NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
63 reportsClear category filterMileage unknown · Aug 29, 2014
Electrical SystemElectronic Stability Control (esc)EngineCrash
THIS OCCURRED ABOUT 6 TIMES ALREADY. WHEN MAKING A LEFT OR RIGHT TURN THE VEHICLE SHUTS OFF AND COASTS UNTIL YOU STOP TO SHUT IT OFF AND TURN BACK ON. THE BATTERY AND OIL PRESSURE LIGHTS COME ON DURING THE COASTING. CAME VERY CLOSE TO BEING HIT TWICE DUE TO THIS PROBLEM, BUT THE DEALER SAY THEY HAVEN'T HEARD ANYTHING LIKE THIS B…
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THIS OCCURRED ABOUT 6 TIMES ALREADY. WHEN MAKING A LEFT OR RIGHT TURN THE VEHICLE SHUTS OFF AND COASTS UNTIL YOU STOP TO SHUT IT OFF AND TURN BACK ON. THE BATTERY AND OIL PRESSURE LIGHTS COME ON DURING THE COASTING. CAME VERY CLOSE TO BEING HIT TWICE DUE TO THIS PROBLEM, BUT THE DEALER SAY THEY HAVEN'T HEARD ANYTHING LIKE THIS BEFORE. *TR
NHTSA ODI #10629299
49,837 miles · Jun 16, 2014
Electrical SystemElectronic Stability Control (esc)Steering
PULLING AWAY FROM A STOP LIGHT UNDER LIGHT ACCELERATION, MULTIPLE WARNING LIGHTS CAME ON INCLUDING "ESC DISABLED" AND MULTIPLE LIGHT WARNINGS FOR THE GEARBOX, THE STEERING, ELECTRONIC THROTTLE CONTROL, GENERAL MALFUNCTION LIGHT, ESC OFF LIGHT, AND ESC MALFUNCTION LIGHT, AND LOST POWER STEERING, ALMOST CAUSING AN ACCIDENT WHILE T…
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PULLING AWAY FROM A STOP LIGHT UNDER LIGHT ACCELERATION, MULTIPLE WARNING LIGHTS CAME ON INCLUDING "ESC DISABLED" AND MULTIPLE LIGHT WARNINGS FOR THE GEARBOX, THE STEERING, ELECTRONIC THROTTLE CONTROL, GENERAL MALFUNCTION LIGHT, ESC OFF LIGHT, AND ESC MALFUNCTION LIGHT, AND LOST POWER STEERING, ALMOST CAUSING AN ACCIDENT WHILE TRYING TO GET THE CAR OFF THE ROAD. THE CAR WAS SHUT OFF AND RESTARTED IMMEDIATELY WITH NO CHANGE. AFTER LETTING THE CAR SIT FOR A HALF-HOUR, THE CAR WAS RESTARTED AND STEERING WAS RESTORED AND NO WARNING LIGHT WERE ON. THE VEHICLE WAS DRIVEN HOME AND PARKED UNTIL IT WAS TOWED TO THE DEALERSHIP. THEY DROVE THE CAR OVER 50 MILES AND WERE UNABLE TO REPEAT THE INCIDENT OR IDENTIFY THE PROBLEM SO THEY RELEASED THE UNREPAIRED VEHICLE TO THE OWNER. *TR
NHTSA ODI #10598709
6,520 miles · May 16, 2014
Electrical System
PERIODICALLY THE STARTER WILL NOT ENGAGE. IT DOES A WHINE AS THOUGH THE STARTER ON THE VEHICLE IS A STARTER THAT IS GOING OUT. I TOOK IT BACK TO BUTLER FIAT IN INDIANAPOLIS, IN ON APRIL 1ST , AS THE PROBLEM BECAME WORSE AND WORSE. THEY REPLACED THE STARTER UNDER WARRANTY BUT IT STARTED DOING THE SAME THING LESS THAN TWO WEEK…
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PERIODICALLY THE STARTER WILL NOT ENGAGE. IT DOES A WHINE AS THOUGH THE STARTER ON THE VEHICLE IS A STARTER THAT IS GOING OUT. I TOOK IT BACK TO BUTLER FIAT IN INDIANAPOLIS, IN ON APRIL 1ST , AS THE PROBLEM BECAME WORSE AND WORSE. THEY REPLACED THE STARTER UNDER WARRANTY BUT IT STARTED DOING THE SAME THING LESS THAN TWO WEEKS AFTER REPLACEMENT. SOMETHING WAS MENTIONED AT THE TIME ABOUT FAULTY BOLT OR A PART IN THE STARTER CAUSING A MALFUNCTION. IF ANYONE HAS EVER HAD A STARTER GO OUT IN A CAR IT IS THE SAME SOUND WHEN THE ROTARY DOES NOT ENGAGE AND YOU HAVE TO MAKE A SECOND ATTEMPT TO START THE CAR. MY VEHICLE STILL HAS LESS THAN 13,000 MILES ON IT AND I NEED THE PROBLEM FIXED. *TR
