Chrysler recalls vehicles with defective brake pedal switches

 

Auburn Hills, Mich. – Feb. 16, 2018 – Fiat Chrysler Automobiles has recalled more than 39,000 vehicles potentially equipped with defective brake pedal switches, according to documentation submitted to the National Highway Transportation Safety Administration. The campaign affects multiple vehicles across two brands, including:

  • 2017 Jeep Wrangler sport utility vehicles produced between Aug. 7, 2017, and Sept. 20, 2017.
  • 2017 Dodge Caravan minivans produced between Aug. 7, 2017, and Sept. 18, 2017.

FCA suspects just 1 percent of the models referenced in the recall contain the defective parts.

The Defect

Affected vehicles could contain brake pedal switches prone to malfunction. In the event that these fixtures fail, shifting out of park without depressing the brake pedal becomes possible. This poses a serious safety hazard to occupants. However, FCA has yet to receive reports connecting any accidents or injuries to the defect.

Owners operating vehicles equipped with the defective brake pedal switches have noticed that rear brake lights and interior malfunction indicator lamps illuminate continuously when failure has occurred.

Timeline of Events

Engineers conducting end-of-line production testing on Sept. 11, 2017, at the Windsor Assembly Plant in Windsor, Ontario, Canada encountered a vehicle with an out-of-position brake pedal, according to an NHTSA chronology document. The FCA engineering team immediately notified Multicraft International, the U.S.-based vendor responsible for manufacturing brake switch components. The firm immediately quarantined the potentially defective parts. FCA initiated containment protocol, requesting the staff at the Ontario facility and Toledo South Assembly Plant in Toledo, Ohio to set aside all brake switch parts that arrived from Multicraft.

The vendor inspected its production processes between Sept. 13, 2017, and Sept. 15, 2017, and ultimately found that the brake switches manufactured at its space in Pelahatchie, Mississippi were not properly ratcheted at the minimum required standard of seven pounds. The error occurred due to gas buildup in a plunger mold tool core and resulted in the production of between 90,000 and 180,000 out-of-specification parts.

FCA filed a Product Related Issue report for the defective brake pedal switches Oct. 8, 2017. And, on Oct. 24, 2017, the FCA Vehicle Safety and Regulatory Compliance took up the issue.

The American automaker conducted an extensive read-across investigation throughout the remainder of October and November. The inquiry revealed that the brake switch had been used across multiple models but that it did not pose a serious issue for some due to production quirks or the presence of brake system redundancies. On Dec. 8, 2017, engineering personnel conducted an internal test evaluate the impact of the defective brake switch and determined that drivers with manual vehicles could shift out of park without depressing the brake pedal. A similar test involving a vehicle equipped with an automatic transmission was conducted Dec. 19, 2017, and yielded identical results.

On Feb. 1, 2018, the FCA Vehicle Regulations Committee reviewed the matter opted to launch a voluntary safety recall. As of Jan. 26, 2018, FCA has received two customer assistance inquiry records and five field reports related to the defective brake pedal switches.

The Solution

FCA intends to direct dealers to replace the brake pedal switches in affected vehicles free of charge, according to an NHTSA recall acknowledgement document. The company will notify both dealers and owners March 30, 2018. Owners in need of more immediate assistance can contact FCA customer service at (800) 853-1403. They should use the internal recall reference code U09 when calling. Owners can also reach out to the NHTSA directly using its Vehicle Safety Hotline at (888) 327-4236.

Sean ReyesChrysler recalls vehicles with defective brake pedal switches

FCA recalls vehicles with defective fire extinguishers

 

Auburn Hills, Mich. – Jan. 22, 2017 – Chrysler Fiat Automobiles has recalled more than 62,000 vehicles believed to contain defective fire extinguishers, according to documents submitted to the National Highway Transportation Safety Administration. Per an NHTSA recall acknowledgment document, the campaign affects numerous models across multiple brands, including:

