Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
80–25K
725–50K
350–75K
375–100K
0100–150K
1150K+
22 reports with mileage · 18 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 21 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Power Train. Review the 9 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
Electrical System. Review the 7 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
0 crash reports4 fire reports0 injury reports
What owners actually said
40 reports
73,031 miles · Apr 11, 2023
Engine
The contact owns a 2012 Dodge Ram. The contact stated that while driving at approximately 55 mph the vehicle started making noise coming from the engine compartment. The smoke originates from the engine compartment and the exhaust pipe in the rear of the vehicle and when the accelerator was depressed the vehicle did not accelera…
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The contact owns a 2012 Dodge Ram. The contact stated that while driving at approximately 55 mph the vehicle started making noise coming from the engine compartment. The smoke originates from the engine compartment and the exhaust pipe in the rear of the vehicle and when the accelerator was depressed the vehicle did not accelerate. Additionally, the check engine safety warning light became illuminated. The contact stated that the vehicle veered to the side of the road where the vehicle was turned off but the engine continued to run. The vehicle was towed to a dealer where the Engine, Intake system, and Exhaust needed to be replaced. The manufacturer was notified, The failure mileage was 73,031.
NHTSA ODI #11516561
27,000 miles · Jun 14, 2019
Structure
TL* THE CONTACT OWNS A 2012 RAM 5500. WHILE PERFORMING MAINTENANCE ON THE VEHICLE, THE CONTACT NOTICED THAT THE FRAME WAS CRACKED IN THE REAR ON BOTH SIDES NEAR THE REAR WHEELS. THE VEHICLE WAS TAKEN TO WICKSTROM CHRYSLER JEEP DODGE RAM (LOCATED AT 660 W NORTHWEST HWY, BARRINGTON, IL 60010, (847) 382-5400), BUT WAS NOT DIAGNOSED…
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TL* THE CONTACT OWNS A 2012 RAM 5500. WHILE PERFORMING MAINTENANCE ON THE VEHICLE, THE CONTACT NOTICED THAT THE FRAME WAS CRACKED IN THE REAR ON BOTH SIDES NEAR THE REAR WHEELS. THE VEHICLE WAS TAKEN TO WICKSTROM CHRYSLER JEEP DODGE RAM (LOCATED AT 660 W NORTHWEST HWY, BARRINGTON, IL 60010, (847) 382-5400), BUT WAS NOT DIAGNOSED OR REPAIRED. THE DEALER TOOK PICTURES OF THE FAILURE AND SENT IT TO THEIR CORPORATE OFFICE. THE CONTACT TOOK THE VEHICLE TO A WELDING SHOP AND WAS INFORMED THAT THE VEHICLE WAS UNSAFE TO DRIVE. THE MANUFACTURER WAS NOTIFIED AND PROVIDED CASE NUMBER: 58372436. THE APPROXIMATE FAILURE MILEAGE WAS 27,000.
NHTSA ODI #11220183
26,850 miles · Apr 27, 2019
Suspension
FRAME ON TRUCK HAS CRACKED ON BOTH SIDES JUST BEFORE THE REAR WHEELS.
NHTSA ODI #11204115
30,000 miles · Dec 27, 2018
Electrical System
THE IGNITION SWITCH IS FAULTY! THE SWITCH MUST BE MOVED AROUND IN THE SWITCH TO START THE TRUCK. ADDITIONALLY WHILE DRIVING THE TRUCK MAY JUST QUITE RUNNING, THIS CAUSES THE POWER STEERING AND BRAKES TO BECOME MANUAL. THIS BECOMES VERY DANGEROUS WHEN HAULING LOADS AS STOPPING DISTANCES ARE GREATLY INCREASED, NOT TO MENTION N…
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THE IGNITION SWITCH IS FAULTY! THE SWITCH MUST BE MOVED AROUND IN THE SWITCH TO START THE TRUCK. ADDITIONALLY WHILE DRIVING THE TRUCK MAY JUST QUITE RUNNING, THIS CAUSES THE POWER STEERING AND BRAKES TO BECOME MANUAL. THIS BECOMES VERY DANGEROUS WHEN HAULING LOADS AS STOPPING DISTANCES ARE GREATLY INCREASED, NOT TO MENTION NEARLY IMPOSSIBLE TO STEER. IF YOU ARE GOING AROUND A CORNER WHEN THIS HAPPENS YOU MAY NOT MAKE THE CORNER RESULTING IN A COLLISION WITH ONCOMING VEHICLES. THIS IGNITION SWITCH FAILURE IS COMMON IN THIS YEAR OF RAM TRUCK IT DOESN'T SEEM TO MATTER IF YOUR DRIVING OR SETTING AT A LIGHT THE TRUCK QUITS RUNNING AND MAY NOT BE ABLE TO RESTART WITHOUT REPLACING OR REPAIRING THE SWITCH. SO FAR FIAT CHRYSLER HAS NOT DONE ANYTHING TO FIX THE DESIGN, IT APPEARS THEY ARE HAPPY COLLECTING THE $300 + DOLLARS TO REPLACE THE SWITCH JUST TO HAVE THEM GO OUT AGAIN IN LESS THAN A YEAR. JUST LOOK AT THE INTERNET, MANY ISSUES. THIS IS DEFIANTLY A SAFTY HAZARD AND SHOULD BE A RECALL ITEM. *DT*JB
