2011 Dodge Ram 3500

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.

A mechanic at professional auto shop diagnosed the failed TIPM. It caused the fuel sending pump in the fuel tank to stop pumping. The truck stalled while driving on the highway leaving me stranded in 2-degree weather. I read online that there was a lawsuit for this issue but don't know how to file to recoup the $1200+ repair bill on top of the $200 cost to tow it to the auto repair shop. There was an electrical draw and emergency flashers randomly turning on causing the batteries to die a month prior to the failure of the TIPM. I did have the check engine light come on when the fuel pump was cutting out and stalling. The truck is currently in the shop, and they ordered a new remanufactured TIPM.

NHTSA ID

11721694

Incident

Mar 1, 2026

The contact owns a 2011 Ram 3500. The contact stated that the OEM trailer brake controller indicated that the trailer brake was disconnected even though it was attached correctly. The failure occurred while different trailers were hitched to the vehicle. The vehicle was taken to a certified mechanic, but the cause of the failure was not determined. The contact replaced the OEM brakes with new OEM brakes; however, the failure persisted. The vehicle was taken back to an independent mechanic, who diagnosed and determined that there was not enough amp signal to recognize that the trailer was connected. The mechanic attached a magnetic pigtail line with magnets attached to both ends, and the vehicle recognized that the trailer was connected. The cause of failure was found; however, the vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was 145,000.

NHTSA ID

11703652

Incident

Mar 8, 2025

Mileage

145,000 mi

While driving 70mph on the interstate, the truck randomly shut off. I lost power steering. Luckily I was going straight and there were no curves in the road, and I managed to pull the truck and trailer to the side of the road. All electrical assist, steering and brakes turned completely off, radio turned off, all electrical power was off. The engine shut off as well. As I was pulling over, the electrical turned back on but the engine did not. Once I was stopped, I turned the key off, waited 30 seconds, and then started the truck. It ran fine the rest of the way home, approximately 30 miles. I have not drove the truck since. This has happened 3 times, once parked idling after I pressed the door unlock button and the other time in the middle of an intersection. I took the truck to the dealership, paid for the inspection fee, but they could not recreate or find any wiring problems. It did throw a code when it happened, U0121 (Lost communication with ABS module). The dealer said they had to recreate it to diagnosis. I am fearful if I continue to drive the truck to pull my trailer, this could happen again while I am in a turn and I will not be able to continue to turn or stop the vehicle without electrical assist. Dodge does not seem interested in trying to fix this safety issue.

NHTSA ID

11703434

Incident

Nov 19, 2025

The contact owns a 2011 Ram 3500. The contact stated that during cold weather, the engine would not heat up properly and hesitated to start. In addition, the contact stated that on several occasions, the heater grid connector on the driver's side melted bolts and wiring that intruded into the engine, causing piston #6 to misfire. The contact related the failure to NHTSA Campaign Number: 23V060000 (Electrical System) however, the VIN was not included. There was no warning light illuminated. The local dealer was contacted; however, the VIN was not included in the recall. The manufacturer was made aware of the failure. The failure mileage was approximately 96,000.

NHTSA ID

11627228

Incident

Jan 15, 2022

Mileage

96,000 mi

The contact owns a 2011 Ram 3500. The contact stated that on several occasions while attempting to make a right turn, the steering wheel seized. No warning light was illuminated. The failure occurred on several occasions. The vehicle was taken to the dealer where it was diagnosed but the cause of the failure was not yet determined. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 20,000.

NHTSA ID

11615609

Incident

Aug 1, 2013

Mileage

20,000 mi

Coming home at night ran into a horde of bugs, I had just had the wiper reservoir filled. It was empty and I had to stop and wipe my windshield by hand. i looked on line I seen several owners had the same problem this I believe to be a manufactured problem. The dealer wants 400 hundred to replace the reservoir I believe this to be a Chrysler safety problem that has occurring to to many 2011 and 2012 vehicles,

NHTSA ID

11555819

Incident

Nov 13, 2023

Don’t know, the fireman,said the engine caught on fire, some how look like from on top pointed to the top. I believe I believe it was exhaust? Fire department would write out report and send it to me. Devastated 68+ miles truck was paid off melted the whole front and top of the engine everything down! I want to know what happened?! 2011, dodge ram 1 ton 6.7diesel Cummings ! also melted my boat 2010 nitro Z7 with a 150 mercury bass boat $28,000 boat worth more than that now whet up in value! It had 15 hours only on engine! It’s not completely lost I pray…

NHTSA ID

11516414

Incident

Apr 10, 2023

I had a recall on the fuel heater plug and took care of the problem a few years back. I noticed today that the plug is leaking fuel and was wondering if the problem was ever fixed or if they used the same recalled parts? Do you ever recall an already recalled part? or do they ever pay for the part if I fix it myself?

NHTSA ID

11454389

Incident

Feb 12, 2022

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