2017 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.

Just before coming to a stop the brakes grab and jerk the car. The brakes work normally otherwise.

NHTSA ID

11572652

Incident

Feb 18, 2024

The contact owns a 2017 Fiat 500. The contact stated that the driver's side and passenger's side door handles fractured and detached from the inner side of the handle. The contact called the local dealer, but the vehicle was not diagnosed or repaired. The vehicle was taken to an independent mechanic and the contact was informed that water had entered the door handles. The door handles were replaced. The manufacturer was not notified about the failure. The approximate failure mileage was 20,000.

NHTSA ID

11562997

Incident

Dec 26, 2023

Mileage

20,000 mi

After a sudden stop (no impact), the car would no longer go into or come out of gear while running. When the car is not running it will still shift normally. The repair shop initially thought it was the slave cylinder but the problem persisted. They then changed the clutch and are now recommending replacing the inner CV axle boot. The problem described is similar in symptons to the existing recall on 2012-2016 Fiat 500s and the partial recall on 2017 Fiat 500s. It seems logical that all of these issues are somehow related to a flaw in the design or manufacturing.

NHTSA ID

11562042

Incident

Oct 10, 2023

THE LIGHT THAT INFORMS OF AN AIR BAG PROBLEM GOES ON. THE DEALER SHIP REPAIRS AND A WEEK LATER THE LIGHT GOES ON AGAIN. BACK TO DEALERSHIP,FIXES PROBLEM? LIGHT GOES ON IN A DAY. THIS THURSDAY 8/11/22 WILL BE THE 4TH ATTEMPT TO SOLVE THE AIR BAG ISSUE.

NHTSA ID

11478045

Incident

Aug 7, 2022

The PCM system does not work at all and brakes seem off—either they stop too hard or drag when pressing in them

NHTSA ID

11474371

Incident

May 23, 2022

My 2017 Silver FIAT 500 pop has a defective miles odometer that flashes. The car was purchased from Tobin Fiat of Las Vegas on 8/21/2017. I test drove this car to my home for 3 days before buying it. On day 2 it starting flashing. I returned to the dealer, reported it and was told it would be repaired. I have over 40 Videos on my cel phone that prove its defective over a 4 year period. Most resent issues on, 10/30/21, 11/1/21, 11/10/21. All 3 parties have refused to fix, repair or replace what causes the flashing miles indicator in my car. They said it doesn't exist so there is nothing to fix. The car was sent to the Fiat dealership in Henderson for a few days and they said it didn't flash while there so Fiat, Chrysler and Tobin Fiat of Las Vegas saw it as a none issue or as a customer complaint about nothing.

NHTSA ID

11440073

Incident

Aug 18, 2017

CAR STOPPED AND QUICKLY SLOWED DOWN WITHOUT WARNING. I HAD VERY LITTLE TIME TO STEER CAR TO THE SIDE OF THE ROAD. THE RBS/ABS SYSTEM STARTED SLOWING THE CAR ON ITS OWN. I HAD ONLY BEEN GOING 30 MPH, HOWEVER HAD I BEEN IN A CENTER LANE ON A FREEWAY AT 60 MPH, I WOULD HAVE NOT BEEN ABLE TO GET IT OFF THE ROAD.

NHTSA ID

11375410

Incident

Sep 1, 2020

Mileage

32,000 mi

THE MILES INDICATOR FLASHES. PURCHASED 8/21/17 AND STILL FLASHES. DEALERSHIP: TOBIN FIAT 2550 S. JONES BLVD. LAS VEGAS, NV89146

NHTSA ID

11352416

Incident

Aug 18, 2017

Mileage

17 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.

High Voltage Air Conditioning Refrigerant Dye

Aluminum Body Panel Corrosion Repair Aluminum corrosion or bubbling along the leading edge of hood, hinges or other exterior surface areas of the hinges, doors, fenders, swing gates or liftgates.

Aluminum Body Panel Corrosion Repair Aluminum corrosion or bubbling along the leading edge of hood, hinges or other exterior surface areas of the hinges, doors, fenders, swing gates or liftgates.

Aluminum Body Panel Corrosion Repair Aluminum corrosion or bubbling along the leading edge of hood, hinges or other exterior surface areas of the hinges, doors, fenders, swing gates or liftgates

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