NHTSA ODI #11163746
Mileage unknown · Mar 19, 2018
StructureSuspension
2012 DODGE RAM 5500. CONSUMER WRITES IN REGARDS TO DEFICIENT WELDS ON THE FRONT DRIVE AXLE RECALL NOTICE. *SMD THE CONSUMER STATED THE RECALL WAS COMPLETED AS DIRECTED BY THE NOTICE, BUT DID NOT FULLY REPAIR THE VEHICLE. THERE WERE STILL SERIOUS CRACKS IN THE AXLE AND FRAME. THE MANUFACTURER WAS NOTIFIED, BUT DID NOT OFFER …
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2012 DODGE RAM 5500. CONSUMER WRITES IN REGARDS TO DEFICIENT WELDS ON THE FRONT DRIVE AXLE RECALL NOTICE. *SMD THE CONSUMER STATED THE RECALL WAS COMPLETED AS DIRECTED BY THE NOTICE, BUT DID NOT FULLY REPAIR THE VEHICLE. THERE WERE STILL SERIOUS CRACKS IN THE AXLE AND FRAME. THE MANUFACTURER WAS NOTIFIED, BUT DID NOT OFFER ANY ASSISTANCE. *JS
NHTSA ODI #10689351
Mileage unknown · Sep 11, 2017
Steering
2012 DODGE 5500. CONSUMER WRITES IN REGARDS TO STEERING ANGLE SENSOR AND CLOCKSPRING IN THE STEERING COLUMN ISSUES AND OTHER ELECTRICAL FAILURES. *LD THE CONSUMER STATED THE ELECTRONIC FUNCTIONS ON THE STEERING WHEEL WERE INOPERABLE. THIS INCLUDES THE HORN AND CRUISE CONTROL. THE CONSUMER WAS ADVISED PARTS ARE ON BACK ORDER…
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2012 DODGE 5500. CONSUMER WRITES IN REGARDS TO STEERING ANGLE SENSOR AND CLOCKSPRING IN THE STEERING COLUMN ISSUES AND OTHER ELECTRICAL FAILURES. *LD THE CONSUMER STATED THE ELECTRONIC FUNCTIONS ON THE STEERING WHEEL WERE INOPERABLE. THIS INCLUDES THE HORN AND CRUISE CONTROL. THE CONSUMER WAS ADVISED PARTS ARE ON BACK ORDER BUT THERE WAS NO RECALL. UPDATED 09/11/2017*JS
NHTSA ODI #11021970
78,025 miles · May 10, 2017
Electrical System
TL* THE CONTACT OWNS A 2012 RAM 5500. AFTER THE VEHICLE WAS REPAIRED PER NHTSA CAMPAIGN NUMBER: 16V739000 (ELECTRICAL SYSTEM), THE VEHICLE STALLED WITHOUT WARNING ON MULTIPLE OCCASIONS. THE VEHICLE WAS TAKEN TO A DEALER, BUT THEY COULD NOT DUPLICATE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE …
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TL* THE CONTACT OWNS A 2012 RAM 5500. AFTER THE VEHICLE WAS REPAIRED PER NHTSA CAMPAIGN NUMBER: 16V739000 (ELECTRICAL SYSTEM), THE VEHICLE STALLED WITHOUT WARNING ON MULTIPLE OCCASIONS. THE VEHICLE WAS TAKEN TO A DEALER, BUT THEY COULD NOT DUPLICATE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 78,025.
NHTSA ODI #10984734
Mileage unknown · Aug 25, 2016
Steering
HAVE PROBLEMS WITH TRUCK WANDERING ALL OVER ROAD AT SPEEDS OVER 40-45-MPH FROM WHEN TRUCK WAS NEW... MANY TIMES I TRIED TO GET TRUCK IN AFTER RECALL NOTICES AND DID NOT HAVE PARTS. NOT RESOLVED TO THIS DATE. NOW NEW PROBLEM I HAVE IS STEERING IS VERY TIGHT AND DOES NOT RETURN TO CENTER AFTER TURNING AND IS A MAJOR DANGER. TRUCK …
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HAVE PROBLEMS WITH TRUCK WANDERING ALL OVER ROAD AT SPEEDS OVER 40-45-MPH FROM WHEN TRUCK WAS NEW... MANY TIMES I TRIED TO GET TRUCK IN AFTER RECALL NOTICES AND DID NOT HAVE PARTS. NOT RESOLVED TO THIS DATE. NOW NEW PROBLEM I HAVE IS STEERING IS VERY TIGHT AND DOES NOT RETURN TO CENTER AFTER TURNING AND IS A MAJOR DANGER. TRUCK WAS JUST IN DEALER FOR THE PROBLEM AND FIXED ONE RECALL WHICH WAS TO REPLACE STEERING LINKAGE THAT WAS DONE BUT DID NOTHING NOTHING TO FIX MY HARD STEERING AND NOT RETURNING TO CENTER STEERING PROBLEM .I HAVE BEEN WAITING ALMOST A WEEK FOR A CALL BACK FROM DODGE CUSTOMER CAR NOW. THERE IS STILL A RECALL ON FRONT AXLE WELDS THAT HAS NOT BEEN TAKEN CARE OF BECAUSE OF LACK OF PARTS THAT I HAVE TRIED TO TAKE CARE OF ON NUMEROUS OCCASIONS ?
