2004 Dodge RAM 2500 recalls and problems

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity co…

RMD opened this audit query (AQ) investigation in order to better understand and evaluate Chrysler's process(es) for timely and efficient execution of its safety recall campaigns, including its oversight and management of its parts division Mopar.Prior to opening this investigation, RMD had raised concerns with the company related to its execution of two safety recalls, 13V-528 and 13V-529, both of which involved safety defects that could cause the involved vehicles, FCA?s heavier Dodge Ram trucks, to lose steering control suddenly and without warning.Specifically, RMD inquired about the availability of parts for recall repairs, by email and phone on January 15, 2014 and February 19, 2014, due to the volume of complaints it was receiving from owners alleging parts scarcity and parts restrictions. FCA steadfastly denied it had placed parts restrictions on its dealers to manage issues of parts scarcity.FCA shared material showing it had uncommitted stock of parts available for its dealers. Nevertheless, consumer complaints of lack of parts continued.RMD made independent inquiries tosome dealers tobetter understand the conflicting claims between owners alleging lack of ability to repair their defective vehicles due to lack of parts, and FCA?s information showing availability of parts.Dealers informed and provided documentation to RMD on February 21, 2014 and February 25, 2014 showing FCA had, in fact, put into place parts restrictions and, further, had in some instances canceled…

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with consistently high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly, ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolu…

On December 16, 2104, Chrysler Group LLC submitted a Safety Recall Report to NHTSA describing a defect in the clutch ignition interlock switches in approximately 66,819 model year (MY) 2006 through early-2007 Dodge Ram Trucks, Dodge Dakota, and Mitsubishi Raider vehicles equipped with manual transmissions and built between July 1, 2005 and July 31, 2006 (NHTSA Recall No. 14V-795, Chrysler Recall No. P80), including 38,969 MY 2006 Dodge Ram 2500 and 3500 vehicles that are part of the subject vehicle population for PE14-013.Chrysler's Safety Report states that:1) the clutch ignition interlock switch return springs may experience fatigue failure due to material issues; 2) if the return springs are broken, the switch contacts may not reflect actual clutch pedal position; and 3) the failures could result in a vehicle experiencing unintended movement if the ignition is cranked when the clutch pedal is not being pressed.Chrysler's recall remedy will replace the clutch ignition interlock switch on all affected vehicles with a switch with a more robust design.On May 19, 2014, ODI opened PE14-013 to investigate clutch ignition interlock failure in MY 2004 through 2006 Dodge Ram 2500 and 3500 trucks with manual transmissions, based on two MY 2006 complaints and one MY 2004 complaint.One of the MY 2006 complaints involved a fatality that occurred when a young child was able to start a MY 2006 Ram 3500 truck that was parked with the transmission in gear, without depressing the clutch.The …

ANALYSIS OF THE COMPLAINT, FIELD REPORT AND WARRANTY DATA SHOWS THAT THE MAJORITY OF STALLING INCIDENTS IN THE SUBJECT VEHICLES APPEAR TO BE RELATED TO THE ENGINE CALIBRATION CONCERNS THAT DAIMLERCHRYSLER ADDRESSED WITH SERVICE BULLETINS RELEASING REVISED PCM SOFTWARE.ANALYSIS OF THE COMPLAINTS AND ODI'S SURVEY OF OWNERS OF VEHICLES THAT RECEIVED ENGINE MANAGEMENT SOFTWARE UPDATES UNDER TSB #18-013-05 SHOW THAT THESE STALLING INCIDENTS HAVE THE FOLLOWING CHARACTERISTICS: - THEY OCCUR AT LOW SPEEDS, OFTEN DURING PARKING LOT ORDRIVEWAY MANEUVERS; - THEY OCCUR DURING DECELERATIONS, SUCH AS BRAKING FOR A STOP SIGN OR TRAFFIC SIGNAL; AND - THE OPERATOR IS ALMOST ALWAYS ABLE TO IMMEDIATELY RESTART THE VEHICLE.WHEN COMPARED WITH OTHER SAFETY DEFECT INVESTIGATIONS AND RECALLS OF CONDITIONS THAT RESULT IN STALLING DURING LOW-SPEED DECELERATION WITH IMMEDIATE ENGINE RESTART POSSIBLE, THE FAILURE RATE IN THE SUBJECT VEHICLES IS LOW.ANALYSES OF COMPLAINT AND WARRANTY DATA ALSO SHOW A DECLINING TREND.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR ADDITIONAL INFORMATION REGARDING THIS RESUME.

