2010 Dodge Ram 2500

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.

The contact owns a 2010 Dodge Ram 2500. The contact stated that while performing routine maintenance on the vehicle, the contact observed that the passenger’s and driver’s side support rails on the sub frame had several sections that were severely rusted. The contact stated that there were gaps of approximately 2-feet on both rails where the metal was rusted through. The contact had not taken the vehicle to a local dealer or independent mechanic. The vehicle was not diagnosed or repaired. The contact researched online and became aware that the failure was a known issue. The manufacturer was not informed of the failure. The failure mileage was approximately 189,000.

NHTSA ID

11688824

Incident

Sep 13, 2025

Mileage

189,000 mi

The contact owns a 2010 Ram 2500. The contact stated while driving approximately 70 MPH, the vehicle was driven over uneven pavement, causing the ignition key to fall out of the ignition. The contact coasted to the side of the road and placed the key back in the ignition and continued driving; however, the failure reoccurred several more times. The contact found information of NHTSA Campaign Number: 10V200000 (Electrical System). The contact called the dealer about the failure and confirmed that the VIN was not included in the recall. The contact called another dealer, R C Bliss Inc (901 Lyndale Ave N, Faribault, MN 55021) and it was confirmed that the VIN was not included. The vehicle was not repaired. The vehicle was taken to a certified mechanic however, the vehicle was not diagnosed or repaired. The manufacturer was informed of the failure and confirmed that VIN was not included in the recall. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was unknown.

NHTSA ID

11664513

Incident

Jun 2, 2025

This is the 3rd time this happened to me. The first time I was driving around 55 and the truck started to shake so bad I could not actually hold onto the steering wheel, and I made it to the side of the road. I thought was a flat tire and I pulled over to find nothing wrong. The second was bad as it shook so violently, I was unable to make it to the side of the road, so I hit the brakes in the middle of traffic to stop. This 3rd time I happen to be traveling 65 mph on the interstate in PA and hit a small bump and all of the sudden the truck felt like it was bouncing off of the road. I hit the brakes to slow down and drove to the side and into a field. I purchased tie rods and actually the entire front suspension. This was the worst shaking I have ever felt in 45 years of driving. This is going to get me killed when this happens on the road. Please help. [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ID

11443944

Incident

Dec 15, 2021

Fuel pump failed with no warning. Best One of Indy confirmed and replaced. It was parked and would not start.

NHTSA ID

11437231

Incident

Oct 3, 2021

TL* THE CONTACT OWNS A 2010 RAM 2500. THE CONTACT STATED THAT THE EXHAUST SYSTEM REGENERATION REQUIRED NOW WARNING LIGHT WAS ILLUMINATED. THE VEHICLE WAS NOT TAKEN TO A LOCAL DEALER. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS INFORMED OF THE FAILURE AND INFORMED THE CONTACT THAT THE VIN WAS NOT UNDER RECALL. THE FAILURE MILEAGE WAS APPROXIMATELY 43,000.

NHTSA ID

11415977

Incident

May 8, 2021

Mileage

43,000 mi

I RECEIVED A VE5 LATE LIFE EMISSION PERFORMANCE DEGRADATION RECALL IN JANUARY 2021. I HAD THE RECALL PERFORMED ON 1.27/2021 AT RAZZARI DODGE, MERCED. THEY INSTALLED A NEW CAT CONVERTER AND EXHAUST MANIFOLD. WHEN I GOT MY TRUCK BACK, I HAD AN CEL ERROR CODE P2271 O2 SENSOR. I HAD TO PAY $707.74 AND $978.98 TO GET THE TRUCK RUNNING. I HAD NO PREVIOUS CEL. I THINK THEY BROKE THE WIRING HARNESS OR O2 SENSORS WHEN THEY PERFORMED THE RECALL. . I THINK THE VE5 RECALL REPAIR, SHOULD MAKE THE ENTIRE EMISSIONS SYSTEM FUNCTION, INCLUDING THE CONTROL ELECTRONICS.

NHTSA ID

11408550

Incident

Jan 28, 2021

Mileage

144,074 mi

I TOOK IT TO THE DODGE DEALER FOR A RECALL NOTICE I RECEIVED, THE RECALL WAS FOR THE CATALYTIC CONVERTER AND THE EXHAUST MANIFOLD TO BE REPLACED. THE WORK WAS COMPLETED, I TOOK THE TRUCK HOME AND ASSUMED THINGS WERE FINE. IN JANUARY OF THIS YEAR I WENT UNDER THE TRUCK TO SEE ABOUT A OIL LEAK I WAS HAVING A PROBLEM WITH, I NOTICED THE CATALYTIC CONVERTER WAS DIRTY LOOKING AND HAD SCRATCHES ON IT. IT HAD A BROWNISH KIND OF LIGHT FILM ON IT. I DID NOT LOOK LIKE A NEW ONE. I TOOK IT TO ANOTHER REPAIR SHOP FOR THEIR OPINION. THEY COULDN'T BE SURE BUT THEY SAID IT LOOKS LIKE AN OLD ONE ALSO, THEY INSPECTED THE EXHAUST MANIFOLD AND TOLD ME IT HAS RUST STAINS ON IT AND DOES NOT LOOK LIKE A NEW ONE. I AM IN NEED OF SOMEONE TO REFER ME TO AN EXPERT SO WE CAN DETERMINE IF WEATHER OR NOT THE DEALER ACTUALLY REPLACED THE THE PARTS OR NOT. CAN YOU HELP PLEASE.

NHTSA ID

11397778

Incident

Sep 29, 2020

IT'S A RANDOM OCCURRENCE. WHILE I'M STARTING IT, I HAVE TO RESTOP WHEN I'M DRIVING NO WARNING, IT'S A MANUAL TRANSMISSION. THAT ADDS A HUGE DANGER WHEN YOUR TRUCK DIES IN MOTION IT'S A BIG TRUCK IT'S A WORK TRUCK WHICH MAKES IT EVEN MORE HORRIFYING.!! PLEASE TAKE THIS SERIOUSLY THIS IS A HUGE DANGER I CAN'T STRESS HOW IMPORTANT THIS IS AND I'M SURE ALL THE ALL OF THEM ARE

NHTSA ID

11385056

Incident

Jan 1, 2005

Mileage

60,000 mi

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

BEARING - CRANKSHAFT THRUST and KIT

BEARING - CRANKSHAFT THRUST and KIT

SPEAKER - NONE

SPEAKER - NONE

LAMP - DOME