The vehicle dossier US · 2010

2010 Dodge
RAM 3500Problems & recalls

150 distinct owner reports in the NHTSA snapshot. Steering appears in 92 of them. Explore what was reported—and which official actions are on file.

Snapshot Sep 28, 2026Live NHTSA complaint API How this dossier is compiled

01 / Owner-reported evidence

What owners reported.

Categories attached to 150 distinct reports. A report can mention more than one component, so category totals can overlap.

Steering92 reports
Suspension23 reports
Engine22 reports
Fuel system18 reports
Electrical system17 reports
Other components14 reports
Brakes9 reports
Transmission & drivetrain8 reports
Air bags3 reports
Body & structure1 reports
See original component labels
STEERING87
SUSPENSION22
ENGINE17
ELECTRICAL SYSTEM15
FUEL/PROPULSION SYSTEM10
POWER TRAIN8
FUEL SYSTEM, DIESEL7
SERVICE BRAKES7
STEERING:LINKAGES:TIE ROD ASSEMBLY6
UNKNOWN OR OTHER4
ENGINE AND ENGINE COOLING4
WHEELS4
ENGINE AND ENGINE COOLING:ENGINE:DIESEL3
AIR BAGS3
VEHICLE SPEED CONTROL2
FUEL SYSTEM, GASOLINE2
TIRES2
SUSPENSION:FRONT1
STEERING:HYDRAULIC POWER ASSIST:PUMP1
ELECTRICAL SYSTEM: INTEGRATED TRAILER BRAKE CONTROL1
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:CONTROL UNIT/MODULE1
TIRES:PRESSURE MONITORING AND REGULATING SYSTEMS1
EQUIPMENT1
SERVICE BRAKES, ELECTRIC1
STEERING:LINKAGES1
STRUCTURE:BODY1
VEHICLE SPEED CONTROL:CRUISE CONTROL1
ELECTRICAL SYSTEM:IGNITION1

These are reports made to NHTSA, not verified diagnoses. More reports can reflect more vehicles, more time on the road, or greater reporting activity.

The reporting timeline

When reports arrived.

Reports by year filed, not by the year a problem occurred. Showing the latest 15 years with reports.

Year filed (last two digits)Latest report: Sep 18, 2024
Mileage, where supplied

51,000 miles is the median among 95 reports with usable mileage. The middle half spans 25,000–92,000 miles.

This describes the submitted reports. It does not predict when a vehicle will fail.

02 / Official safety campaigns

9 recall campaigns on file.

A campaign can cover only certain production dates or configurations. The count does not tell you whether an individual car has an open recall.

Jan 15, 2019 Safety recallAIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULECampaign 19V018000

A do-not-drive advisory is recorded. Verify applicability immediately with NHTSA or the manufacturer.

Reported concern

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.

Manufacturer’s stated response

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.

Manufacturer campaign: V01

Read campaign 19V018000 at NHTSA
Jan 9, 2018 Safety recallAIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULECampaign 18V021000

A do-not-drive advisory is recorded. Verify applicability immediately with NHTSA or the manufacturer.

Reported concern

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.

Manufacturer’s stated response

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.

Manufacturer campaign: U03

Read campaign 18V021000 at NHTSA
Dec 20, 2017 Safety recallPOWER TRAIN:AUTOMATIC TRANSMISSION:LEVER AND LINKAGE:COLUMN SHIFTCampaign 17V821000

Reported concern

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.

Manufacturer’s stated response

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.

Manufacturer campaign: T79

Read campaign 17V821000 at NHTSA
Dec 22, 2016 Safety recallAIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULECampaign 16V947000

A do-not-drive advisory is recorded. Verify applicability immediately with NHTSA or the manufacturer.

Reported concern

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.

Manufacturer’s stated response

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.

Manufacturer campaign: S92

Read campaign 16V947000 at NHTSA
Oct 13, 2016 Safety recallELECTRICAL SYSTEM:ALTERNATOR/GENERATOR/REGULATORCampaign 16V739000

Reported concern

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.

Manufacturer’s stated response

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.

Manufacturer campaign: S68

Read campaign 16V739000 at NHTSA
May 24, 2016 Safety recallAIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULECampaign 16V352000

A do-not-drive advisory is recorded. Verify applicability immediately with NHTSA or the manufacturer.

Reported concern

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.

Manufacturer’s stated response

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.

Manufacturer campaign: S43

Read campaign 16V352000 at NHTSA
Oct 8, 2014 Safety recallFUEL SYSTEM, DIESELCampaign 14V635000

Reported concern

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.

Manufacturer’s stated response

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.

Manufacturer campaign: P65

Read campaign 14V635000 at NHTSA
Nov 6, 2013 Safety recallSTEERING:LINKAGES:TIE ROD ASSEMBLYCampaign 13V529000

Reported concern

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.

Manufacturer’s stated response

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.

Manufacturer campaign: N49

Read campaign 13V529000 at NHTSA
Jul 6, 2011 Safety recallSTEERING:LINKAGES:TIE ROD ASSEMBLYCampaign 11V350000

Reported concern

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.

Manufacturer’s stated response

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.