NHTSA ODI #10898510
76,000 miles · Jan 22, 2016
Electrical System
WHEN DRIVING THE MAGNETIC KEY IGNITION MODULE WAS SHORTING OUT. THIS CAUSED THE TRUCK TO LOOSE THE MAJORITY OF DRIVERS CONTROL AT 65 MPH ON THE HIGHWAY, THEN THE KEY WOULD MAKE CONTACT AND RESTART THE MOTOR CAUSING CONVULSIONS IN RUNNING. THIS OPERATING CONDITION ALMOST CAUSED A SEMI TRUCK TO REAR END MY TRUCK. FOUR DAYS AFTER R…
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WHEN DRIVING THE MAGNETIC KEY IGNITION MODULE WAS SHORTING OUT. THIS CAUSED THE TRUCK TO LOOSE THE MAJORITY OF DRIVERS CONTROL AT 65 MPH ON THE HIGHWAY, THEN THE KEY WOULD MAKE CONTACT AND RESTART THE MOTOR CAUSING CONVULSIONS IN RUNNING. THIS OPERATING CONDITION ALMOST CAUSED A SEMI TRUCK TO REAR END MY TRUCK. FOUR DAYS AFTER REPLACING THE $800 IGNITION SYSTEM, WE ALSO HAD TO REPLACE THE FLEX PLATE & STARTER DUE TO THE CENTRIFUGAL FORCE FROM THE MOTOR RESTARTING UNDER HIGHWAY SPEEDS IT DESTROYED THE FLEX PLATE BACKED THE FLEX PLATE BOLTS OUT AND DEFORMED THE BOLT HOLES IN THE BACK OF THE CRANK.
NHTSA ODI #10821759
91,386 miles · Jan 11, 2016
Steering
TL* THE CONTACT OWNS A 2012 RAM 5500. WHILE DRIVING APPROXIMATELY 5-10 MPH, THE STEERING FAILED DUE TO THE DRIVER SIDE TIE ROD BALL DETACHING FROM THE VEHICLE. THE FAILURE HAPPENED WITHOUT WARNING. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE DRIVER SIDE TIE ROD ASSEMBLY DETACHED AND NEEDED TO BE REPLACED.…
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TL* THE CONTACT OWNS A 2012 RAM 5500. WHILE DRIVING APPROXIMATELY 5-10 MPH, THE STEERING FAILED DUE TO THE DRIVER SIDE TIE ROD BALL DETACHING FROM THE VEHICLE. THE FAILURE HAPPENED WITHOUT WARNING. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE DRIVER SIDE TIE ROD ASSEMBLY DETACHED AND NEEDED TO BE REPLACED. PRIOR TO THE FAILURE, THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE CONTACT WAS NOTIFIED THAT THE VEHICLE WAS REMEDIED ACCORDING TO NHTSA CAMPAIGN NUMBERS: 13V527000 (STEERING) AND 15V459000 (AIR BAGS). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 91,386.
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.
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.
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.
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.
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.
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)
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.
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.
Chrysler Group LLC (Chrysler) is recalling certain model year 2008-2012 RAM 4500 and 5500 trucks manufactured February 20, 2007, through December 22, 2012. 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: On May 19, 2015 Chrysler notified owners that dealers would replace the tie rod assembly, free of charge. In July 2015, and under a consent order with NHTSA, the company agreed to offer owners three options for remedying their vehicles: perform the original remedy, offer to repurchase the vehicle at the fair market value plus 10%, or offer an additional incentive offer towards the purchase of a new Dodge, Jeep, Chrysler, or Fiat vehicle. Chrysler will notify owners of the new recall options in a letter expected to be mailed on August 31, 2015. Owners may contact Chrysler at 1-800-247-9753. Chrysler's recall campaign number is R16.
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.
Chrysler Group LLC (Chrysler) is recalling certain model year 2012 RAM 4500 and 5500 trucks manufactured February 2, 2012, to December 22, 2012. Due to a welding issue with the front axle carrier, the front drive shaft may fracture and result in a loss of motive power and damage to surrounding components if the shaft continues to spin.
Consequence & remedy
Consequence: Damage to other components, or sudden loss of drive power may increase the risk of a crash.
Remedy: Chrysler will notify owners, and dealers will replace or repair the front axle assembly, free of charge. The recall began on May 1, 2014. Owners may contact Chrysler at 1-800-247-9753. Chrysler's recall campaign number is N26.
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.
2012 Dodge RAM 5500 Problems, Complaints & Recalls | Skip That Year
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