Fiat Chrysler Automobiles (FCA) USA will be contacting the owners of certain 2022 Ram trucks because their vehicles may have a manufacturing defect within the Engine Control Module (ECM) that could affect vehicle safety. This defect affects vehicles equipped with Cummins 6.7L turbo diesel engines and could result in an unexpected engine stall.

The RAM trucks affected by this defect include:

2022 Ram 2500
2022 Ram 3500
2022 Ram 3500 Cab Chassis
2022 Ram 4500 Cab Chassis
2022 Ram 5500 Cab Chassis

The FCA Technical Safety and Regulatory Compliance (TSRC) organization became aware of the problem in August 2022 when they were contacted by the RAM truck assembly plant regarding suspect ECMs manufactured with a defective component. According to the NHTSA safety report, some ECMs may have been manufactured with a misaligned capacitor that could short-circuit and create an internal loss of communication. This internal loss of communication could result in a loss of motive power and an increased chance of an accident.

The suspect period for these defective ECMS began on May 31, 2022, and ended on August 23, 2022, when the ECMs were quarantined. This time period was determined using supplier traceability and vehicle production records. Similar vehicles not included in the recall did not receive suspect ECMs or were repaired prior to release from the assembly plant control.

Owners who receive notices will be asked to return to their dealers to have ECMs in their trucks replaced. FCA US, LLC’s number for this recall is Z87 and the NHTSA campaign number is 22V-642.

A small number of 2021-2022 Chevrolet Corvette owners will be contacted by the manufacturer regarding a problem affecting the rear half shaft assemblies in their vehicles. According to the defect report, Some Corvettes may have a rear half-shaft assembly that is missing one or more ball bearings. If any ball bearings are missing, the half-shaft will eventually fail, resulting in a loss of propulsion.

In September 2021, a General Motors (GM) engineer carried out a warranty inspection of a rear half shaft recovered from a 2021 Chevrolet Corvette. The half shaft fractured and caused the vehicle to lose propulsion. Upon further inspection, it was found that the half shaft was missing two of six ball bearings. Follow-up, discussions with the supplier identified a potential failure in the inspection process that led to the miss-build. In October, the GM engineer submitted a report to GM’s Speak Up For Safety (SUFS) program and the supplier identified 19 vehicle identification numbers (VINs) containing half-shafts that may have been improperly inspected.

GM is not aware of any injuries or crashes related to this condition. In February, GM’s Safety and Field Action Decision Authority decided to conduct a safety recall for any 2021-2022 Chevrolet Corvette that may have received suspect rear half shaft assemblies.

Those receiving notices will be asked to return to their GM dealers to have the left and/or right rear half-shaft assemblies inspected and replaced as necessary. Owner notification letters are expected to be mailed in April. GM’s number for this recall is N212351320 and the NHTSA campaign number is 22V-091.

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In August 2020, Volkswagen / Audi received an inquiry about a gateway control module failure in an Audi Q5 vehicle in China. An inspection of the situation found that the gateway control module had gone into fail safe mode because of liquid entering the module from a rear bench seat spill.

The gateway control module has been programmed to go into a fail-safe mode when an implausible signal is detected in the control unit. If an implausible signal is detected, the gateway switches off its function in order to avoid unwanted vehicle reactions. The vehicle remains steerable and the brake system will work, but the engine will go into emergency mode and remains in operation with reduced power.

Audi performed a safety assessment to evaluate the potential conditions and consequences that could result from a power shutdown of the gateway control module due to liquid ingress. Audi also conducted a risk assessment which indicated that the risk of a liquid spill leading to a failure of the gateway control module is very low and rare over the lifetime of the vehicle. At the time there were only isolated cases in the North American region and all of them happened after an outside influence, mostly after a beverage spill. Audi continued to monitor the problem.

