2012 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.

Driving my 2012 dodge ram 3500, just as I was crossing one of the busiest intersections in my town my truck lost all power and dropped from 35mph to 5 mph. Barley made it acrossed and pulled over. As soon as I pulled over the engine light comes on, checked code, and U010C lost coms with turbo actuator comes up. Turned truck off and rest code and everything back to normal. About a week later it happened again, luckily not as busy of a spot. Called dealer and soonest appointment was in April. Meanwhile I look up code and see hundreds of post for same issue, bad actuator replace. 28 years as a diesel mechanic for the military, so I found the part online and ordered. Replaced the actuator, drove about 50 miles, light comes back on. Finally get my appointment with dealer and they say my turbo is bad, they want $8k to fix. I ordered the turbo and replaced it myself along with another actuator, test drove. Light still comes on but have not lost power yet?? Dealer is not helping. This is a major issue that is all over the internet! The truck just goes to limp and your in the middle of traffic. If this has not caused an accident it’s only a matter of time before it does. The dealer ship just wants to replace big parts for lots of money. I’m already $2500 into this and still having an issue

NHTSA ID

11734962

Incident

Nov 28, 2025

The contact owns a 2012 Dodge Ram 3500. The contact stated that while driving 70 MPH, the steering wheel was loose. The contact pulled over and discovered that the steering shaft had detached. The vehicle was towed to an independent mechanic, who repaired the steering shaft. The manufacturer was not made aware of the failure. The failure mileage was approximately 151,000.

NHTSA ID

11730792

Incident

Apr 3, 2026

Mileage

151,000 mi

This truck has had to have several high temp burnoffs because of failures in the EGR and Carbon build up. The recent recall for Rams does not cover the 2012, and began at 2013, however, we are experiencing the same exact issues with the same type of system. In addition, we have had repeated airbag issues due to the positioning of the cockspring and wiring getting choked out.

NHTSA ID

11688894

Incident

Sep 2, 2025

Drivers side rear wheel broke loose from hub and bounced into the opposing lane of traffic.

NHTSA ID

11687970

Incident

Sep 8, 2025

The contact owns a 2012 Ram 3500. The contact stated that while that while the vehicle was in for service, the independent mechanic discovered fuel leaking from the fuel filter heater assembly. The contact was advised that the fuel filter heater assembly needed to be replaced. The vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The contact was informed that the vehicle was previously repaired under NHTSA Campaign Number: 14V635000 (ENGINE AND ENGINE COOLING, FUEL SYSTEM, DIESEL). The contact stated that the vehicle had experienced the failure listed in the recall. The failure mileage was 202,000.

NHTSA ID

11647551

Incident

Mar 6, 2025

Mileage

202,000 mi

The wireless ignition module loses connection internally and the truck will lose power while driving. It usually happens when hitting a small bump and the key in the ignition moves. Truck loses electrical power which shuts the engine off which means loss of power steering and brakes.

NHTSA ID

11644035

Incident

Feb 13, 2025

The contact owns a 2012 Ram 3500. The contact stated that while driving uphill at 55 MPH, the contact became aware that the vehicle was not exceeding 55 MPH. The contact stated that the check engine warning light was illuminated. The contact continued driving to the destination. The vehicle was parked; however, upon inspection, the contact became aware that there were damages on top of the front driver’s side ball joint, the rear driver’s side axle leaf spring shackle, and the driver’s side overload spring. Additionally, there were metal fragments found in the engine oil, and a diagnostic scan retrieved DTC: P0087, P0471, U029D. The vehicle was taken to a local dealer where it was inspected; however, the vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 215,000.

NHTSA ID

11642736

Incident

Nov 29, 2024

Mileage

215,000 mi

Driving vehicle and lost the ability to steer. The inner drag link tie rod broke at pitman arm.

NHTSA ID

11630408

Incident

Dec 12, 2024

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