2004 Dodge Ram 3500

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016 four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016 four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The investigation now includes all manufacturers and vehicles known to be affected at this time.ODI's investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The five ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

RMD opened this audit query (AQ) investigation in order to better understand and evaluate Chrysler's process(es) for timely and efficient execution of its safety recall campaigns, including its oversight and management of its parts division Mopar.Prior to opening this investigation, RMD had raised concerns with the company related to its execution of two safety recalls, 13V-528 and 13V-529, both of which involved safety defects that could cause the involved vehicles, FCA?s heavier Dodge Ram trucks, to lose steering control suddenly and without warning.Specifically, RMD inquired about the availability of parts for recall repairs, by email and phone on January 15, 2014 and February 19, 2014, due to the volume of complaints it was receiving from owners alleging parts scarcity and parts restrictions. FCA steadfastly denied it had placed parts restrictions on its dealers to manage issues of parts scarcity.FCA shared material showing it had uncommitted stock of parts available for its dealers. Nevertheless, consumer complaints of lack of parts continued.RMD made independent inquiries tosome dealers tobetter understand the conflicting claims between owners alleging lack of ability to repair their defective vehicles due to lack of parts, and FCA?s information showing availability of parts.Dealers informed and provided documentation to RMD on February 21, 2014 and February 25, 2014 showing FCA had, in fact, put into place parts restrictions and, further, had in some instances canceled dealerships? back orders for parts.In addition, during the course of its dialogue with dealers, RMD discovered that FCA had notified their dealerships on February 27, 2014 to return the recall remedy parts over quality concerns, and had therefore effectively canceled its safety recall program without notification to NHTSA. RMD issued a request for information (IR) on October 21, 2014.The company failed to respond to a number of the questions RMD asked that required it to produce specifics surrounding the repairs and parts ordering process with the recalls, including a question about whether a dealer order for recall parts could be canceled and under what circumstances.

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with consistently high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly, ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016, four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016, four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The PE is now closed/upgraded to an Engineering Evaluation (EA15-001) to include all manufacturersand vehicles known to be affected at this time.ODI's EA investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The recalls related to this PE are: 14V343, 14V344, 14V348, 14V351, 14V353, 14V655, 14V700, 14V701, 14V752, 14V763, 14V770, 14V773, 14V787, 14V802 and 14V817.The number of vehicles affected are an estimate since some vehicles may have both the driver and passenger side inflators recalled. The five ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

On December 16, 2104, Chrysler Group LLC submitted a Safety Recall Report to NHTSA describing a defect in the clutch ignition interlock switches in approximately 66,819 model year (MY) 2006 through early-2007 Dodge Ram Trucks, Dodge Dakota, and Mitsubishi Raider vehicles equipped with manual transmissions and built between July 1, 2005 and July 31, 2006 (NHTSA Recall No. 14V-795, Chrysler Recall No. P80), including 38,969 MY 2006 Dodge Ram 2500 and 3500 vehicles that are part of the subject vehicle population for PE14-013.Chrysler's Safety Report states that:1) the clutch ignition interlock switch return springs may experience fatigue failure due to material issues; 2) if the return springs are broken, the switch contacts may not reflect actual clutch pedal position; and 3) the failures could result in a vehicle experiencing unintended movement if the ignition is cranked when the clutch pedal is not being pressed.Chrysler's recall remedy will replace the clutch ignition interlock switch on all affected vehicles with a switch with a more robust design.On May 19, 2014, ODI opened PE14-013 to investigate clutch ignition interlock failure in MY 2004 through 2006 Dodge Ram 2500 and 3500 trucks with manual transmissions, based on two MY 2006 complaints and one MY 2004 complaint.One of the MY 2006 complaints involved a fatality that occurred when a young child was able to start a MY 2006 Ram 3500 truck that was parked with the transmission in gear, without depressing the clutch.The diesel engine started and the vehicle moved forward under power running over another child resulting in fatal injuries.ODI's analysis of failure data from all sources identified a total of 14 complaints and 16 warranty claims for the subject vehicles.Thirteen (13) of the complaints and all 16 warranty claims were for the 38,969 MY 2006 Dodge Ram 2500 and 3500 trucks that were included in 14V-795.The single complaint that was outside the scope of Chrysler's recall was the MY 2004 ODI complaint identified in the opening resume for PE14-013.Further analysis of this incident indicates that the cause of the clutch switch failure in this vehicle was spring damage caused by hydraulic fluid leakage from the clutch master cylinder into the switch.The field data did not show any other similar incidents of switch failures caused by clutch master cylinder leakage. This investigation is closed based on Chrysler's recall.