In March 2021, Audi experienced an increase in customer reports related to gateway control module failures on Q5 vehicles after a liquid spill. Audi conducted additional testing and continued to investigate a potential solution to be implemented in production and in the field. Due to single field cases alleging the failure without a liquid spill, an additional investigation was initiated to rule out other root causes for liquid ingress. In August 2021 Audi identified a potential manufacturing issue in the factory in Mexico. “Due to a programming error of a glue bead robot, an underbody seam may not have been sealed sufficiently and therefore allow water ingress from underneath in very rare cases when driving through heavy rain or deep puddles.” The adjustment to the robot was implemented immediately and analysis continued regarding the impact of this additional potential cause for liquid ingress.

The Audi Safety Committee began to issue a service campaign in order to install a protective cover for the gateway control module and to seal the underbody in the area of the insufficient glue bead, but after a meeting with Transport Canada and the Defective Product Administrative Center in China, the Audi Product Safety Committee re-evaluated their decision and decided to conduct a voluntary recall to fix affected vehicles.

The Vehicles Affected Include:
2018-2022 Audi Q5 Sportback
2018-2022 Audi SQ5 Sportback

The NHTSA Office of Defects Investigation (ODI) have opened up an investigation into certain 2019-2020 RAM trucks after receiving 22 complaints and 2 field reports alleging incidents of stalling and loss of engine power. The vehicles affected are equipped with 6.7L Cummins turbo diesel engines. According to the investigation report, the complaints found that most stall/loss of motive power incident allegations occurred at speeds above 25 MPH and resulted in permanent disablement of the vehicle.

The Vehicles Affected Include:
2019-2020 Ram 2500
2019-2020 Ram 3500
2019-2020 Ram 4500
2019-2020 Ram 5500

In November 2019, FCA issued Warranty Bulletin D-19-02 to announce to its dealers a Fast Feedback Program wherein they were notified of a campaign to collect, monitor, and correct quality issues on certain 2018-2020 Ram trucks equipped with the 6.7L Cummins engine. As a result of this campaign, high-pressure fuel pumps have been collected and inspected by the manufacturer and pump manufacturer.

ODI is opening this investigation to further assess the scope, frequency, root cause, and potential safety-related consequences of the alleged defect leading to stall/loss of motive power on 2019-2020MY RAM heavy-duty trucks.

As the result of an investigation into malfunctioning coolant valves, Volkswagen will be contacting the owners of certain 2010-2013 Audi A8 cars to return to their dealerships for repairs. According to the defect report, over time it is possible for coolant to leak through a coolant valve wire connection and migrate into the engine control module (ECM). The ECM could short and switch the engine into “limp home mode” or stall the engine completely. Drivers will be alerted of a problem through illuminated malfunction indicator and engine cooling system warning lights. Continue reading

Ford will be contacting the owners of certain 2015-2016 Ford Focus Electric vehicles about a problem affecting the power train system. According to the defect report, certain cars manufactured between August 20, 2015 – April 13, 2016, may have been equipped with differential pinion gear bores without a friction reduction coating. The problem could result in localized overheating and eventual fracture of the pinion shaft or pinion gears. Drivers may hear an audible indication of wear prior to a fracture. Continue reading

Chrysler will be asking the owners of certain 2012-2016 Fiat 500 and 2013-2016 Fiat 500E vehicles to return to their dealerships to repair two separate problems that could result in loss of motive power.

2012-2016 Fiat 500: These vehicles are equipped with a C514 manual transmission which could experience a cracked or damaged clutch diaphragm spring. If the spring fails the driver will not be able to shift gears or the vehicle may lose motive power. Continue reading

BMW will be contacting a small number of M3 Sedan and M4 Coupe owners about a manufacturing problem affecting the powertrain of their vehicles. According to reports filed with the NHTSA, the driveshaft slip-joint between the transmission and the rear axle may not have been filled with grease and could fail over time. The problem could result in loud clunking noises and sudden loss of power. Continue reading