NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
395 reports32,000 miles · Oct 20, 2015
Unknown Or Other
MY 2012 FIAT500C HAD CLUTCH/PRESSURE PLATE FAILURE A FEW WEEKS AGO. I GOT INTO MY CAR TO RUN SOME ERRANDS AND IT STARTED FINE ALTHOUGH I DID FEEL THE CLUTCH WAS A BIT STIFF. I GOT UP TO 3RD GEAR AND DROVE 2 BLOCKS TOWARD THE INTERSECTION. AS I TRIED TO SHIFT THE GEAR TO NEUTRAL AT THE RED LIGHT I COULD NOT CHANGE GEARS. LUCKILY …
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MY 2012 FIAT500C HAD CLUTCH/PRESSURE PLATE FAILURE A FEW WEEKS AGO. I GOT INTO MY CAR TO RUN SOME ERRANDS AND IT STARTED FINE ALTHOUGH I DID FEEL THE CLUTCH WAS A BIT STIFF. I GOT UP TO 3RD GEAR AND DROVE 2 BLOCKS TOWARD THE INTERSECTION. AS I TRIED TO SHIFT THE GEAR TO NEUTRAL AT THE RED LIGHT I COULD NOT CHANGE GEARS. LUCKILY I PRESSED DOWN HARD ENOUGH PRESSING ON THE BREAKS AND MANAGED TO BRING THE GEAR TO NEUTRAL. I PUT MY HAZARD LIGHTS ON AND MANAGED TO ROLL TO THE SIDE OF THE ROAD. I IMMEDIATELY CALLED MY FIAT SERVICE CENTER AND TOLD THEM WHAT HAD HAPPENED. THEY INSTRUCTED ME TO CALL THE COMPLIMENTARY TOW SERVICE. I GOT A CALL ON MONDAY MORNING SAYING THAT THE PRESSURE PLATE AND CLUTCH NEEDED TO BE REPLACED AND IT WOULD COST ~$1000. I ASKED THE SERVICE ADVISOR WHY IT WASN'T COVERED BY THE WARRANTY AND HE SAID THAT IT WAS CONSIDERED A WEAR AND TEAR ISSUE. IN OTHER WORDS, IT WAS MY FAULT THE CLUTCH FAILED AT 32,000 MILES. I CONTACTED FIATCARES AND THEY SAID THEY WOULD LOOK INTO IT. THEIR REPLY WAS THAT THE CAR NEEDED A NEW PRESSURE PLATE AND NEW CLUTCH AND THAT THE TECHNICIAN DID NOT BELIEVE THAT THIS WAS CAUSED BY A DEFECT ON THE MANUFACTURER'S PART AND THEREFORE THEY WERE UNABLE TO PROVIDE ASSISTANCE WITH THE REPAIR. NO CLUTCH SHOULD WEAR OUT WITHIN 3 YEARS AND ~30K MILES WHEN IT HAS HAD ONLY ONE DRIVER WITH EXPERIENCE IN DRIVING A MANUAL TRANSMISSION VEHICLE. IT IS QUITE CLEAR FROM PUBLIC ACCOUNTS THAT 2012 FIAT 500'S EXHIBIT PREMATURE CLUTCH WEAR PROBLEMS. IN ADDITION TO THE CLUTCH ISSUE, I'VE ENCOUNTERED PROBLEMS WITH MY CAR ALMOST FROM THE VERY BEGINNING, WHEN IT ONLY HAD A FEW HUNDRED MILES ON IT. I'VE HAD NUMEROUS FALSE-START ISSUES WITH THE IGNITION, I'VE EVEN HAD A INCIDENT WHERE MY ENGINE COMPLETELY SHUT OFF WHILE DRIVING! LUCKILY THIS OCCURRED WHILE DRIVING IN THE CITY. IMAGINE HOW DANGEROUS THAT WOULD HAVE BEEN IF I WERE DRIVING 70 MPH ON A HIGHWAY.