NHTSA ODI #10592031
25,000 miles · Nov 7, 2013
Electrical SystemVisibility/wiper
AFTER DEALER REPLACED FAULTY REAR MAIN SEAL IN JULY/AUGUST 2013, REAR WIPER BLADE WOULD ACTIVATE WITH CONTROLS IN OFF POSITION, CAUSING ME TO HAVE TO MOVE FRONT WINDSHIELD WIPER CONTROL ARM UP AND DOWN, AND THEN REAR WIPER BLADES WOULD STOP. ALSO THE CAR STARTER WOULD INTERMITTENTLY MAKE A ELECTRICAL NOISE AFTER TURNING THE KEY…
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AFTER DEALER REPLACED FAULTY REAR MAIN SEAL IN JULY/AUGUST 2013, REAR WIPER BLADE WOULD ACTIVATE WITH CONTROLS IN OFF POSITION, CAUSING ME TO HAVE TO MOVE FRONT WINDSHIELD WIPER CONTROL ARM UP AND DOWN, AND THEN REAR WIPER BLADES WOULD STOP. ALSO THE CAR STARTER WOULD INTERMITTENTLY MAKE A ELECTRICAL NOISE AFTER TURNING THE KEY AND THE CAR WOULDN'T START, THEN I HAD TO TURN KEY TWO TO THREE TIMES TO START CAR. AFTER TWO MONTHS WITH ABOVE, IN COLD WEATHER BELOW 35 DEGREES THE STEREO, CD PLAYER, BLUEME SYSTEMS WON'T WORK! IT ONLY STARTS TO WORK AFTER THE CAR AND SURROUNDING ENVIRONMENT REACHES 40-45 DEGREES. CALLED INTO DEALER AND HAVE APPOINTMENT FOR CHECKING ALL AND REPAIR/REPLACE COMPONENTS NOT WORKING PROPERLY AND SAFELY. *TR
NHTSA ODI #10551414
3,500 miles · Oct 31, 2013
Air BagsElectrical SystemVehicle Speed Control
AIR BAG LIGHTS ARE NOT SHOWING ON THE INSTRUMENT CLUSTER THE AIRBAGS ARE NOT WORKING! *TR
NHTSA ODI #10550428
45,000 miles · Oct 18, 2013
Electrical SystemFuel System, Gasoline
REPORTED ELECTRICAL BURNING SMELL THRU VENTILATION SYSTEM. DEALERSHIP DENIED ELECTRICAL BURNING BUT FOUND GAS PUNCTURE IN PLASTIC GAS TANK, SAYS SMELL IS FROM BURNING GAS. (OWNER DISAGREES) HOWEVER WITH NO OTHER SUSPENSION OR BODY DAMAGE FOUND EXCEPT THE GAS TANK PUNCTURE THERE IS GREAT CONCERN THAT THIS IS A SERIOUS DANGEROUS…
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REPORTED ELECTRICAL BURNING SMELL THRU VENTILATION SYSTEM. DEALERSHIP DENIED ELECTRICAL BURNING BUT FOUND GAS PUNCTURE IN PLASTIC GAS TANK, SAYS SMELL IS FROM BURNING GAS. (OWNER DISAGREES) HOWEVER WITH NO OTHER SUSPENSION OR BODY DAMAGE FOUND EXCEPT THE GAS TANK PUNCTURE THERE IS GREAT CONCERN THAT THIS IS A SERIOUS DANGEROUS DESIGN FLAW. THAT THE TANK CAN BE PUNCTURED SO EASILY WITHOUT THE KNOWLEDGE OF DRIVER OF ANY EVENT. *TR
NHTSA ODI #10548386
39,000 miles · Aug 22, 2013
Electrical SystemPower Train
TL* THE CONTACT OWNS A 2012 FIAT 500. THE CONTACT STATED THAT WHILE ATTEMPTING TO START THE VEHICLE, THE VEHICLE STALLED AND THE KEY BECOME STUCK IN THE IGNITION. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS NOT NOTIFIED. THE APPROXIMATE FAILURE MILEAGE WAS 39,000.
