Ram 4500 Investigations
7 ODI actions on file.
- RQRQ25003OPENOpened 7/3/2025Post Recall Remedy Brake Transmission Shift Interlock (BTSI) FailurePOWER TRAIN:AUTOMATIC TRANSMISSION
The Office of Defects Investigation (ODI) has received 14 Vehicle Owner Questionnaire (VOQ) reports and 6 EWR Death & Injury (D&I) reports describing post recall remedy failures of the brake transmission shift interlock (BTSI) system in certain Model Year (MY) 2013-2018 RAM pickup trucks.The subject vehicle models include 1500, 2500, 3500, 4500, and 5500 trucks equipped with a column mounted shift lever.The failures of the BTSI described in the VOQs occurred on vehicles that had all previously been repaired under recall 17V-821 or 18V-100.Both recalls address a potential condition which can cause the BTSI locking pin to become stuck allowing the transmission to be shifted out of Park without depressing the brake pedal and/or without having a key in the ignition.Shifting the transmission out of Park when not having the brake pedal depressed can result in a vehicle rollaway. ODI is opening this Recall Query (RQ) to review the effectiveness of the 17V-821 and 18V-100 recall remedies, understand the root cause of additional vehicle rollaway incidents, and identify any other possible root cause that may affect the performance of the BTSI system. To review the ODI reports cited in the Opening Resume ODI Report Identification Number document, go to NHTSA.gov.
- PEPE24009OPENOpened 3/27/20242022 RAM Transmission Snap Ring FailurePOWER TRAIN:AUTOMATIC TRANSMISSION
The Office of Defect Investigations (ODI) has received 82 complaints alleging loss of motive power due to an internal transmission failure of the K1 snap ring in model year 2022 Ram 3500, 4500, and 5500 vehicles. Of these complaints, 16 describe a complete loss of motive power at speeds greater than 25 miles per hour, without the ability for the vehicle to resume normal operation. The subject vehicles can be up-fit as an ambulance and other emergency response vehicle or may be heavily loaded when used for towing. During the failure event, the snap ring becomes dislodged and forward gears 1-4 are no longer functional, potentially leaving the vehicle disabled in or near the roadway and/or negatively affect the emergency mission. ODI contacted the manufacturer, FCA US, LLC d/b/a Stellantis North America (FCA), and learned that technical service bulletin (TSB) TSB-21-002-23 is related to the alleged defect condition. Additionally, FCA has conducted dynamometer and field testing and has explained to ODI that during the event a warning message will display to the operator, and gear 5 and reverse will remain available. ODI is opening this Preliminary Evaluation (PE) to evaluate the severity of the potential problem and to fully assess the potential safety-related problems. To review the ODI reports cited in the Opening Resume ODI Report Identification Number document, go to NHTSA.gov.
- EAEA23001RECALLOpened 3/17/2023High pressure fuel pump failureFUEL SYSTEM, DIESEL:DELIVERY:FUEL PUMP
The Office of Defects Investigation (ODI) opened PE21-021 on October 14, 2021, to investigate incidents alleging a stall/loss of motive power as a result of high-pressure fuel pump failures in certain model year (MY) 2019-2020 Ram 2500, 3500, 4500, and 5500 heavy duty trucks equipped with 6.7L Cummins turbodiesel engines. During the investigation, ODI sought to determine if the related defect allegation was limited in scope to the recalled population. After review of information request response materials from both FCA and BMW, NHTSA determined that sufficient information to identify a comprehensive recall population could not be produced by FCA and BMW.During the investigation FCA filed recalls 22V406, 22E048, 22V767, and 22E087 which include vehicles not identified in the initial subject population by ODI. ODI also received recall 21V586, involving loss of motive power due to failed CP4 fuel pumps on certain BMW manufactured vehicles. An information request letter response received from BMW indicated that failed pumps on their vehicles were caused by an interaction between pump internal components and US market diesel fuel, leading to increased slip and eventual particle-generating wear surface. Additional work will be done to identify whether a similar root cause is associated with the FCA recalled population and if similar wear dynamics occur on pumps supplied to vehicle manufacturers other than those included in the recalled population.ODI has upgraded this investigation to an EA in order to 1) determine engineering