NHTSA ODI #10783693
54,000 miles · Oct 12, 2015
Suspension
LOWER BALL JOINTS ON BOTH SIDES LOOSE AND SHOW EXCESSIVE WEAR. DEALERSHIP PERFORMED MAINTENCE AND DID NOT NOTICE ANYTHING WHILE UNDER WARRANTY BUT NEXT MAINTENCE SHOWED EXCESSIVE WEAR AND CAR WAS JUST OUT OF WARRANTY AND FIAT WOULD NOT COVER REPAIR. NUMEROUS DOCUMENTED INCIDENTS ON 2012 FIAT 500'S WHERE BALL JOINTS HAVE BROKEN L…
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LOWER BALL JOINTS ON BOTH SIDES LOOSE AND SHOW EXCESSIVE WEAR. DEALERSHIP PERFORMED MAINTENCE AND DID NOT NOTICE ANYTHING WHILE UNDER WARRANTY BUT NEXT MAINTENCE SHOWED EXCESSIVE WEAR AND CAR WAS JUST OUT OF WARRANTY AND FIAT WOULD NOT COVER REPAIR. NUMEROUS DOCUMENTED INCIDENTS ON 2012 FIAT 500'S WHERE BALL JOINTS HAVE BROKEN LOOSE. A SERIOUS SAFETY ISSUE THAT FIAT NEEDS TO ADDRESS AS THE BALL JOINTS ARE WEARING WITHIN 50,000-60000 MILES
NHTSA ODI #10781386
46,000 miles · Oct 2, 2015
Power Train
WHILE DRIVING THE VEHICLE, AND A NEED TO SHIFT OCCURS, THE CLUTCH WILL LOCKUP, COMPLETELY FROZEN, MAKING IT IMPOSSIBLE NO MATTER HOW HARD YOU PUSH, TO DEPRESS THE PEDAL MAKING IT IMPOSSIBLE TO SHIFT GEAR. THIS HAPPENS EVERY 20,000 MILES AND EACH TIME, DEALER SERVICE DEPT SAYS IT'S A "BENT PRESSURE PLATE". BUT FIAT CLASSIFIES …
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WHILE DRIVING THE VEHICLE, AND A NEED TO SHIFT OCCURS, THE CLUTCH WILL LOCKUP, COMPLETELY FROZEN, MAKING IT IMPOSSIBLE NO MATTER HOW HARD YOU PUSH, TO DEPRESS THE PEDAL MAKING IT IMPOSSIBLE TO SHIFT GEAR. THIS HAPPENS EVERY 20,000 MILES AND EACH TIME, DEALER SERVICE DEPT SAYS IT'S A "BENT PRESSURE PLATE". BUT FIAT CLASSIFIES THIS A "WEAR & TEAR" ITEM AND CANNOT HELP. DEALER SERVICE WANTS $2000 EACH TIME (THOUGH INDEPENDENT REPAIR SHOPS LIKELY WOULD CHARGE LESS). THIS HAS ALREADY HAPPENED TWICE AND FIAT WILL NOT HELP. HARD TO BELIEVE THAT FIAT BELIEVES THIS IS NORMAL EXPECTED BEHAVIOR ON THEIR VEHICLES, FOR OWNERS TO HAVE TO FORK OUT $2000 EVERY 20,000 MILES FOR NEW PRESSURE PLATES. WHEN IT HAPPENS TO YOU, IT CAN BE VERY DANGEROUS DEPENDING WHERE YOU HAPPEN TO BE AT THE TIME. INTERNET SEARCHES FOR FIAT PRESSURE PLATE WILL SHOW A PATTERN OF THIS ISSUE, AND NO OFFICIAL RESPONSE FROM FIAT.