ON MAY 16, 2005,ODI OPENED PRELIMINARY EVALUATION PE05-027 TO INVESTIGATE COMPLAINTS OF ENGINE STALLING IN MODEL YEAR 2004-05 DODGE DURANGO SUVS AND RAM 1500 SERIES PICKUPS EQUIPPED WITH THE 5.7L V8 ENGINE.INFORMATION PROVIDED BY DAIMLERCHRYSLER DURING PE05-027 INDICATED THAT A LARGE PERCENTAGE OF THE COMPLAINTS ARE RELATED TO AN IDLE UNDERSHOOT CONDITION THAT MAY CAUSE THE ENGINE TO STALL DURING TURNING MANEUVERS.IN FEBRUARY 2005, DAIMLERCHRYSLER REVISED THE POWERTRAIN CONTROL MODULE SOFTWARE IN PRODUCTION VEHICLES AND ISSUED A TECHNICAL SERVICE BULLETIN (TSB 18-013-05) RELEASING THE NEW SOFTWARE AS A SERVICE REMEDY FOR THE IDLE UNDERSHOOT CONDITION.THE BULLETIN WAS SUPERCEDED BY TSB 18-013-05A IN APRIL 2005.DAIMLERCHRYSLER BELIEVES THAT THE FAILURE RATE FOR STALLING WHILE DRIVING DUE TO THE IDLE UNDERSHOOT CONDITION IS LOW AND THAT THE BULLETIN HAS ADEQUATELY ADDRESSED THE PROBLEM. SINCE PE05-027 WAS OPENED, ODI HAS CONTINUED TO RECEIVE COMPLAINTS FROM OWNERS OF THE SUBJECT VEHICLES WHO ALLEGE EXPERIENCING ENGINE STALL INCIDENTS UNDER ALL TYPES OF DRIVING CONDITIONS.IN SOME INSTANCES THE STALLING HAS CONTINUED AFTER THE VEHICLE RECEIVED THE SERVICE BULLETIN REPAIRS.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA05-018) TO FURTHER ASSESS THE SCOPE, FREQUENCY, AND SAFETY CONSEQUENCES OF THE ALLEGED DEFECT IN DODGE DURANGO AND RAM 1500/2500/3500 SERIES PICKUP TRUCKS.

