2012 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 switch to start the vehicle has to be pushed down and turned at the same time. Vehicle starts but shuts the engine down when the key returns sometimes. On one occasion vehicle shut down while driving.

NHTSA ID

11753537

Incident

Jul 24, 2026

We purchased our 2012 Dodge Ram heavy duty with tow package new. At just over 152000 miles, the engine started knocking while on vacation. We were not towing at the time. We put in injector cleaner to try and help the knocking. During our vacation, we were on the freeway when we suddenly lost power, the service engine light popped on, and the engine died. We were literally driving one minute and the next were trying to get out of the traffic lane with no control. We restarted the engine, the knocking had stopped and power was restored. Two days later, another episode of power decrease but with no engine service light. We used premium gas, injector cleaner and listened for the knocking that came and went, to drive home. We were told by our local dealership it is a lifter failure and the truck needs a replacement engine.

NHTSA ID

11740399

Incident

Sep 25, 2025

My passenger headlights keeps going in and out. The wiring harness has been replaced twice and it still does it. My check engine light keeps coming on for the evap system even though its been replaced.

NHTSA ID

11708616

Incident

Jan 3, 2026

Our 2012 RAM 2500 truck with 135k miles, had it's fuel tank fail. The dealership in Oak Ridge, TN tested the vehicle and found that the gas tank tubes were broken causing us to not be able to fill the tank. The dealership recommended "NEED TO REPLACE GAS TANK". Mopar aka Stellantis does not make the fuel tank anymore, the "replacement" fuel tank does not work (completely wrong configuration), there is not an aftermarket tank. We have a Million Mile bumper to bumper warranty with MOPAR. "Customer Care" does not care.

NHTSA ID

11697955

Incident

Mar 6, 2025

Recall T79 or 17V-821 or break transmission shift pin stuck in open position. This is the 2nd time this has happened and serious damage has occurred to the vehicle. Dodge won't do anything about it. Vehicle was parked, turned off, no key. I came out of building and it shifted into gear on its own and rolled backwards into a pole.

NHTSA ID

11596979

Incident

Jun 17, 2024

The contact owns a 2012 Ram 2500. The contact stated while driving at an undisclosed speed, the vehicle drove over a bump in the roadway and started to shake violently. The vehicle was taken to an independent mechanic where it was determined that the reinforcement bracket over the front track bar bracket had failed and needed to be replaced. The vehicle was repaired; however, the failure recurred. Neither the dealer nor the manufacturer were notified of the failure. The failure mileage was approximately 205,000.

NHTSA ID

11552066

Incident

Oct 26, 2022

Mileage

205,000 mi

The contact owns a 2012 Ram 2500. The contact stated while the vehicle was parked, the vehicle rolled away. The contact was standing near the vehicle with the key fob. There were no warning lights illuminated. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The contact related the failure to NHTSA Campaign Number: 17V821000 (Power Train). The manufacturer was not contacted. The failure mileage was approximately 220,000.

NHTSA ID

11545591

Incident

Jul 22, 2023

Mileage

220,000 mi

The contact owns a 2012 Ram 2500. The contact stated the vehicle failed to start intermittently. The contact also stated that the air bag warning light was illuminated. The vehicle was taken to the local dealer and the dealer was made aware of the failure. The vehicle was not repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 168,000.

NHTSA ID

11532307

Incident

Jan 1, 2023

Mileage

168,000 mi

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

BEARING - CRANKSHAFT THRUST and KIT

BEARING - CRANKSHAFT THRUST and KIT

LAMP - DOME

LAMP - DOME

LAMP - DOME