The contact owns a 2004 Dodge RAM. The contact received recall notifications, NHTSA Capaign Number: 16V352000 (Air Bags and NHTSA Campaign Number: 15V313000 (Air Bags) however the parts were unavailable. The dealer was contacted, however the contact was informed that the parts were in back order. In addition, the contact was informed that the parts were unavailable until October 2026. The manufacturer was contacted. The cotnact was informed that the parts were unavailalbel.

NHTSA ID

11736578

Incident

May 8, 2026

The contact owns a 2004 Dodge Ram 3500. The contact received notifications of NHTSA Campaign Numbers: 13V528000 (Steering), 16V352000 (Air Bags), 15V313000 (Air Bags), and 05V462000 (Power Train); however, the parts to do the recall repairs were not yet available while the vehicle was in for service. The local dealer was made aware of the issue, and an appointment was scheduled to repair the vehicle. The vehicle remained with the dealer for a week before the contact was informed that parts for the recall repairs were unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated that on several occasions, while the vehicle was in park(P), the vehicle unexpectedly rolled without warning. The brake pedal was depressed with extra force while shifting to park(P). The manufacturer was not made aware of the issue. The failure mileage was unknown.

NHTSA ID

11726711

Incident

Jan 1, 2008

upper control arm cracked which is a safety violation and should be a recall. TRW 52106776 Control arm is the cracked part in the picture My son replace both control arm and send it for alignment total cost was as below; Parts $280 + Alignment $192.59= $472.59 I like Dodge to refund me for $460

NHTSA ID

11686102

Incident

Apr 7, 2021

WHILE TRAVELING ON INTERSTATE 90 IN WASHINGTON STATE, TRAVELING AT ABOUT 60 MPH I NOTICED A HAZE BEHIND THE TRUCK THROUGH THE PASSENGER SIDE DOOR MIRROR. AT THE TIME, THERE WERE NO INDICATIONS BY INSTRUMENTS OR WARNING LIGHTS THAT ANYTHING WAS AMISS WITH THE TRUCK. WONDERING IF IT WAS COMING FROM THE TRUCK I PULLED TO THE SHOULDER TO CHECK. AS SOON AS I STOPPED I SMELLED HOT OIL, SO SHUT OFF THE ENGINE, RELEASED THE HOOD LATCH AND CHECKED THE ENGINE COMPARTMENT. UPON LIFTING THE HOOD OF THE ENGINE COMPARTMENT I IMMEDIATELY NOTICED FLAMES BETWEEN THE ENGINE AND FIRE WALL. I RETRIEVED A FIRE EXTINGUISHER FROM THE CAMPER THE TRUCK WAS HAULING AND ATTEMPTED TO EXTINGUISH THE FIRE. TWO MOTORISTS WITH FIRE EXTINGUISHERS STOPPED TO HELP AND THE COMBINED USE OF THREE DRY CHEMICAL FIRE EXTINGUISHERS WOULD NOT PUT THE FIRE OUT AND THE TRUCK AND CAMPER COMPLETELY BURNED. WHEN I REPORTED THIS TO MY INSURANCE COMPANY WE DISCOVERED AN ERROR IN THE VIN NUMBER ON MY INSURANCE POLICY. OUT OF CURIOSITY I RESEARCHED THAT VIN NUMBER AND WAS SURPRISED TO SEE THAT SAME STYLE TRUCK HAD ALSO BURNED. IT'S VIN IS 3D7MU48C84G269656 AND CAN BE SEEN IN THE 7TH PHOTO THAT IS UPLOADED TO THIS REPORT. BOTH WERE 2004 DODGE DIESEL TUCKS WITH LOW MILEAGE. IT SEEMS TOO MUCH OF A COINCIDENCE AND I WONDER IF THERE IS A DEFECT THAT CAUSED THIS AND HOW MANY OTHER OF THIS YEAR, MAKE AND MODEL HAVE BEEN DESTROYED BY FIRE.

