2012 Fiat 500

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 clutch went out while downshifting upon making a turn onto a street. The gear shift became wobbly and would not shift into any gear. This happened without warning. Minutes before, my passenger and I were driving across town on a freeway.

NHTSA ID

11737416

Incident

May 11, 2026

I have been dealing with identity theft and not really sure why when I put vin number to my vehicle I purchased September 25 2025 it says a different color

NHTSA ID

11692186

Incident

Oct 8, 2025

The vehicle had been stalling out on numerous occasions one being a freezing Xmas eve in Drive thru if it had happened somewhere isolated the driver could have frozen. I rented cars several times and replaced the alternator ,battery and at the final point at the dealership the mechanic suggested I purchase a $600 battery though I had a brand new one. The dealership gave me a $200 credit but it happened again, the mechanic in town said the Bluetooth component was draining the battery. They removed it and no problem since. The dealership mechanic talked around the issue and would not answer my questions about this. The safety issues related to this are dangerous and it appears to be known by mechanics about this model.

NHTSA ID

11668228

Incident

Dec 24, 2023

The contact owns a 2012 Fiat 500. The contact stated that while driving at an undisclosed speed, there was an abnormal clunking sound coming from underneath the front of the vehicle. No warning lights were illuminated. The vehicle was not taken to the dealer or an independent mechanic. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was unknown.

NHTSA ID

11641144

Incident

Feb 6, 2025

The wiring harness bundle leading to the trunk failed between the trunk & upper drivers side of the car. Upper brake lights stopped working, then rear defroster, then trunk wouldn’t open & I got a license plate light warning on the dash. Mechanic tried to replace switch, still didn’t work, the tried to replace handle (with license plate light). Mechanic broke more wires in bundle, back brake lights stopped working. The wiring harness bundle leading into the trunk is defective.

NHTSA ID

11621183

Incident

Jun 1, 2024

The contact owns a 2012 Fiat 500. The contact stated while driving at approximately 65 MPH, the accelerator pedal was depressed; however, the vehicle lost motive power and stalled. The contact stated no warning light was illuminated. The contact was able to exit the highway. The contact stated that while attempting to restart the vehicle, the clutch pedal went to the floorboard and the contact was unable to start the vehicle. The contact had the vehicle towed to a dealer. The dealer diagnosed the vehicle and determined that the clutch pedal limiter and a clutch pedal switch needed to be replaced. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 16V302000 (Power Train) which had been completed in 2023 on the vehicle by the same dealer. The manufacturer was not informed of the failure. The failure mileage was approximately 214,000.

NHTSA ID

11611834

Incident

Aug 16, 2024

Mileage

214,000 mi

Front Wheel hub bearings grinding, very fast wear and tear Transmission still not shifting right after recall shifter cable replaced not grabbing gears

NHTSA ID

11607886

Incident

Aug 9, 2024

The contact owns a 2012 Fiat 500. The contact received notification of NHTSA Campaign Number: 16V302000 (Power Train) however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact stated while attempting to reverse, the transmission failed to respond as needed. There were no warning lights illuminated. The vehicle was towed to the dealer, and it was confirmed that the recall repair was not yet available and there was no expected date when parts would be available. The manufacturer was made aware of the issue. The failure mileage was 170,000. Parts distribution disconnect.

NHTSA ID

11606101

Incident

Apr 1, 2024

Mileage

170,000 mi

Broken Exterior Driver And/Or Passenger Door Handles XB2 Warranty Extension Customers may comment the following: ● One or both exterior door handles are broken. This bulletin involves replacing one or both exterior door handles.

Verify Reman part number availability. Order the "R" part number for all orders:

LIFTER, Hydraulic Roller Deactivating Please do not replace MDS lifters because the disconnecting pin is not lined up, this is normal and not a defect.

LIFTER, Hydraulic Roller Deactivating Please do not replace MDS lifters because the disconnecting pin is not lined up, this is normal and not a defect.

Connector kit Before ordering this connector repair kit 68018957A$, check it in the Mopar Connector Repair Kit Website to confirm part number and applicability. There is an error with the wiring diagrams in Service Library that is causing the incorrect repair kit part number to populate. Please use the Mopar Connector Repair Kit Website until this issue is resolved.

Connector kit Before ordering this connector repair kit 68018957A$, check it in the Mopar Connector Repair Kit Website to confirm part number and applicability. There is an error with the wiring diagrams in Service Library that is causing the incorrect repair kit part number to populate. Please use the Mopar Connector Repair Kit Website until this issue is resolved.