  • 2018 Chrysler Pacifica minivans.
  • 2014-2016 Chrysler Town and Country minivans.
  • 2007 Dodge Caliber sedans.
  • 2009 Dodge Challenger sports cars.
  • 2017 Dodge Charger sports cars.
  • 2015-2016 Dodge Dart sedans.
  • 2004 Dodge Durango sport utility vehicles.
  • 2014-2016 Dodge Caravan minivans.
  • 2014 Dodge Journey sport utility vehicles.
  • 2014-2016 Jeep Cherokee sport utility vehicles.
  • 2017 Jeep Compass sport utility vehicles.
  • 2011 Jeep Patriot sport utility vehicles.
  • 2012 and 2015 Ram 1500 pickup trucks.
  • 2013-2018 Ram 2500 pickup trucks.
  • 2012-2018 Ram 3500, 4500 and 5500 pickup trucks.
  • 2014-2017 Ram Promaster and Promaster City pickup trucks.

FCA believes 100 percent of the vehicles named in the action contain the defective parts.

The Defect

The models referenced in the action come equipped with miniature fire extinguishers prone to clogging or breakage due to defective lever and valve assemblies. These items pose a serious threat to owners, especially those involved in accidents where gasoline ignition is likely to occur. That said, FCA has yet to receive reports linking the defective components to any injuries.

Timeline of Events

On Nov. 3, 2017, the FCA Vehicle Safety and Regulatory Compliance group learned that fire extinguishers supplied by Walter Kidde Portable Equipment were defective. The FCA Global Regulatory Compliance compared the items to a roster of Kidde fire extinguishers involved in an earlier U.S. Consumer Product Safety Commission recall and found multiple matches. The automotive conglomerate then retrieved samples of the defective products and sent them to specialists at FCA U.S. Engineering and Mopar, an FCA-owned autoparts organization.

Between Nov. 6 and Nov. 8, analysts at Mopar reviewed the parts and found that production teams were installing them in multiple models across a number of brands. At the same time, the VSRC group launched an investigation into the parts and began evaluating the vehicle populations containing them. On Nov. 10, FCA initiated a yard hold in an effort to stop the production and shipment of vehicles equipped with the Kidde fire extinguishers. Ten days later, an investigator with the VSRC group started combing through historical parts and production information with timestamps dating back to 1973.  Over the next three weeks, employees for FCA U.S. Engineering, Mopar and the VSRC group reviewed individual part identification codes and associated vehicle identification numbers to understand the breadth of the impact of the defect.

On Dec. 18, the FCA Vehicle Regulations Committee decided to conduct a voluntary safety recall.

The Solution

FCA intends to swap the defective fire extinguishers installed in affected vehicles for new models with metal valves that prevent clogging. The automotive company plans to notify both dealers and owners Feb. 2, 2018. individuals in need of more immediate assistance can contact Chrysler customer service at (855) 271-0773. Callers should use the internal recall identification code T82. Owners can also reach out the NHTSA directly using its Vehicle Safety Hotline at (888) 327-4236.

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Chrysler recalls vehicles with defective oil pump housings

 

Auburn Hills, Mich. – Nov. 30, 2017 – Fiat Chrysler Automobiles has recalled more than 350 vehicles potentially equipped with defective oil pump housings, according to documentation submitted to the National Highway Transportation Safety Administration. The campaign affects 2018 Jeep Compass sport utility vehicles produced on Sept. 11, 2017 and Jeep Cherokee sport utility vehicles produced between Sept. 9, 2017 and Sept. 28, 2017. FCA estimates that just 1 percent of the vehicles referenced in the action possess the defective features.

The Defect

The affected models include 2.4 liter engines that were constructed using cracked oil pump housings that are prone to failure. Should failure occur, the vehicle engine will stall without warning. This poses a serious safety threat to owners as an unexpected stall could result in a collision. That said, FCA has not received any reports connecting the defective feature to accidents or injuries.

Timeline of Events

On Sept. 13, 2017, an oil pump supplier collaborating with FCA notified that company that cracks had been discovered in the housing for multiple oil pumps. Two days later, the FCA Vehicle Safety and Regulatory Compliance committee launched an investigation into the matter, which engineers at assembly plants in Toluca, Mexico and Belvedere, Illinois had independently confirmed via separate Product Related Issue reports.