Manufacturer campaign: L16

Read campaign 11V350000 at NHTSA
Check this car’s VIN at NHTSA

03 / The manufacturer’s record

Instructions. Updates. Responses.

223 distinct communications list this model-year. Showing the latest 12. A matching model-year does not establish that every engine, trim or reported symptom is covered.

Jun 26, 2026 Service Bulletin/Repair InstructionsS1203000003 REV.ATrac-Rite Operation Diagnosis, Chatter, Shudder, Moving From A Stop And TurningNHTSA ID 11034393

Trac-Rite Operation Diagnosis, Chatter, Shudder, Moving From A Stop And Turning

Components: SERVICE BRAKES. Confirm detailed applicability in the original document.

Source record 11034393 at NHTSA
Jun 17, 2026 Service Bulletin/Repair Instructions112906BEARING - CRANKSHAFT THRUST and KITNHTSA ID 11034373

BEARING - CRANKSHAFT THRUST and KIT

Components: ENGINE. Confirm detailed applicability in the original document.

Source record 11034373 at NHTSA
Jun 17, 2026 Service Bulletin/Repair Instructions112906BEARING - CRANKSHAFT THRUST and KITNHTSA ID 11034337

BEARING - CRANKSHAFT THRUST and KIT

Components: ENGINE. Confirm detailed applicability in the original document.

Source record 11034337 at NHTSA
Mar 3, 2026 Service Bulletin/Repair Instructions110603SPEAKER - NONENHTSA ID 11030026

SPEAKER - NONE

Components: ELECTRICAL SYSTEM. Confirm detailed applicability in the original document.

Source record 11030026 at NHTSA
Mar 3, 2026 Service Bulletin/Repair Instructions110604SPEAKER - NONENHTSA ID 11030025

SPEAKER - NONE

Components: ELECTRICAL SYSTEM. Confirm detailed applicability in the original document.

Source record 11030025 at NHTSA
Jul 28, 2025 Service Bulletin/Repair Instructions106241LAMP - DOMENHTSA ID 11021585

LAMP - DOME

Components: ELECTRICAL SYSTEM. Confirm detailed applicability in the original document.

Source record 11021585 at NHTSA
Jun 12, 2025 Service Bulletin/Repair Instructions104974LAMP - DOMENHTSA ID 11019776

LAMP - DOME

Components: ELECTRICAL SYSTEM. Confirm detailed applicability in the original document.

Source record 11019776 at NHTSA
May 1, 2025 Service Bulletin/Repair Instructions103774LAMP - DOMENHTSA ID 11017451

LAMP - DOME

Components: ELECTRICAL SYSTEM. Confirm detailed applicability in the original document.

Source record 11017451 at NHTSA
Dec 17, 2024 Service Bulletin/Repair Instructions102307GEAR - REACTION SUNNHTSA ID 11012351

GEAR - REACTION SUN

Components: POWER TRAIN. Confirm detailed applicability in the original document.

Source record 11012351 at NHTSA
Oct 30, 2024 Service Bulletin/Repair Instructions101232Plate - PlanetaryNHTSA ID 11010205

Plate - Planetary

Components: POWER TRAIN. Confirm detailed applicability in the original document.

Source record 11010205 at NHTSA
Jul 19, 2024 Service Bulletin/Repair InstructionsS2408000078Replacement Totally Integrated Power Module (TIPM) Displays Incorrect Vehicle Identification Number (VIN) Current and ActiveNHTSA ID 11004993

Replacement Totally Integrated Power Module (TIPM) Displays Incorrect Vehicle Identification Number (VIN) Current and Active

Components: ELECTRICAL SYSTEM. Confirm detailed applicability in the original document.

Source record 11004993 at NHTSA
Sep 15, 2023 Service Bulletin/Repair Instructions9100226Connector kit Before ordering this connector repair kit 68018957A$, check it in the Mopar Connector Repair Kit Website to confirm part number and applicability. There is an error with the wiring diagrams in Service Library that…NHTSA ID 10248509

Connector kit Before ordering this connector repair kit 68018957A$, check it in the Mopar Connector Repair Kit Website to confirm part number and applicability. There is an error with the wiring diagrams in Service Library that is causing the incorrect repair kit part number to populate. Please use the Mopar Connector Repair Kit Website until this issue is resolved.

Components: ELECTRICAL SYSTEM. Confirm detailed applicability in the original document.

Source record 10248509 at NHTSA
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Records below contain the NHTSA bulk summary unless a document-reviewed explainer is linked. A service bulletin is not a safety recall or a promise of a free repair. Records may be revised or superseded; verify the current document with the manufacturer.

04 / Agency investigations

Official inquiries.

An investigation is an inquiry into a potential concern. Its presence does not establish a defect, and a closed case does not certify a car’s condition.

Opened Sep 17, 2021 No close date recordedDesiccated Air Bag Inflator RuptureEA21002

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.

Find investigation EA21002
Opened Apr 19, 2019 ClosedElectrical overstressEA19001

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.

Recorded closure: Sep 19, 2024

Campaign reference in the source: 20V024

Find investigation EA19001

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