THE SUBJECT VEHICLES ARE HEAVY DUTY PICKUP TRUCKS WITH DIESEL ENGINES AND AUTOMATIC TRANSMISSIONS COMMONLY USED FOR COMMERCIAL AND WORK PURPOSES.A COLUMN MOUNTED SHIFT LEVER IS USED FOR GEAR SELECTION AND AN ELECTRONIC PRNDL ON THE INSTRUMENT PANEL PROVIDES GEAR POSITION INFORMATION TO THE DRIVER.THE SUBJECT VEHICLES ARE ALSO EQUIPPED WITH A BRAKE-TRANSMISSION SHIFT INTERLOCK THAT PREVENTS THE SHIFT LEVER FROM BEING MOVED FROM THE PARK POSITION (WHEN THE ENGINE IS ON) UNLESS THE BRAKE PEDAL IS DEPRESSED AND AN IGNITION-SHIFT INTERLOCK THAT PREVENTS KEY REMOVAL UNLESS THE TRANSMISSION IS IN THE PARK POSITION.COMPLAINANTS GENERALLY REPORT THAT THE VEHICLE WAS BEING OPERATED IN A FORWARD GEAR AND BROUGHT TO A STOP THROUGH BRAKE APPLICATION ON ALEVEL SURFACE, AT WHICH TIME THE OPERATOR MOVED THE SHIFT LEVER TO ENGAGE THE PARK POSITION.THE OPERATOR THEN OPENED THE DRIVER SIDE DOOR AND, WITHOUT VERIFYING PARK ENGAGEMENT (E.G., PRNDL GEAR INDICATION), SECURING THE PARK BRAKE, OR TURNING THE ENGINE OFF, EXITED THE VEHICLE.INITIALLY, NO VEHICLE MOVEMENT WAS APPARENT, HOWEVER, A SHORT TIME LATER, TYPICALLY REPORTED AS 10 TO 30 SECONDS, THE VEHICLE MOVED REARWARD UNDER ENGINE POWER.THE INCIDENT OFTEN ENDED IN A VEHICLE CRASH, AND SOMETIMES INVOLVED SERIOUS INJURY.TWO FATALITIES ARE ALLEGED.ODI?S ANALYSIS OF TEST VEHICLES AND SOME INCIDENT VEHICLES FOUND NO EVIDENCE TO INDICATE THAT A SHIFT LEVER PROPERLY PLACED IN PARK COULD UNINTENTIONALLY (I.E., WITHOUT DRIVER INPUT) DISENGAGE FROM TH…

THERE HAVE BEEN 50 COMPLAINTS TO ODI AND DAIMLERCHRYSLER ALLEGING INCIDENTS OF REVERSE POWERED ROLLAWAY IN SUBJECT VEHICLES THAT WERE PARKED WITH THE ENGINE RUNNING AND THE PARKING BRAKE DISENGAGED.THE INCIDENTS ARE ALLEGED TO HAVE RESULTED IN 42 CRASHES AND 3 INJURIES. ACCORDING TO DAIMLERCHRYSLER, INCIDENT VEHICLE INSPECTIONS HAVE NOT IDENTIFIED ANY MISADJUSTED OR BROKEN PARTS.A TYPICAL INCIDENT IS BELIEVED TO INVOLVE THE FOLLOWING SET OF CONDITIONS:(1) WITH THE VEHICLE ON A RELATIVELY LEVEL SURFACE, AN ATTEMPTED SHIFT INTO PARK INADVERTENTLY PLACES THE TRANSMISSION IN A POSITION BETWEEN THE REVERSE AND PARK GEAR DETENTS; (2) THE DRIVER EXITS THE VEHICLE WITH THE KEY IN THE IGNITION, THE ENGINE RUNNING, AND THE PARKING BRAKE DISENGAGED; AND (3) AFTER SOME DELAY, THE VEHICLE BEGINS TRAVELING REARWARD.IN PRIOR INVESTIGATIONS OF OTHER DAIMLERCHRYSLER PRODUCTS, REVERSE MOTION WAS FOUND TO RESULT FROM A GRADUAL PRESSURIZATION OF THE REVERSE CIRCUIT (HYDRAULIC REVERSE). DAIMLERCHRYSLER ATTRIBUTES THE INCIDENTS TO OPERATOR ERROR IN USING A SYSTEM THAT FUNCTIONED AS DESIGNED.ACCORDING TO DAIMLERCHRYSLER, THE ALLEGED DEFECT CANNOT OCCUR IF THE DRIVER:(1) SHIFTS FULLY INTO PARK AS INDICATED BY END OF SHIFTER TRAVEL SLAM, THE FORWARD THROW OF THE SHIFT LEVER, AND/OR THE ILLUMINATION OF THE PARK INDICATION IN THE PRNDL DISPLAY; (2) REMOVES THE KEY FROM THE IGNITION; (3) TURNS THE ENGINE OFF; OR (4) ENGAGES THE PARKING BRAKE. THE SUBJECT VEHICLES ARE EQUIPPED WITH:(1) DAIMLERCHRYSLER'S …