Throughout September and October, FCA confirmed the existence of the defective components in finished vehicles through production inspections and parts data. On Oct. 5, the automaker finished gathering data and submitted the evidence to the Vehicle Regulations Committee, which decided to conduct a voluntary safety recall Oct. 17. FCA notified dealers Oct. 24.

The Solution

The car manufacturer has directed dealers to inspect and replace the oil pump housing assemblies in affected vehicles free of charge, according to an NHTSA recall acknowledgement document. FCA plans to notify owners on or around Dec. 13. Those in need of more immediate assistance can contact FCA customer service at (800) 853-1403. Callers should use the internal recall identification code T65. Owners can also reach out to the NHTSA directly using its Vehicle Safety Hotline at (888) 327-4236.

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Chrysler recalls vehicles with defective occupant restraint features

 

Auburn Hills, Mich. – Nov. 3, 2017 – Fiat Chrysler Automobiles has recalled more than 414,000 vehicles potentially equipped with defective occupant restraint controllers, according to documentation filed with the National Highway Transportation Safety Administration. The campaign affects models across multiple brands, including:

  • 2012 Jeep Liberty sport utility vehicles manufactured between June 17, 2011 and Aug. 16, 2012.
  • 2012-2013 Chrysler 200 midsize sedans produced between June 25, 2011 and Jan. 15, 2012.
  • 2012-2013 Dodge Avenger midsize sedans produced between June 25, 2011 and Jan. 15, 2012.

FCA speculates that approximately 5 percent of the vehicles named in the recall contain defective parts.

The Defect

The models referenced in the action may come equipped with damaged ORC assemblies that are prone to jumper resistor failure, a condition that materializes following prolonged electrical overstress. ORC shutdown may cause the active headrests in affected vehicles to malfunction. This poses a serious risk to occupants involved in collisions, as the lack of AHR support may increase the likelihood of cranial concussion. That said, FCA has yet to receive field reports connecting the defective ORC assemblies to any accidents or injuries.

The air bag warning light normally illuminates in vehicles with defective ORC assemblies.

Timeline of Events

On July 2, 2013, FCA launched a voluntary safety recall for 2012 Jeep Liberties, 2012-2013 Chrysler 200s and 2012-2013 Dodge Avengers, after discovering that these vehicles contained integrated power modules that were causing ORC failure and inhibiting AHR operation, according to a chronology document. Dealers reprogrammed the TIPM units in these models to address both issues. Almost four years later on May 16, 2017, the NHTSA contacted FCA and notified the company of several driver complaints referencing the three models included in the 2013 recall. These reports described instances in which the air bag warning light turned on with no clear explanation, apparently indicating some safety feature malfunction. On May 19, the FCA Vehicle Safety and Regulatory Compliance group launched an investigation into the reports. One day later, the auto conglomerate ordered parts from the field for analysis. The NHTSA opened a concurrent inquiry June 1.

Throughout June and August, FCA received 13 ORC assemblies from the vehicles mentioned in the initial NHTSA reports. In July, the car company determined that at least two parts showed signs of jumper resistor failure due to electrical overstress. On Aug. 11, FCA engineers pinpointed a third part that ceased working following overstress and on Oct. 2, they encountered a fourth problematic component. Two days later, the FCA Vehicle Regulations Committee determined that a voluntary safety recall was necessary.

As of Sept. 29, FCA has received 122 vehicle owner questionnaires, 367 customer assistance inquiry requests and 2,453 warranty claims related to defective ORC equipment.

The Solution

FCA intends to direct dealers to replace the ORC assemblies in affected vehicles free of charge, according to a recall acknowledgment document submitted to the NHTSA. The vehicle manufacturer will notify both dealers and owners on or about Nov. 29. The latter should expect to receive word from FCA via first-class mail. Owners in need of more immediate assistance can contact FCA customer service at (800) 853-1403. Callers should use the internal recall identification code T56. Owners can also reach out the NHTSA directly using its vehicle safety hotline at (888) 327-4236.