NHTSA ODI #10779332
952 miles · Oct 1, 2015
Engine
CAR SUDDENLY STOPS RUNNING WHILE JUST DRIVING FORWARD. IGNITION KEY REMAINS IN "ON" POSITION, BUT ALL ACCESSORY/WARNING LIGHTS COME ON. THIS HAS HAPPENED 3 TIMES, THE FIRST WHILE CAR HAD 950 MILES ON IT IN OCTOBER 1012. CAR WAS TAKEN TO DEALERSHIP SERVICE DEPARTMENT. WHEN I RECEIVED IT BACK I WAS TOLD THAT THEY HAD "CHANGE…
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CAR SUDDENLY STOPS RUNNING WHILE JUST DRIVING FORWARD. IGNITION KEY REMAINS IN "ON" POSITION, BUT ALL ACCESSORY/WARNING LIGHTS COME ON. THIS HAS HAPPENED 3 TIMES, THE FIRST WHILE CAR HAD 950 MILES ON IT IN OCTOBER 1012. CAR WAS TAKEN TO DEALERSHIP SERVICE DEPARTMENT. WHEN I RECEIVED IT BACK I WAS TOLD THAT THEY HAD "CHANGED THE SOFTWARE". THE SECOND TIME THE CAR CEASED RUNNING (5,414 MILES) WHILE BEING DRIVEN FORWARD, I HAD IT TOWED TO THE DEALERSHIP AND RECEIVED IT BACK WITH THE INFORMATION THAT THEY COULD NOT FIND ANYTHING WRONG WITH IT. I STOPPED DRIVING THE VEHICLE EXCEPT FOR OCCASIONALLY DRIVING IT AROUND MY QUIET NEIGHBORHOOD TO KEEP THE BATTERY CHARGED UP. ON SEPTEMBER 26, 2015, I DECIDED TO DRIVE THE CAR TO A NEARBY TARGET (APPROX. 1.5 MILES FROM MY HOME). THE CAR DROVE THERE PERFECTLY BUT CEASED RUNNING AS I DROVE TOWARDS HOME. AGAIN I HAD THE CAR TOWED TO THE SERVICE DEPARTMENT AT FIAT/ALFA ROMEO OF AUSTIN. TODAY FIAT CUSTOMER SERVICE CALLED ME AND SAID THE SERVICE FACILITY WAS NOT ABLE TO FIND ANYTHING WRONG WITH THE CAR AND WAS RETURNING THE CAR TO ME AGAIN WITHOUT DIAGNOSIS OR REPAIR OF THE PROBLEM. MY CASE NUMBER WITH FIAT CUSTOMER SERVICE IS: 278-579-22. ALL THREE OF THESE VERY FRIGHTENING SUDDEN STALLS OCCURRED ON CITY STREETS. THERE IS NO UNUSUAL NOISE OR WARNING, THE CAR JUST SUDDENLY STOPS RUNNING. I WAS DRIVING STRAIGHT AHEAD EACH TIME. THE ENGINE WAS NOT HOT OR WERE THERE ANY UNUSUAL ODORS OR SOUNDS. I TURNED ON MY EMERGENCY FLASHERS, TURNED THE IGNITION KEY TO THE "OFF" POSITION, PUT THE SHIFT LEVER IN "PARK" AND THE CAR IMMEDIATELY STARTED AGAIN AND RAN WITHOUT FURTHER DIFFICULTY. I WAS VERY, VERY LUCKY THAT I WAS NOT HIT FROM BEHIND AS THE LAST TWO INCIDENTS WERE IN BUSY TRAFFIC AREAS. I WILL NOT DRIVE THIS VEHICLE AGAIN.
