2012 Dodge Ram 4500

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.

FRONT WHEEL BEARING ON DRIVER SIDE WENT OUT ON THE TRUCK IT MADE A CRUNCHING SOUND. I WAS ON A CITY STREET HEADED BACK HOME. HAD TO TOW TRUCK TO REPAIR SHP, HAD TO REPLACE HUB ASSY, BRAKE ROTOR'S, BRAKE CALIPER, AXLE SEAL, AXLE COLLAR. THE COST WAS $1,589.43. THE IS A 2012 DODGE RAM 4500.

NHTSA ID

11207857

Incident

May 9, 2019

Mileage

32,000 mi

2012 DODGE RAM 4500. CONSUMER WRITES IN REGARDS TO DIESEL FUEL HEATER ELECTRICAL CONNECTOR & FRONT AXLE HOUSING RECALL NOTICES REPAIR ISSUES. *SMD THE CONSUMER STATED SHE HAS RECEIVED FOUR RECALL NOTICES IN THE MAIL. EACH TIME SHE GOES TO THE DEALER, THEY INFORM HER THE PARTS ARE NOT AVAILABLE. *JB

NHTSA ID

10721949

Incident

Jun 1, 2015

LEFT OUTER TIE ROD BROKE!!! LUCKILY ONLY MAKING A U TURN WHEN IT HAPPENED. RECALL IS ABOUT A YEAR OLD AND STILL NO PARTS AVAILABLE BUT CHRYSLER WE WILL TAKE CARE OF IT AND HAVE THE DEALER INSTALL FACTORY PART THAT COULD BREAK AGAIN BUT AT LEAST IT WILL GET YOU BACK ON THE ROAD AGAIN AND MAYBE IT WILL LAST UNTIL WE GET THE CORRECT PART.MIND YOU THIS IS A PART THAT COULD BREAK AND CAUSE LOSS OF CONTROL OF YOUR VEHICLE AND POSSIBLY KILL SOMEONE. WHILE MY COMPANY TRUCK IS SITTING BROKE DOWN AND WAITING FOR THE LOCAL DEALER ARRIGO TO CALL CHRYSLER BACK FOR 5 DAYS AND LET THEM KNOW THAT I CAN HAVE MY TRUCK TOWED TO THEIR SHOP AT MY EXPENSE FOR THE REPAIR THAT IS BEING PAID FOR BY CHRYSLER. *TR

NHTSA ID

10678938

Incident

Jan 21, 2015

Mileage

77,953 mi

TL* THE CONTACT OWNS A 2012 DODGE RAM 4500. THE CONTACT RECEIVED A NOTIFICATION FOR NHTSA CAMPAIGN NUMBER: 13V527000 (STEERING) AND NHTSA CAMPAIGN NUMBER: 14V635000 (ENGINE AND ENGINE COOLING, FUEL SYSTEM, DIESEL). HOWEVER, THE PARTS NEEDED TO DO THE REPAIRS WERE UNAVAILABLE. THE CONTACT STATED THAT THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME FOR THE RECALL REPAIR. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE CONTACT HAD NOT EXPERIENCED A FAILURE. UPDATED 1/23/15*CN

NHTSA ID

10662968

Incident

Dec 8, 2014

THIS HAS BEEN AN ON GOING PROBLEM SINCE I BOUGHT THE TRUCK NEW LAST YEAR. THE TIPM HAS BEEN REPLACED TWICE ALONG WITH COUNTLESS USELESS TRIPS TO THE DEALER JUST TO LISTEN TO THEM SAY THEY CAN'T FIX IT UNTIL IT GETS WORSE SO THEY CAN FIND IT, AND GO FIGURE IT IS IN THE SHOP AGAIN WITH INSUFFICIENT VOLTAGE ISSUES WHICH CAUSE LIGHTS TO GO OUT OR STAY ON OR BLINK, THE TRUCK NOT TO START OR TO INVOLUNTARILY ACCELERATE, MELTED CHARGERS IN THE CHARGER PORT THAT ONLY WORKS WHEN IT WANTS TO, INTERMITTENT POWER TO MY TRAILER BRAKES, AND LOST TIME AND MONEY AS THIS IS MY WORK TRUCK!!! THEY ARE QUICK TO REPLACE THE TIPM BUT THEIR FIX NEVER SEEMS TO LAST LONG. *TR