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Chrysler recalls vans with defective seatbelts

 

Auburn Hills, Mich. – Sept. 20, 2017 – Fiat Chrysler Automobiles has recalled more than 47,000 minivans possibly equipped with defective second-row seatbelts, according to documentation filed with the National Transportation Safety Administration. The campaign affects 2017-2018 Chrysler Pacifica minivans with production dates ranging from Nov. 1, 2015 to Aug. 24, 2017. FCA estimates that all of the vehicles named in the recall contain the defective safety features.

The Defect

The affected models contain second-row center seatbelt assemblies that were installed in such a way that can cause the left outboard seatbelt buckle may to come unlatched. This poses a serious safety risk to passengers in the left seating position in the second row, as they could be left unrestrained in the event of an accident. However, FCA has not received reports connecting crashes or injuries to the defective fixtures.

Timeline of Events

On May 12, 2017, members of the FCA Interior Restraints Engineering Department notified the company’s Vehicle Safety and Regulatory Compliance of an issue involving second-row seatbelt assemblies installed in 2017-2018 Chrysler Pacifica minivans. Engineers for the department had seen the left outboard seatbelt buckle in one recently assembled vehicle come unlatched during a chassis validation tests involving a water dummy ballast. From May 13 to Aug. 2, members of the FCA VSRU reviewed field information and conducted an investigation to see if the problem could be duplicated for testing. The automaker’s Vehicle Dynamics team succeeded in duplicating the issue during a laboratory test July 31.

On Aug. 2, the VSRU further reviewed the vehicle at the center of the original report and met with engineers from the VD group who confirmed that they had duplicated the issue described in the internal communication. The FCA Vehicle Regulations Committee reviewed the matter Aug. 24 and decided to conduct a voluntary safety recall to address the defective second-row seatbelt assemblies. The car company notified owners of the intended action Aug. 31.

The Solution

FCA has directed dealers to install shortened second-row seatbelt buckles designed to prevent unlatching free of charge, according to an NHTSA recall acknowledgement. The automaker will notify owners via first-class mail Oct. 20. Those in need of more immediate assistance can contact Chrysler customer service personnel at (800) 853-1403. Callers should use the internal recall identification code T54. Owners can also reach out directly to the NHTSA via its Vehicle Safety Hotline at (888) 327-4236.

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Chrysler recalls sports cars with defective oil cooler lines

 

Auburn Hills, Mich. – Aug. 24, 2017 – Fiat Chrysler Automobiles has recalled more than 1,200 sports cars with defective oil cooler lines, according to documentation filed with the National Highway Transportation Safety Administration. The campaign affects 2017 Dodge Charger and Challenger sports cars equipped with eight-cylinder Hellcat performance engines. FCA suspects 10 percent of the total number of vehicles referenced in the recall contain the defective parts.

The Defect

The models involved in this recall are equipped with engines whose engine oil cooler lines are not properly joined. Specifically, on the section of the EOC lines where chlorinated polyethylene hose meets aluminum tubing, the joints are not suitably crimped. This can lead to line separation and engine oil spillage, resulting in engine seizure and the risk of fire. Additionally, drivers may lose visibility due to oil spray covering the windshield. All of these outcomes pose serious safety hazards to drivers and increase the risk of an accident. However, FCA has not received any reports connecting the defect to any accidents or injuries thus far.

Timeline of Events

On May 13, 2017, engineers at the FCA assembly plant in Ontario, Canada, initiated a product recall after receiving three warranty claims mentioning EOC line separation, according to a chronology document submitted to the NHTSA. The FCA Vehicle Safety and Regulatory Compliance division immediately launched an investigation to better understand the consequences of the issue. On May 15, the parts supplier, Hutchings Automotive Products, performed production tests to determine if increasing the adhesive temperature during assembly would improve the structural integrity of the EOC line connections. These trials failed. Fifteen days later, FCA tested EOC line joints from aftermarket Mopar stock. These fixtures showed no signs of failure.