NHTSA ODI #10536743
4,000 miles · Jun 11, 2013
Electrical SystemFire
I OWN A 2012 FIAT POP THAT I PURCHASED NEW ABOUT A YEAR AGO. ONE THING THAT DID NOT GO AWAY AND WAS EVER PRESENT AT ANY TIME WAS THE LIMP MODE FOR THE ENGINE OVER THE LAST FEW DAYS. RECYCLING DID NOT WORK TO CORRECT PROBLEM AND GAUGES WERE OUT. THE INDICATOR LIGHT ON PANEL SHOWED IN LIMP MODE WHEN IT WORKED. GAUGES KEPT GOING O…
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I OWN A 2012 FIAT POP THAT I PURCHASED NEW ABOUT A YEAR AGO. ONE THING THAT DID NOT GO AWAY AND WAS EVER PRESENT AT ANY TIME WAS THE LIMP MODE FOR THE ENGINE OVER THE LAST FEW DAYS. RECYCLING DID NOT WORK TO CORRECT PROBLEM AND GAUGES WERE OUT. THE INDICATOR LIGHT ON PANEL SHOWED IN LIMP MODE WHEN IT WORKED. GAUGES KEPT GOING ON AND OFF SOMETIMES FOR SHORT PERIODS AND OTHER TIMES FOR LONGER PERIODS. ON 6/10/13 MY VEHICLE CAUGHT FIRE IN THE DASHBOARD. I WAS TRAVELING BACK FROM THE STORE IN LIMP MODE HOPING IT WOULD GO OUT BUT NEVER DID.I PARKED THE CAR IN FRONT OF MY DEVELOPMENT POOL AND WENT TO VISIT MY EMPLOYEE THERE. WITHIN ABOUT 5 MINUTES OR SO SHE SAID THAT MY LIGHTS WERE FLASHING. I CHECKED AND WENT TO THE VEHICLE. IT WAS ENGULFED WITH SMOKE AND A NASTY ELECTRICAL SMELL. FIRE DEPARTMENT CAME. I WAS TOLD THAT I HAD TO WAIT FOR THE FIRE INSPECTOR TO COME AND EXAMINE MY VEHICLE. HE CAME. BEGAN TEARING MY DASHBOARD APART TO FIND THE CAUSE OR SOURCE OF THE FIRE. IT WAS DETERMINED BY HIS KNOWLEDGE AND EXPERIENCE THAT THE BODY CONTROL UNIT HAD FAILED AND CAUSED THE FIRE. VEHICLE IS TOTALED. THE VEHICLE HAS ONLY ABOUT 4000 MILES ON IT. EARLIER THAT DAY BEFORE THE INCIDENT I HAD CALLED THE LOCAL FIAT DEALER. EXPLAINED THE PROBLEM OF THE GAUGES NOT WORKING, AND LIMP MODE, I ASKED IF IT WAS SAFE TO DRIVE AND HE SAID YES. AT THIS POINT I MADE AN APPOINTMENT TO HAVE THE VEHICLE LOOKED AT HOPEFULLY THAT DAY. ONLY OPENING WAS NEXT DAY AT 2PM. I HAVE FILED AN INSURANCE CLAIM AND THE VEHICLE HAS BEEN TOWED AWAY. *TR
NHTSA ODI #10516179
1,000 miles · Jan 11, 2013
Electrical System
THE KEY FOB BUTTON IS NOT RECESSED. THIS MEANS THE IGNITION KEY OFTEN OPENS INTO MY POCKET JUST FROM NORMAL BODY MOVEMENT. IT STABS MY THIGH. THIS IS A VEHICLE SAFETY PROBLEM BECAUSE IT HAPPENS WHEN I AM DRIVING MY OTHER VEHICLE AND CAN BE EXTREMELY DISTRACTING. *TR
NHTSA ODI #10492227
200 miles · Feb 3, 2012
Electrical SystemStructure
BODY SEAMS LEFT OPEN/UNWELDED DURING MANUFACTURING CAUSING WATER LEAKS AND ELECTRICAL PROBLEMS AFFECTING BRAKES, LIGHTING, RESTRAINT SYSTEMS, POWER DOOR LOCKS, WINDOWS, MIRRORS, ABS, ESP, HILL START ASSIST, ETC. OPEN/UNWELDED AREAS ALSO WEREN'T PAINTED DURING MANUFACTURING. IMPROPER REPAIRS PERFORMED. "SEALANT" APPLIED TO CLOSE …
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BODY SEAMS LEFT OPEN/UNWELDED DURING MANUFACTURING CAUSING WATER LEAKS AND ELECTRICAL PROBLEMS AFFECTING BRAKES, LIGHTING, RESTRAINT SYSTEMS, POWER DOOR LOCKS, WINDOWS, MIRRORS, ABS, ESP, HILL START ASSIST, ETC. OPEN/UNWELDED AREAS ALSO WEREN'T PAINTED DURING MANUFACTURING. IMPROPER REPAIRS PERFORMED. "SEALANT" APPLIED TO CLOSE SEAMS THAT SHOULD HAVE BEEN WELDED. PURCHASED 12/22/2011. FOUND INTERIOR WET ON 12/25/2011. RETURNED TO DEALER ON 01/02/2012. SPENT 21 DAYS IN THE SHOP. PROBLEM WAS FOUND TO BE, "NUMEROUS OPEN BODY SEAMS MEASURING OVER 10 INCHES LONG THAT WERE LEFT OPEN AND UNWELDED AND UNPAINTED DURING MANUFACTURING." CAR WAS RETURNED TO ME "REPAIRED" ON 1/23/2012. I IMMEDIATELY BEGAN EXPERIENCING NUMEROUS ELECTRICAL PROBLEMS. THEN, NOTICED THAT THE CAR WAS LEAKING, AGAIN, AND EVEN WORSE, ON 1/30/2012. CAR WAS NEVER REPAIRED/IMPROPERLY REPAIRED. INTERIOR VERY WET. ELECTRICAL PROBLEMS GETTING WORSE. PROBLEMS WITH BRAKES AND 'HILL START ASSIST'. FIAT WILL NOT RETURN MY CALLS. I'VE SENT LETTERS ASKING THAT THE CAR BE REPLACED. THE CAR IS UNSAFE TO DRIVE. *KB
NHTSA ODI #10446594
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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