NHTSA ID

10654631

Incident

Nov 12, 2014

Mileage

85,104 mi

WE RECEIVED A SAFETY RECALL NOTICE FOR OUR BASIC LIFE SUPPORT AMBULANCE N26/NHTSA 13V-239 FOR FRONT AXLE TUBE WELDS. THE NOTICE ADVISED THAT THE VEHICLE COULD CRASH OR HAVE A LOSS IN MOTIVE POWER IF USED. WE HAVE CONTACTED CHRYSLER MANY TIMES TO HAVE THIS EMERGENCY AMBULANCE REPAIRED BUT THEY HAVE NOT REPAIRED, INSPECTED OR EVEN SEND CORRESPONDENCE WHEN THE VEHICLE MAYBE REPAIRED IN MORE THEN TEN WEEKS. THIS VEHICLE IS A 4 WHEEL DRIVE AMBULANCE WHICH IS NEEDED FOR OUR REMOTE COVERAGE AREA FOR ACCESS TO HOMES ON DIRT LANES, SNOW AND ICE TRAVEL. WE FEEL THAT AN EMERGENCY VEHICLE SHOULD HAVE A HIGHER PRIORITY TO GET REPAIRED AND WE ARE LOOSING REVENUE NOT BEING ABLE TO USE THIS UNIT YET WE ARE PAYING INSURANCE AND LOAN PAYMENTS. WE ARE A VOLUNTEER ASSOCIATION SO OUR RESOURCES ARE LIMITED AND HAVING THIS AMBULANCE OUT OF SERVICE IS A GREAT HARDSHIP TO OUR COMMUNITY.

NHTSA ID

10567208

Incident

Aug 9, 2013

TL* THE CONTACT OWNS A 2012 DODGE RAM 4500. THE CONTACT STATED THAT HE RECEIVED THE NOTIFICATION OF NHTSA CAMPAIGN NUMBERS: 13V527000 (STEERING) AND 13V239000 (POWER TRAIN). THE CONTACT MENTIONED THAT HE WAS CONCERNED FOR HIS SAFETY SINCE THE MANUFACTURER DID NOT HAVE THE NECESSARY PARTS AVAILABLE IN ORDER TO REPAIR THE VEHICLE. THE DEALER WAS CONTACTED AND ADVISED THE CONTACT OF THE DELAY ON RECEIVING THE PARTS. THE MANUFACTURER WAS MADE AWARE OF THE PROBLEM. THE CONTACT HAD NOT EXPERIENCED A FAILURE.

NHTSA ID

10566035

Incident

Dec 4, 2013

TL* THE CONTACT OWNS A 2012 DODGE RAM 4500. HE RECEIVED TWO RECALL NOTICES, NHTSA RECALL 13V239000 POWER TRAIN WAS RECEIVED IN JULY 2013; AND NHTSA RECALL, 13V527000 , STEERING WAS RECEIVED IN JANUARY 2014 BOTH RECALLS INDICATED HE COULD LOSE CONTROL AND CRASH WITHOUT WARNING. HE WAS REQUIRED TO SIGN A MOTOR VEHICLE DOCUMENT INDICATING THE VEHICLE WAS SAFE TO DRIVE FOR COMMERCIAL PURPOSES INCLUDING CARRYING A LOAD. HE NOW HAS LIMITED USE OF THE VEHICLE DUE TO THE POTENTIAL SAFETY RISK STATED IN BOTH RECALLS ONE OF WHICH INDICATED THAT THE FRONT END COULD FAIL DUE TO IMPROPER WELDING AND THE LEFT TIE ROD MANY FRACTURE. THERE ARE NO FAILURES AT THIS TIME. HE WAS ADVISED BY THE CHRYSLER RECALL CENTER THAT THEY WILL DISCUSS WHAT ACTIONS THEY WOULD TAKE REGARDING A CRASH ONLY WHEN OR IF A CRASH DID OCCUR. THE CONTACT IS EXTREMELY CONCERNED ABOUT THE SAFETY RISK INVOLVED.

NHTSA ID

10559549

Incident

Jan 8, 2014

Mileage

5,000 mi

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

BEARING - CRANKSHAFT THRUST and KIT

BEARING - CRANKSHAFT THRUST and KIT

Verify Reman part number availability. Order the "R" part number for all orders: Warranty, Mopar, customer pay and service contract. Order "68" part number for New unsold units only.

LAMP - DOME

LAMP - DOME