Over the week of June 12, FCA conducted more in-house tests to pinpoint the root cause of the EOC line separation. More than two weeks later, dealers in the U.S. market inspected approximately 50 vehicles to determine if they were equipped with the defective parts and needed repair.

On July 12, Hutchinson sent FCA results from an internal evaluation of the EOC hose material. The parts provider concluded that the material used to make the defective lines was out of specification. Two days later, FCA US Master Black Belt performed a parallel materials test and determined with 95 percent certainty that Hutchinson engineers were correct in their examination of the hose material.

With this information in hand, the FCA Vehicle Regulations Committee called for an official voluntary safety recall Aug. 1. As of that date, the car manufacturer had received a total of eight customer assistance and information requests, zero vehicle owner’s questionnaires and zero field reports related to the defective EOC line.

The Solution

FCA will direct dealers to replace the EOC lines in affected vehicles free of charge, according to a recall acknowledgment document sent to the NHTSA. The automaker plans to notify both owners and dealers on or around Sept. 22. However, owners in need of more immediate assistance can contact Chrysler customer service personnel at (800) 853-1403 or call the NHTSA Vehicle Safety Hotline at (888) 327-4236.

Sean ReyesChrysler recalls sports cars with defective oil cooler lines

Chrysler recalls vehicles with damaged alternator diodes

Auburn Hills, Mich. – July 14, 2017 – Fiat Chrysler Automobiles has recalled an estimated 442,214 vehicles potentially equipped with damaged alternator diodes, according to a company press release. The campaign affects a variety of models across multiple brands, including:

  • 2011-2014 Chrysler 300 sedans
  • 2011-2014 Two-door Dodge Challenger sports cars
  • 2011-2014 Four-door Dodge Charger sports cars
  • 2011-2014 Dodge Durango sport utility vehicles
  • 2012-2014 Jeep Grand Cherokee sport utility vehicles

Approximately 318, 781 of the vehicles originated from U.S. dealers, while 37,504 are circulating the Canadian and Mexican markets. The remaining 85, 292 are outside of the North American Free Trade Agreement zone. FCA estimates 100 percent of the vehicles named in the recall contain the defective part, according to documentation filed with the National Highway Transportation Administration.

The Defect

Vehicles named in the recall are suspected to contain alternators with diodes susceptible to thermal fatigue failure stemming from overstressed electric hydraulic power steering systems. In the event of a diode failure, the alternator ceases supplying the engine with electricity, leading to the unexpected loss of multiple features, including the antilock braking system, the electronic stability control system and the engine control module. In some cases, the vehicle my cease operation entirely. The diodes can also short circuit and cause fire, heat and smoke to rise from the engine.

FCA has received reports of two accidents related to the faulty diodes. However, the car company has yet to receive notification of any injuries connected to the defect.

Timeline of Events

FCA has not released details into the internal investigation that uncovered the problem. The company is expected to notify dealers on or around Aug. 24.

The Solution

FCA will direct dealers to replace the alternators in affected vehicles, free of charge, according to a recall acknowledgement document filed with the NHTSA. Owners should expect to receive notification via first-class mail on or around Aug. 24. However, those in need of more immediate assistance can contact the FCA U.S. Customer Care Center at (800) 853-1403 or the NHTSA Vehicle Safety Hotline at (888) 327-4236.

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Chrysler recalls hybrid minivans with defective batteries

 

Auburn Hills, Mich. – June 9, 2017 – Fiat Chrysler Automobiles has recalled more than 1,600 hybrid minivans equipped with defective batteries, according to a company press release. The campaign affects 2017 Chrysler Pacific minivans, roughly 1,300 of which originated from American showrooms. The remaining vehicles were sold on the Canadian market. The car manufacturer is unsure how many of the models named in the recall contain the defective battery.

The Defect
Affected vehicles may include hybrid batteries with improperly functioning control module diodes. These fixtures, which manage the flow of electrical current between the battery and dependent parts, are prone to involuntary shutoff. If this occurs, the vehicle loses propulsion and ceases to operate. This possess a risk to owners, as such a stoppage could result in an accident. However, the automaker has found no accidents or injuries related to the faulty battery diode as yet. Should propulsion suddenly halt due to the defect, drivers will be able to continue their forward momentum and pull over, Road Show by CNET reported.

