Safety Recall W57 / NHTSA 20V-511 Powertrain Control Module Software – 2019-2020 Ram 3500/4500/5500 Cab Chassis

August 27, 2020 NHTSA CAMPAIGN NUMBER: 20V511000

Inadequate Warmup Protection

A damaged engine block may leak oil, which can contact hot engine or exhaust components, increasing the risk of a fire.

 

NHTSA Campaign Number: 20V511

Manufacturer Chrysler (FCA US LLC)

Components ELECTRICAL SYSTEM, ENGINE AND ENGINE COOLING

Potential Number of Units Affected 32,318

 

Summary

Chrysler (FCA US LLC) is recalling certain 2019-2020 Ram 3500, 4500 and 5500 cab chassis built with a Cummins 6.7L High Output engine. Inadequate warmup protection can cause a lack of oil film on the engine connecting rod bearings while the engine is reaching operating temperature. This can result in engine damage and connecting rod failure, which could potentially puncture the engine block.

 

Remedy

Chrysler will notify owners, and dealers will flash the engine calibration software to enhance the engine warm up protection, free of charge. The recall began September 10, 2020. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler’s number for this recall is W57.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Vehicle has a Recall

 

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Revision 1 September 2020

Dealer Service Instructions for:

Safety Recall W57 / NHTSA 20V-511 Powertrain Control Module Software

NOTE: Removed the word “Main” from the subject statement.

 

Remedy Available  

2019 – 2020	(DD)	Ram 3500 Cab Chassis
	(DP)	Ram 4500/5500 Cab Chassis

 

NOTE:  This recall applies only to the above vehicles equipped with a 6.7L Cummins engine (sales code ETN).

NOTE:  Some vehicles above may have been identified as not involved in this recall and therefore have been excluded from this recall.

 

IMPORTANT:  Some of the involved vehicles may be in dealer new vehicle inventory.  Federal law requires you to complete this recall service on these vehicles before retail delivery.  Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service.  Involved vehicles can be determined by using the VIP inquiry process.

Subject

The Powertrain Control Module (PCM) on about 34,000 of the above vehicles may have engine calibration software that does not provide adequate engine warm up protection. Inadequate warmup protection can cause a lack of oil film on the rod bearings while the engine is reaching operating temperature, resulting in engine damage and potential connecting rod failure, which may puncture the engine block, and result in oil contacting a competent ignition source and a vehicle fire may occur. A vehicle fire may increase the risk of injury to occupants and persons outside of the vehicle, as well as property damage.

 

Repair

Reprogram the Powertrain Control Module (PCM) follow section A. Inspection Procedure below before reprogramming the PCM.

 

NOTE: You may be presented with two calibration choices when Fuel Pump, requiring the PCM to b e reprogrammed again with the reprogramming the PCM. Please follow the inspection steps closely to avoid choosing the incorrect calibration. Choosing the incorrect calibration will result in an undesirable noise from the High Pressure correct calibration.

 

Parts Information

No parts are required to perform this service procedure.

 

Parts Return

No parts return required for this campaign.

 

Special Tools

The following special tools are required to perform this repair:

NPN	wiTECH MicroPod II
NPN	Laptop Computer
NPN	wiTECH Software

 

Inspection Procedure

 

A. Inspection Procedure

 

The fuel injection pump must be inspected to determine which design pump is installed on the vehicle. Older design pumps have an exception of specific identification ma rks machined into the body of the Asymmetrical design internal cam. The newer design pumps have a Symmetrical design internal cam. The design of the pump will determine which calibration will need to be programmed into the PCM. From outward appearance both pumps look identical, with the pump.

 

1. Inspect the fuel injection pump to see which pump the vehicle has.

 

• Vehicles with the new style Symmetrical pump will have one large single dot embossed in the pump housing (Figure 1).

 

• For vehicles equipped with a Symmetrical pump, choose the calibration labeled Symmetric, or Sym Pump (Figure 1).

 

• Vehicles with the old style Asymmetrical pump will have multiple dots embossed in the pump housing (Figure 2).

 

• For vehicles with an Asymmetrical pump, choose the calibration labeled Asymmetric or Asym Pump (Figure  2).

 

2. Proceed to section B. Reprogramming the PCM Procedure

 

Service Procedure

 

B. Reprogramming the PCM Procedure

 

CAUTION: Do not interrupt the software update process in any way once it has begun. It may cause permanent damage to the PCM which will NOTE: The wiTECH scan tool must be used to perform this recall.  The  require replacement. It is highly recommended to have a new generic PCM unit available at the workshop before starting the Repair Procedure.

 

wiTECH software is required to be at the latest release level before performing this procedure.  

 

1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts.  Do not allow the charger to time out during the flash process.  Set the battery charger timer (if so equipped) to continuous charge.

 

NOTE:  Use an accurate stand-alone voltmeter.  The battery charger volt meter may not be sufficiently accurate.  Voltages outside of the specified range will cause an unsuccessful flash.  If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage.

 

2. Connect the wiTECH micro pod II to the vehicle data link connector.

 

3. Place the ignition in the “RUN” position.

 

4. Open the wiTECH 2.0 website.

 

5. Enter your “User id” and “Password” and your “Dealer Code”, then select “Sign In” at the bottom of the screen. Click “Accept”.