NHTSA ODI #10779157
122,290 miles · Sep 29, 2015
Air BagsElectronic Stability Control (esc)Fuel/propulsion System
I TOOK MY CAR IN TO FIAT IN SLC UTAH KEN GARFF THEY TOOK MY CAR SAID I HAD AN OIL LEAK THEN CAME BACK AND SAID I NEEDED A CATALYST CONVERTER I BELIEVE THE ELECTRONIC SYSTEM HAS BEEN HACKED INTO BY THE DEALERSHIP IN ORDER TO MAKE MONEY WHICH PUTS ME AND MY 13 YEAR OLD CHILD ARE AT RISK IN THIS CAR PLEASE HELP I HAVE BEEN THOUGH T…
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I TOOK MY CAR IN TO FIAT IN SLC UTAH KEN GARFF THEY TOOK MY CAR SAID I HAD AN OIL LEAK THEN CAME BACK AND SAID I NEEDED A CATALYST CONVERTER I BELIEVE THE ELECTRONIC SYSTEM HAS BEEN HACKED INTO BY THE DEALERSHIP IN ORDER TO MAKE MONEY WHICH PUTS ME AND MY 13 YEAR OLD CHILD ARE AT RISK IN THIS CAR PLEASE HELP I HAVE BEEN THOUGH THIS SAME THING IN BUFORD GA PLEASE HELP I WANT FIAT TO BUY MY CAR BACK I OWN IT OUT RIGHT PLEASE I DONT TRUST THE DEALER SOMETHING IS GOING ON WITH THE ELECTONIC SYSTEM
NHTSA ODI #10778316
95,000 miles · Sep 9, 2015
Power Train
TL* THE CONTACT OWNS A 2012 FIAT 500. WHILE DRIVING APPROXIMATELY 45 MPH, THE GEAR WAS NOT ABLE TO SHIFT FROM THE FOURTH GEAR. VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FINGER PLATE ON THE CLUTCH WAS CRACKED AND THE CLUTCH WOULD NOT DISENGAGE. THE VEHICLE WAS REPAIRED BUT THE REMEDY FAILED. THE…
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TL* THE CONTACT OWNS A 2012 FIAT 500. WHILE DRIVING APPROXIMATELY 45 MPH, THE GEAR WAS NOT ABLE TO SHIFT FROM THE FOURTH GEAR. VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FINGER PLATE ON THE CLUTCH WAS CRACKED AND THE CLUTCH WOULD NOT DISENGAGE. THE VEHICLE WAS REPAIRED BUT THE REMEDY FAILED. THE PART FOR THE REPAIR WAS ORDERED BUT IT WAS DISCOVERED THAT THE CLUTCH ASSEMBLY WAS ALREADY CRACKED BEFORE USE. THE PART WAS REORDERED AND THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 95,000.
NHTSA ODI #10762694
48,000 miles · Sep 8, 2015
Engine
MY 2012 FIAT IS HAVING STARTER ISSUES. SOMETIMES THE ENGINE JUST CUTS OFF. I TOOK THE CAR IN AND THEY TOLD ME THAT ALL 2012 FIATS RECENTLY SERVICED, ARE HAVING THIS ISSUE. THERE IS NO FIX UNTIL CHRYSLER CREATES A CODE FOR THE SYSTEM. I ASKED HOW LONG HAS THIS BEEN GOING ON AND HE SAID 3 MONTHS NOW. SO BASICALLY I HAVE TO DEAL WI…
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MY 2012 FIAT IS HAVING STARTER ISSUES. SOMETIMES THE ENGINE JUST CUTS OFF. I TOOK THE CAR IN AND THEY TOLD ME THAT ALL 2012 FIATS RECENTLY SERVICED, ARE HAVING THIS ISSUE. THERE IS NO FIX UNTIL CHRYSLER CREATES A CODE FOR THE SYSTEM. I ASKED HOW LONG HAS THIS BEEN GOING ON AND HE SAID 3 MONTHS NOW. SO BASICALLY I HAVE TO DEAL WITH MY CAR BARLEY STARTING AND POSSIBILY CUTTING OFF AND THERE IS NO SOLUTION. THIS COULD BE DANGEROUS AND MAY LEAD TO OTHER DAMAGES. SOMETHING NEEDS TO BE DONE.
