2010 Dodge 1500

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.

During unrelated work, a mechanic discovered the retaining ring for recall N08 (rear axle pinion nut) was not installed and the pinion nut was loose enough to turn by hand. He stated the recall had either been performed incorrectly or not at all, and that the vehicle was unsafe to drive. The recall shows “completed” in 2013, but the defect is still present. I contacted Stellantis Customer Care, submitted photos, and they confirmed in writing that if the defect still exists, the recall must be performed free of charge regardless of age, mileage, or ownership. I sent the photos of the missing ring, screenshots showing the recall marked completed, and Stellantis’ confirmation to the dealership before having the vehicle towed to verify coverage. The truck was towed to Time Chrysler Dodge Jeep Ram of Portland. My initial contact was [XXX] at that location. However, all recall decisions and communication later came from [XXX] , who works at a different dealership. Over the next month, the dealership repeatedly stalled the recall, saying they were waiting on approval from the district manager and then from the recall department, but no action was ever taken. Despite having Stellantis’ written confirmation and clear photographic evidence of the unresolved defect, the dealership refused to perform the recall. They insisted on treating it as a “warranty” issue and cited reasons such as mileage, age, and not being the original owner—none of which apply to safety recalls. They then stated that teardown and diagnosis “would run $1000,” even though the defect has already been documented by both the mechanic and Stellantis. All communication, including photos, the mechanic’s findings, Stellantis’ confirmation of coverage, and the dealership’s refusal, is available upon request. The truck has now been sitting at the dealership for over a month with an unresolved safety defect. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11700012

Incident

Oct 13, 2025

Was just driving and the engine shut off and a check engine light came on and won’t start again believe timing chain failed

NHTSA ID

11697784

Incident

Nov 1, 2025

2010 Dodge Ram 1500 truck purchased used late May 2025 with 57000 miles. Late August 2025 with 60000 miles rear axle fell off when driving on Freeway at 60 miles per hour. Very serious accident was narrowly avoided as could not steer vehicle.Truck was serviced at dealership for recall of a pinion nut coming loose at 36107 miles in September 2013. Per this recall, the loose pinion nut can cause the axle to fail. The recall maintenance done in September 2013 at 36107 miles only lasted 24000 miles and serious safety issues reoccurred. In my opinion, on my vehicle the recall did not fix the problem. Now I am stuck with a $5000 repair on a vehicle with known recalls and safety issues that was supposedly fixed.Perhaps a second recall should be considered regarding this issue.

NHTSA ID

11687346

Incident

Aug 18, 2025

Me and my husband were driving down the road to go see a friend and all of a sudden the wheel hub assembly broke in half causing us to have to slam on our brakes and keep from crashing. The wheel almost ended up under our truck making the truck look like it was kachowing like Lightening McQueen from the movie Cars

NHTSA ID

11683820

Incident

Jul 10, 2025

Odometer Fraud. The contact purchased a 2010 Dodge Ram 1500. The contact stated that while attempting to obtain an auto warranty from Car Shield, it was discovered that there was a mileage discrepancy. The vehicle was a dealer sale. At the time of purchase, the vehicle mileage was 125,526 and at the time of registration, it was discovered that the mileage was 228,863.

NHTSA ID

11669377

Incident

Jun 25, 2025

Mileage

228,863 mi

I was driving to work on [XXX] when my rear end locked up and I slid sideways down [XXX]. I was going slower than normal due to slippery road conditions. The mechanic told me it was the pinion nut that froze up and locked up the gears and snapped the drive shaft. If it had been clear roads the truck probably would have flipped over. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11663333

Incident

Jan 28, 2025

took the vehicle to the dealer on 2/27/25 on invoice # chcs169951 and they have refused to fix the issue. i was given a proof of correction paper without doing any or the work and told that they are no responsible to fix the issue because it is an older vehicle. I have been trying to register the vehicle but am unable to because it will not pass the brake and light inspection. I was told that it would take 2-3 weeks to update the system and has now been close to 2 months and still no update.

NHTSA ID

11656752

Incident

Feb 27, 2025

The contact owns a 2010 Dodge Ram 1500. The contact stated while driving at an undisclosed speed, there was an abnormally loud sound coming from the rear of the vehicle. The vehicle was taken to an independent mechanic, where it was diagnosed and determined that the rear axle differential pin retaining bolt had failed and needed to be replaced. The vehicle was not repaired. The vehicle was taken to the dealer but was not yet diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 160,704.

NHTSA ID

11656516

Incident

Apr 24, 2025

Mileage

160,704 mi

LAMP - DOME

LAMP - DOME

LAMP - DOME

"Dual EVAP System Extreme Duty Vapor Canister Filter Kit Customers operating fleet or severe/extreme duty gasoline vehicles in continuous dusty driving conditions can plug the single OE filter system and may experience a Malfunction Indicator Lamp (MIL) illumination. Upon further investigation the technician may experience a Malfunction Indicator Lamp (MIL) illumination and the vehicle may exhibit/set one or more of the following Diagnostic Trouble Codes (DTCs): ● P0441 - EVAP Purge System Performance. ● P062A - Fuel Pump Control Performance. Customers may also experience one or more of the following: ● Hard to fill fuel tank with fuel. ● Premature shut-off of the gas nozzle when refueling. ● Flow back of fuel while refueling. "

Plate - Planetary

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