specifications of internal pump components that are correlated with pump failure leading to loss of motive power or other safety related hazards, 2) identify vehicle populations equipped with alleged defective pump variants, 3) assess if vehicles equipped with alleged defective pump variants result in an unreasonable risk to motor vehicle safety and 4) gather and review any other relevant information related to high pressure fuel pump failure associated with the subject populations of recalls 21V586, 21V880, 21E094, 22V406, 22E048, 22V767, and 22E087.Review of the above information will allow NHTSA to confirm root cause and recall remedy viability, and identify and evaluate vehicle populations equipped with pump components that may pose an unreasonable risk to motor vehicle safety.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID using the following complaint identification numbers: 11257550, 11351441, 11361603, 11361616, 11365300, 11365426, 11365858, 11366401, 11372337, 11373793, 11374797, 11376793, 11377871, 11378173, 11384377, 11386063, 11387018, 11399710, 11402550, 11415339, 11418868, 11418870, 11427075, 11434276, 11436807, 11437226, 11437249, 11437273, 11437292, 11437294, 11437394, 11437399, 11437403, 11437405, 11437423, 11437528, 11437565, 11437579, 11437580, 11437590, 11437679, 11437744, 11437781, 11437842, 11437993, 11438006, 11438008, 11438121, 11438138, 11438155, 11438392, 11438629, 11439359, 11439879, 11440397, 11443030, 11446542, 11448163, 11453556, 11458918, 11460558, 11469337
- PEPE21021CLOSEDOpened 10/14/2021High pressure fuel pump failureFUEL SYSTEM, DIESEL:DELIVERY:FUEL PUMP
The Office of Defects Investigation (ODI) opened PE21-021 on October 14, 2021 to investigate allegations of stall/loss of motive power as a result of high pressure fuel pump failures in certain model year (MY) 2019-2020 RAM 2500, 3500, 4500, and 5500 heavy duty trucks equipped with 6.7L Cummins turbodiesel engines.On November 12, 2021, FCA filed vehicle recall 21V-880 and equipment recall 21E-094 on the subject population, identifying an `internally failed component? of the high pressure fuel pump equipped on the 6.7L Cummins Turbodiesel engine that introduced debris into the fuel system potentially causing fuel starvation and consequently an unexpected loss of motive power. Discussions with FCA identified the high pressure fuel pump equipped on these vehicles as the Bosch-supplied CP4. On December 16, 2021, Bosch filed recall 21E-101, stating the pump failure was a consequence of a manufacturer application-specific fuel system design.NHTSA subsequently identified recall 21V-586 involving loss of motive power due to failed CP4 fuel pumps on certain BMW vehicles.As a result of having received multiple recalls related to a common component, from two separate vehicle manufacturers, NHTSA?s focus shifted to determine if the related defect allegation was limited in scope to the recalled population. In early 2022, information request letters were sent to FCA and BMW to determine the root cause and consequentially identify the proper scope of potentially defective vehicles. After ODI received their information request response, FCA filed recalls 22V-406, 22E-048, 22V-767, and 22E-087. During review of information request response materials, NHTSA determined that sufficient information to identify a comprehensive recall population could not be produced by FCA or BMW. On March 17, 2023, this Preliminary Evaluation was upgraded to an Engineering Analysis (EA23-001), expanding the scope to include the Tier-one supplier and any manufacturer who equipped or installed similar high pressure fuel pumps subject to the failures observed in the recall population.The ODI reports cited above can be reviewed at: http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID using the following complaint identification numbers: 11351441, 11361603, 11361616, 11365300, 11365426, 11365858, 11366401, 11372337, 11373793, 11374797, 11376793, 11378173, 11384377, 11386063, 11387018, 11399710, 11402550, 11415339, 11418868, 11418870, 11427075, 11434276, 11436807, 11437226, 11437249, 11437273, 11437292, 11437294, 11437394, 11437399, 11437403, 11437405, 11437423, 11437528, 11437565, 11437579, 11437580, 11437590, 11437679, 11437744, 11437781, 11437842, 11437993, 11438006, 11438008, 11438121, 11438138, 11438155, 11438392, 11438629, 11439359, 11439879, 11440397, 11443030, 11448163, 11458918, 11460558
- EAEA21002OPENOpened 9/17/2021Desiccated Air Bag Inflator RuptureAIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE
From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.