NHTSA ODI #10762239
20,000 miles · Sep 4, 2015
Power Train
PULLED UP TO A STOP LIGHT, DEPRESSED CLUTCH AND SHIFTED TO NEUTRAL. WHEN LIGHT TURNED GREEN, I DEPRESSED THE CLUTCH AND IT LOCKED UP AND WOULD NOT ENGAGE ALLOWING ME TO SHIFT INTO A GEAR. MECHANIC SAID ITS A BENT PRESSURE PLATE AND THE ENTIRE CLUTCH ASSY. NEEDS REPLACED FOR ~$2,000. OBVIOUSLY BENDING OF THE PRESSURE PLATE IS NOT…
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PULLED UP TO A STOP LIGHT, DEPRESSED CLUTCH AND SHIFTED TO NEUTRAL. WHEN LIGHT TURNED GREEN, I DEPRESSED THE CLUTCH AND IT LOCKED UP AND WOULD NOT ENGAGE ALLOWING ME TO SHIFT INTO A GEAR. MECHANIC SAID ITS A BENT PRESSURE PLATE AND THE ENTIRE CLUTCH ASSY. NEEDS REPLACED FOR ~$2,000. OBVIOUSLY BENDING OF THE PRESSURE PLATE IS NOT "NORMAL WEAR AND TEAR" AND ITS ALSO VERY RARE TO HAVE A CLUTCH FAIL SO EARLY (20,000 MILES). UNFORTUNATELY FIAT IS SAYING THIS IS A NORMAL WEAR AND TEAR ISSUE AND IS NOT COVERED UNDER WARRANTY. READING THE FORUMS, THIS SEEMS TO BE A VERY COMMON PROBLEM WITH MANUAL SHIFT FIATS AND IS A TERRIBLE SAFETY HAZARD (THINK IF THE CLUTCH LOCKED UP AT HIGHWAY SPEEDS PREVENTING SOMEONE FROM SHIFTING OUT OF GEAR). THIS PART SHOULD BE RECALLED AND REPLACED ON ALL MANUAL TRANSMISSION FIATS AND COSTS FULLY COVERED.
NHTSA ODI #10761550
6,000 miles · Aug 24, 2015
EnginePower Train
THE CAR GOT STUCK WITH MUD UNDER THE CAR. WHEN WE GO IT PULLED OUT AND TOOK IT TO THE DEALER WOULD HAVE COST US 3000 TO HAVE IT FIXED. THAT WAY TO MUCH AND THEY TOLD THERE WAS PROBLEM WITH THE ENGINE NOW. THEY WOULDN'T WORK A DEAL ON IT. WHEN DRIVING HOME WE NOTICED THRY LEFT A PLATE FROM UNDER THE STERLING WILL AND HAD RIP THE…
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THE CAR GOT STUCK WITH MUD UNDER THE CAR. WHEN WE GO IT PULLED OUT AND TOOK IT TO THE DEALER WOULD HAVE COST US 3000 TO HAVE IT FIXED. THAT WAY TO MUCH AND THEY TOLD THERE WAS PROBLEM WITH THE ENGINE NOW. THEY WOULDN'T WORK A DEAL ON IT. WHEN DRIVING HOME WE NOTICED THRY LEFT A PLATE FROM UNDER THE STERLING WILL AND HAD RIP THE BLACK PEACE THAT WRAPES OROUND IT.WE TO IT TO A TRAMISSION PLACE IN TOWN WHERE THEY FIXED THE TRANSMISSIN , THE CAR DRIVE LIKE A MESS I JUST AFRAID TO GO LOMG DISTANCE.
NHTSA ODI #10758772
38,400 miles · Aug 17, 2015
Electrical System
TL* THE CONTACT OWNS A 2012 FIAT 500. WHILE DRIVING AT VARIOUS SPEEDS, SEVERAL UNKNOWN WARNING LIGHTS ILLUMINATED BEFORE THE VEHICLE STALLED. THE CONTACT STATED THAT WITH MULTIPLE ATTEMPTS, THE VEHICLE WAS ABLE TO RESTART. THE FAILURE RECURRED INTERMITTENTLY. IN ADDITION, WHEN PARKED, THE VEHICLE WAS NOT ABLE TO START AND THE KE…
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TL* THE CONTACT OWNS A 2012 FIAT 500. WHILE DRIVING AT VARIOUS SPEEDS, SEVERAL UNKNOWN WARNING LIGHTS ILLUMINATED BEFORE THE VEHICLE STALLED. THE CONTACT STATED THAT WITH MULTIPLE ATTEMPTS, THE VEHICLE WAS ABLE TO RESTART. THE FAILURE RECURRED INTERMITTENTLY. IN ADDITION, WHEN PARKED, THE VEHICLE WAS NOT ABLE TO START AND THE KEY COULD NOT BE REMOVED FROM THE IGNITION SWITCH. THE VEHICLE WAS TOWED TO A DEALER WHERE IT WAS DIAGNOSED THAT THE VEHICLE'S SYSTEM HAD TO BE REPROGRAMMED. THE VEHICLE WAS SERVICED, BUT THE REMEDY FAILED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 38,400.