Timeline of Events
FCA discovered the defect after receiving reports from customers who experienced propulsion loss while driving. Engineers with the car maker investigated the issue and eventually found that defective diodes were to blame.

The Solution
The automaker has requested dealers replace the control modules in affected vehicles with models equipped with working diodes, free of charge. However, FCA is still working on developing a workable alternative, meaning owners will have to wait some time for service. Those in need of immediate assistance can contact the FCA Customer Care Center at (800) 853-1403. They can also call the National Highway Transportation Safety Administration’s Vehicle Safety Hotline at (888) 327-4236.

adminChrysler recalls hybrid minivans with defective batteries

Chrysler Recalls 300 and Charge Models Over Loose Bolts

Auburn Hills, Mich. – Feb. 16, 2017 – Chrysler has recalled more than 69,000 vehicles due to loose driveshaft bolts. The recall affects Chrysler 300 and Dodge Charger all-wheel-drive sedans produced between 2014 and 2017, according to documentation from the National Highway Traffic Safety Administration.

The Defect

The affected all-wheel-drive models feature abnormally loose driveshaft bolts. These fixtures can slacken to such an extent that the driveshaft disconnects completely and the vehicle loses power. This poses a serious hazard to drivers and can result in injury. There have been no reports of related injuries, according to the car manufacturer.

Timeline of Events

  • In January 2016, police departments across the country reported loose driveshaft bolts in interceptor versions of the Dodge Charger. Chrysler investigated the claim, and one month later evaluated fabrication procedures at its assembly plant in Brampton, Ontario.
  • On March 2, 2016, Chrysler launched an additional investigation into consumer models with the same driveshaft assembly. This included all-wheel-drive Dodge Charger and Chrysler 300 models produced between 2014 and 2017.
  • On June 30, 2016, the automaker advised engineers at the Brampton plant to increase the torque on driveshaft bolts to achieve optimal clamp load. Field reports following this change showed no signs of looseness.
  • Between June 2016 and February 2017, Chrysler collected and analyzed vehicle and warranty data to determine the scope of the problem.
  • On Feb. 3, 2017, Chrysler closed its review, identifying 69,298 potentially affected models.
  • On Feb. 7, 2017, the vehicle manufacturer initiated a voluntary recall.

The Solution

Chrysler has directed dealers to replace the driveshaft bolts in affected models free of charge. The recall is scheduled to begin March 31, 2017. Owners should expect to receive notice soon.

 

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Software Problems Part of New Fiat Chrysler Recall

Auburn Hills, Mich. — August 12, 2016 — Some relatively recent model year FCA vehicles could leave passengers in danger because of a wire harness problem. Autoblog recently featured a press release from the manufacturer of the 323,361 U.S. vehicles involved in the recall. These include the 2014 and 2015 Chrysler 200, Jeep Cherokee and other vehicles.

According to this source, affected vehicles were produced before Sept. 23, 2014. Though the vast majority of these are in the U.S., a total of 43,927 are outside of the NAFTA region, with thousands more in both Canada and Mexico.

The issue itself involves a wire-crimping problem, which could be temporarily fixed if drivers turn their vehicles on and off. The newer versions of these models will benefit from an updated harness manufacturing system.

Crimping a wire can require the right hardware. including a crimp cap or an appropriate crimping tool. The quality of the wire makes a difference, too, as it needs to match the appropriate engine system.

Last year, the 2015 Cherokee was part of multiple Jeep recalls. One of these was in December and involved a possible short circuit in the power liftgate module that may have left drivers at risk of fire. Dealers were instructed to add a water shield in an acknowledgement statement dated for December 17.

Another recent recall with the same make and model was reported in October. That action concerned Jeeps with air conditioning hose issues that could have also left the occupants at risk of fire. The solution involved replacing the hose after inspection to keep it from contacting the exhaust manifold.

MotorSafety.orgSoftware Problems Part of New Fiat Chrysler Recall