- PEPE19017CLOSEDOpened 12/12/2019Front Driveshaft FailurePOWER TRAIN
On December 12, 2019, NHTSA's Office of Defects Investigation (ODI) opened Preliminary Evaluation (PE) 19-017 after receiving three Vehicle Owner Questionnaire (VOQ) reports alleging failures of the front driveshaft and/or transfer case, resulting in conditions of 1) a loss of engine power, 2) loss of steering assist, 3) loss of foundation brakes, 4) unintended air bag deployment and 5) engine/cab fires from combustible fluids striking hot exhaust components. The VOQs involved model year (MY) 2015 through 2017 RAM 4500 and 5500 vehicles. ODI received information from the vehicle manufacturer [Fiat Chrysler Automobiles (FCA)] via information request letters dated February 28, 2020, and April 21,2020. Supplemental information was received on March 17, 2021. A review of the responsive manufacturer information, and related meetings and presentations, showed that the transfer case failures in 97.5% of the claims did not disable the vehicle. Since analysis showed that a failed driveshaft could result in catastrophic damage to the transfer case as well as other safety risks (i.e. steering/brake failures etc.), ODI shifted the investigation to focus only on the front driveshaft failures. The double cardan universal joint design requires maintenance lubrication within every 8000 miles. Despite an under-hood maintenance reminder label and professional servicing at both dealers and independent repair facilities, the driveshafts were often found to be unlubricated due to lack of awareness, difficulty of the operation or the lack of the special tools needed to perform the work. To increase the maintenance lubrication rates, in the summer of 2021, FCA launched a communications campaign, circulating awareness bulletins, training information, special tool options and instructional videos through more than a dozen channels covering both dealer and independent repair facilities. Additionally, in the fall of 2021, FCA mailed a VIN-specific letter to each registered owner reminding them of the maintenance needs, and also sent a special grease gun adapter to every FCA US dealer and fleet operator with an FCA US dealer code. Since January 2022,NHTSA has not received a complaint of front driveshaft failure due to lack of lubrication that can lead to failure conditions such as loss of engine power, loss of steering assist, loss of foundation brakes, unintended air bag deployment and engine/cab fires. This drop in complaints, the communications campaign launched by the manufacturer, and the absence of reports from the manufacturer, support the closing of this Preliminary Evaluation. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.
- RQRQ15004RECALLOpened 7/24/2015Software security vulnerabilityELECTRICAL SYSTEM:SOFTWARE
On July 23, 2015, Fiat Chrysler Automobiles (FCA) launched Safety Recall 15V-461 to remedy security vulnerabilities in approximately 1.4 million model year (MY) 2013 through 2015 vehicles equipped with Uconnect head units (HU) 8.4A (RA3 radio) and 8.4AN (RA4 radio) manufactured by Harman International.On July 24, 2015, the Office of Defects Investigation (ODI) opened Recall Query, RQ 15-004, to investigate HU security vulnerabilities and remedy effectiveness in the recalled population and to determine whether similar units have been supplied for use in other FCA vehicles.In an August 11, 2015 letter, FCA submitted a second Part 573 safety recall report expanding the scope of the Uconnect RA4 model radio to include additional 7,810 MY 2015 Jeep Renegade vehicles manufactured from September 18, 2014 through June 25, 2015 (Recall 15V-508).Scope analysis indicated that Uconnect radios installed in FCA vehicles not included in recalls 15V-461 or 15V-508 (subject recalls) are not equipped with built-in cellular access or short range wireless communication features and, thus, do not contain the security vulnerabilities addressed by the subject recalls. SUBJECT VEHICLES: MY2014 through 2015 Dodge Durango, Jeep Grand Cherokee and Jeep Cherokee sport utility vehicles; MY2013 through 2015 Ram 1500, 2500, 3500 and 4500/5500 pickup trucks; MY2013 through 2015 Dodge Viper vehicles; and MY2015 Chrysler 200, 300, Jeep Renegade, Dodge Charger and Challenger vehicles.According to FCA, long and short range wireless vulnerabilities identified in the recalled vehicles could allow unauthorized third-party access to, and manipulation of, networked vehicle control systems.Successful exploitation of the vulnerabilities, coupled with reverse engineering of networked microprocessor control modules, could result in unauthorized manipulation of vehicle control systems. This unauthorized manipulation of vehicle controls and systems could expose the driver, vehicle occupants or other highway users to an increased risk of injury.FCA and its network provider, Sprint, conducted a nationwide campaign to block access to a radio communications port that was unintentionally left open.On July 27, 2015, short range wireless vulnerabilities were also blocked.Finally, third party security evaluation and regression testing identified vulnerabilities that were either remedied by Sprint or through updates to the FCA Uconnect software.ODI identified a total of 30 complaints or field reports on unique vehicles submitted by FCA (29) or received by NHTSA (1) alleging incidents of theft from a vehicle or anomalous performance that the owner alleged were caused by, or may have been caused by, remote hacking.Twenty-six (87%) of these reports were submitted after a magazine article was published on July 21, 2015, describing the remote hacking of an FCA vehicle by researchers who were able to affect the operation of various vehicle control systems, including the service brakes, steering, throttle and ignition.Most of the complaints involved vehicle systems that were not safety critical (e.g., complaints related to radio, navigation system, or air-conditioning control) and did not affect vehicle control.Three complaints reported engine stalls.One owner reported sudden unintended acceleration allegedly related to hacking.None of the complaints or field reports reviewed involved the steering and braking vehicle control effects demonstrated by the research hackers prior to the recall.There were no confirmed incidents of hacking in any of the records reviewed by ODI.The remedies completed by Sprint and FCA appear to have eliminated vulnerabilities that mi