NHTSA ID

11461850

Incident

Feb 9, 2022

STEERING BECAME LOOSE AND HAD 1-2INCHES OF SLACK BEFORE GUIDING THE VEHICLE PROPERLY. REPLACED WITH NEW STEERING UNIT. TRANSMISSION WOULD NOT SHIFT INTO LOW GEAR AT BUSY INTERSECTION ENTERING FREEWAY. *TR STARTED IN SECOND OR THIRD REQUIRED COSTLY REBUILD. FUEL GAUGE READS EMPTY REQUIRED NEW UNIT IN FUEL TANK.

NHTSA ID

11329101

Incident

Jul 2, 2019

Mileage

124,000 mi

HAVE TO USE FORCE TO ENGAGE CLUTCH TO START VEHICLE. THE VEHICLE WAS STATIONARY WITH A TRAILER ATTACHED. UNABLE TO TURN OFF VEHICLE WHEN FUELING DUE TO PROBABILITY THAT IT WOULD NOT START. TRIED JUMPER CABLES WITHOUT SUCCESS. AFTER STOMPING CLUTCH SEVERAL TIMES VEHICLE STARTED.

NHTSA ID

11289602

Incident

Dec 15, 2019

Mileage

137,887 mi

2004 DODGE RAM 3500. CONSUMER WRITES IN REGARDS TO NUMEROUS REPAIRS MADE TO VEHICLE. *LD THE CONSUMER STATED THE DEALER HAS HELD THE VEHICLE WITHOUT MAKING ANY REPAIRS, OR PREDICTIONS ON WHEN THE REPAIRS WOULD BE COMPLETED. *JS

NHTSA ID

11202470

Incident

Mar 3, 2019

PURCHASED USED 2004 DODGE 3500 AND WHILE DRIVING HOMEDOING 60 MPH I EXPERIENCED SUCH A VIOLENT SHACKING OF THE FRONT END I NEARLY LOSS CONTROL OF MY TRUCK AND STRUCK ANOTHER VEHICLE ON THE HIGHWAY. MY WIFE AND I COULD HAVE BEEN KILLED. I LATER LEARNED THAT THIS TRUCK SUFFERS FROM DEATH WOBBLE WHICH DODGE IS AWARE OF. AS A RETIRED POLICE OFFICER WITH 30 YEARS I WOULD HAVE TOWED THIS TRUCK AS UNSAFE UNTIL PROPER REPAIRS WERE MADE BASED ON THE VIOLENT SHAKING AND LOSS OF STEERING CONTROL THE DRIVER EXPERIENCES. VERY DANGEROUS SITUATION THAT NEEDS TO BE ADDRESSED.

NHTSA ID

11192535

Incident

Feb 8, 2019

Mileage

180,000 mi

Plate - Planetary

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicle, use the "AC" NIC level part and submit a part warranty.

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicle, use the "AC" NIC level part and submit a part warranty.

Disinfectant Solution Recommended for COVID-19

Charging System, Battery Diagnostic Tools and Warranty This information only bulletin discusses using the correct test equipment for testing batteries and charging systems, and also warranty reimbursement when battery replacements are necessary.

Use of Salvage/Recycled Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of recycled or salvage parts.