NHTSA ODI #10749167
Official recalls
3Nov 15, 2019
Chrysler (FCA US LLC) is recalling certain 2012-2013 Fiat 500 vehicles equipped with 6-speed automatic transmissions. The shifter cable bushing may fail allowing the cable to detach from the transmission.
Consequence & remedy
Consequence: If the shifter cable detaches from the transmission, the transmission may not shift into the gear selected by the driver. Additionally, despite selecting PARK with the shifter, the vehicle may roll away. These scenarios may increase the risk of a crash.
Remedy: Chrysler will notify owners, and dealers will replace the shifter cable adjuster, free of charge. The recall began January 9, 2020. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is VB4.
Additional source detail variants (2)
Power Train:automatic Transmission:lever And Linkage:floor Shift
Chrysler (FCA US LLC) is recalling certain 2012-2013 Fiat 500 vehicles equipped with 6-speed automatic transmissions. The shifter cable bushing may fail allowing the cable to detach from the transmission.
Consequence: If the shifter cable detaches from the transmission, the transmission may not shift into the gear selected by the driver. Additionally, despite selecting PARK with the shifter, the vehicle may roll away. These scenarios may increase the risk of a crash.
Remedy: Chrysler will notify owners, and dealers will replace the shifter cable adjuster, free of charge. The recall began January 9, 2020. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is VB4.
Power Train:automatic Transmission
Chrysler (FCA US LLC) is recalling certain 2012-2013 Fiat 500 vehicles equipped with 6-speed automatic transmissions. The shifter cable bushing may fail allowing the cable to detach from the transmission.
Consequence: If the shifter cable detaches from the transmission, the transmission may not shift into the gear selected by the driver. Additionally, despite selecting PARK with the shifter, the vehicle may roll away. These scenarios may increase the risk of a crash.
Remedy: Chrysler will notify owners, and dealers will replace the shifter cable adjuster, free of charge. The recall began January 9, 2020. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is VB4.
May 16, 2016
Chrysler (FCA US LLC) is recalling certain model year 2012-2016 Fiat 500 vehicles manufactured June 21, 2010, through January 12, 2016, equipped with a manual transmission. The clutch diaphragm spring may fracture and fail, causing an inability to switch gears.
Consequence & remedy
Consequence: If the clutch diaphragm spring fails, the driver may not be able to shift gears or the vehicle may lose motive power, increasing the risk of a crash.
Remedy: The remedy for this recall will include the installation of a clutch pedal limiter and a clutch pedal switch. The recall began on November 10, 2016. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is S34.
Nov 10, 2011
CHRYSLER IS RECALLING CERTAIN MODEL YEAR 2012 DODGE JOURNEY AND FIAT 500 VEHICLES MANUFACTURED FROM OCTOBER 24, 2011, THROUGH OCTOBER 26, 2011. SOME VEHICLES WERE ASSEMBLED WITH CONTAMINATED BRAKE FLUID AND MAY EXPERIENCE A DEGRADATION OF THE SEALING COMPONENTS WITHIN THE BRAKE SYSTEM.
Consequence & remedy
Consequence: THIS COULD LEAD TO LOSS OF BRAKING ABILITY INCREASING THE RISK OF A CRASH.
Remedy: CHRYSLER WILL NOTIFY OWNERS AND REPLACE ALL BRAKE COMPONENTS THAT COME IN CONTACT WITH HYDRAULIC BRAKE FLUID. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MARCH 1, 2012. 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
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.