2010 Dodge Ram 3500

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.

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 3500. The contact stated while driving approximately 30 MPH, the air bag warning light illuminated. The contact stated that the vehicle was taken to an independent mechanic who diagnosed the vehicle and determined that the driver's side air bag needed to be replaced. The mechanic informed the contact of NHTSA Campaign Number: 16V947000 (Air Bags). The contact called a dealer and was informed that the VIN was not included. The manufacturer was not made aware of the failure. The failure mileage was approximately 146,000.

NHTSA ID

11615152

Incident

Sep 15, 2024

Mileage

146,000 mi

The contact owns a 2010 Dodge Ram 3500. The contact stated that while driving at various speeds, the vehicle shut off without warning. The contact stated that the failure occurred after driving over a bump in the roadway. The contact stated that occasionally, while wiggling the ignition key the engine would turn on before shutting off. The vehicle was taken to the local dealer who determined that the ignition switch was faulty and needed to be replaced. The manufacturer was notified of the failure, but no assistance was offered. The contact was informed that the VIN was not included in the NHTSA Campaign Number: 14V373000 (Electrical System). The contact stated that the vehicle had experienced the failure listed in the recall. The failure mileage was 270,000.

NHTSA ID

11558508

Incident

Jul 1, 2023

Mileage

270,000 mi

Fobik key ignition vibrates causing switching from (RUN) position to (ACC) position, shutting off the engine and making it almost impossible to steer a 3000kg machine without power steering increasing the risk for accidents.

NHTSA ID

11468887

Incident

Jun 12, 2022

Truck totally destroyed by spontaneous fire, suspected to be related to short in radio or dashboard. Assessment done by fire department and truck paid off by Progressive Insurance but no compensation for contents of truck. Truck in driveway, not running and fire damaged adjacent vehicle at cost of $7000 paid by vehicle owner and USAA insurance.

NHTSA ID

11441379

Incident

Nov 16, 2020

My husband, our son, and I were traveling down the highway at about 60-65mph when we started hearing a low winding sound. Seconds later, before my husband could get the truck over to the shoulder of the road, there was a loud banging sound coming from underneath the truck that sounded like something was coming through the floorboard. He was finally able to get the truck pulled to the shoulder of the road but wasn't able to put the truck in the park position. He had to use the park brake to get the truck to completely stop. Once the tow truck safely lifted the truck, you could clearly see gears hanging amd what looked to be remains of the transfer case. The truck was towed to a body shop where several codes were discovered, which all pertained to the truck going into 4wd by itself without any warning and unknowing to the driver. This glitch is what appears to have caused the transfer case to grenade, further causing damage to the drive shaft and smashing the fuel line. We, as owners, had the transfer case serviced and fluids flushed just two weeks prior to this happening After further investigation and conversations with the local Dodge dealer, it appears that this has happened in several situations yet no safety recalls have been issued. There is a national backorder for transfer cases for our particular year which is a red flag. We're now left with an over $8100.00 bill and everyone pointing the finger at each other. This could have ended tragically had there been more traffic on the road when the truck began stalling on the busy interstate.

NHTSA ID

11427230

Incident

Jul 9, 2021

My family and I were traveling down the interstate about 60-65mph in 2 wheel drive when out of nowhere we started hearing a whining/roaring noise that quickly got louder. Seconds later, there was a loud rumbling noise that sounded like something was coming through the floorboard of the truck. Luckily, I was able to steer the truck to the shoulder of the road and get it to stop, but the truck would not go into park. I had to use the park brake to make sure that it wouldn't roll. After the tow truck arrived and safely jacked the truck up, we immediately noticed that it was the transfer case that had exploded. Gears were hanging out in plain site and it caused a bend in my front driveshaft. There were no warning signs and I had just had the transfer case and my transmission serviced and flushed 2 weeks prior. This put my family's and other lives in danger because had there been more traffic on the road at the time this happened, I wouldn't have had time or room to maneuver my truck safely to get it off the road. We could have been rear ended or had broken parts fly off the truck, that would have been out of my control. The truck was towed to the shop where I had the transfer case serviced, but as of now there's a national backorder on transfer cases for this truck. In speaking with the dealer and doing my own research, I've also learned that there has been a recall on the transfer cases of 2016 and newer Ram 3500 trucks. This needs to be looked into asap. Codes pulled from the truck at the auto shop where the truck currently is are c1404, c1405, c140d stating that the transfer case motor puts the system in 4wd by itself while driving without any warning.

NHTSA ID

11425835

Incident

Jul 9, 2021

WIN ignition module has slowly been causing difficult starting problems. Now, over even slight bumps, the sloppiness in the connection between the key and the WIN module allows the key to move and the vehicle to shut off while driving. This is becoming more and more common and is very dangerous. Just on my 10 minute drive home from work today, it occurred 4 times. One time, I had just turned right on a red light (with plenty of space between me and oncoming traffic) and the truck shut off completely. Without the key being in the exact right position, I had difficulty restarting the truck and could have been very dangerous to me and the vehicle coming toward me.

NHTSA ID

11424690

Incident

Jul 13, 2021

WHILE DRIVING, THE TRUCK JUST SHUTS OFF. RESULTING IN LOSS OF STEERING, LIGHTS AND POWER BREAKS.

NHTSA ID

11405433

Incident

Mar 29, 2021

Mileage

259,300 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