have been recalled, ODI is closing this investigation. ODI is closing this investigation with the following manufacturer safety recalls: 16V-668, 18E-043, 18V-137, 18V-363, and 20V-024. With the recall actions taken by the subject vehicle and equipment manufacturers, this investigation is closed. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exists on other model or model year vehicles outside of the recall scopes. The agency reserves the right to take further action if warranted by the circumstances.
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