 

6. From the “Vehicle Selection” screen, select the vehicle to be updated.

 

7. Using the wiTECH tool or the cluster display record the Oil Life percentage.

 

8. From the “Action Items” screen, select the “Topology” tab.

 

9. From the “Topology” tab, select the “PCM” module icon.

 

10. From the “Flash” tab, compare the “Current Electronic Control Unit (ECU) Part Number” with the “New ECU Part Number” listed.

• If the “Current ECU part Number” is the same as the “New Part Number”, proceed to Step 15.

• If the “Current ECU part Number” is NOT the same as the “New Part Number”, continue with Step 11.

 

11. From the PCM tab, select the PCM flash part number. Read the flash special instructions page.  Select “OK” to continue.

 

12. From the flash ECU agreement page, agree to terms by checking the box.

 

13. Select “Flash ECU” and then follow the wiTECH screen instructions to complete the flash.

 

14. Confirm the software is at the latest available calibration level.

 

15. Is the vehicle equipped with an 68RFE automatic transmission?

• If YES, proceed to Step 16.

• If NO, proceed to Step 17.

 

16. Perform the transmission “Quicklearn” procedure, Follow the detailed service procedure select “TCM”.

 

17. Click “View DTCs”, select “Clear All DTCs”.

 

18. Using wiTECH, perform the ‘Oil Life Restore” procedure located in the ECM “Misc. Functions” tab.

 

19. Remove the wiTECH from the vehicle, disconnect the battery charger from the vehicle.

 

20. Return the vehicle to the customer.

 

Completion Reporting and Reimbursement

Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims paid will be used by FCA to record recall service completions and provide dealer payments.

Use one of the following labor operation numbers and time allowances:

	Labor Operation Number	Time Allowance
Inspect PCM Software Level	18-W5-71-81	0.2 hours
Inspect and Reprogram PCM with Sym Pump	18-W5-71-82	0.4 hours
Inspect and Reprogram PCM with Asym Pump	18-W5-71-83	0.4 hours

 

NOTE:  See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions.

 

Dealer Notification

To view this notification on DealerCONNECT, select “Global Recall System” on the Service tab, then click on the description of this notification.

 

Owner Notification and Service Scheduling

All involved vehicle owners known to FCA are being notified of the service requirement by first class mail.  They are requested to schedule appointments for this service with their dealers.  A generic copy of the owner letter is attached.

 

Vehicle Lists, Global Recall System, VIP and Dealer Follow Up

All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed.

GRS provides involved dealers with an updated VIN list of their incomplete vehicles.  The owner’s name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission.

To use this system, click on the “Service”  tab and then click on “Global Recall System.”  Your dealer’s VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence.

Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair.

Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states.  Use of this information is permitted for this recall only and is strictly prohibited from all other use.

 

Additional Information

If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager.

Customer Services / Field Operations

FCA US LLC

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This notice applies to your vehicle,

 [Model Year and Model]  VIN XXXXXXXXXXXXXXXXX W57/NHTSA 20V–511

 

LOGO

VEHICLE PICTURE

YOUR SCHEDULING OPTIONS

 

1. RECOMMENDED OPTION Call your authorized Chrysler / Dodge / Jeep_® / RAM Dealership

 

2. Call the FCA Recall Assistance Center at 1-800-853-1403. An agent can confirm part availability and help schedule an appointment

 

3. Visit mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App.

 

QR Code

 

Get access to recall notifications, locate your nearest dealer, and more through this website or Mopar Owner’s Companion App. You will be asked to provide your Vehicle Identification Number (VIN) to protect and verify your identity. The last eight characters of your VIN are provided above.

 

DEALERSHIP INSTRUCTIONS

Please reference Safety Recall W57.

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IMPORTANT SAFETY RECALL

Powertrain Control Module Software

Dear [Name],

 

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

 

FCA US has decided that a defect, which relates to motor vehicle safety, exists in certain [2019 – 2020 Model Year (DD) Ram 3500 Cab Chassis, and (DP) 4500/5500 Ram Cab Chassis] vehicles.

 

It is extremely important to take steps now to repair your vehicle to ensure the safety of you and your passengers.

 

WHY DOES MY VEHICLE NEED REPAIRS?

The Powertrain Control Module in your vehicle ^[1] may have engine calibration software that does not provide adequate engine warm up protection. Inadequate warmup protection can cause a lack of oil film on the main rod bearings while the engine is reaching operating temperature, resulting in engine damage and potential connecting rod failure, which may puncture the engine block, and result in oil contacting a competent ignition source and a vehicle fire may occur. A vehicle fire may increase the risk of injury to occupants and persons outside of the vehicle, as well as property damage.

 

HOW DO I RESOLVE THIS IMPORTANT SAFETY ISSUE?

FCA US will repair your vehicle ^[2] free of charge (parts and labor).  To do this, your dealer will inspect and if required reprogram the Powertrain Control Module to include enhanced engine warm up protection. The estimated repair time is about a half hour. In addition, your dealer will require your vehicle for proper check-in, preparation, and check-out during your visit, which may require more time. Your time is important to us, so we recommend that you schedule a service appointment to minimize your inconvenience. Please bring this letter with you to your dealership.

 

Please reference your owner manual to ensure choosing the correct oil type for your use.  In ambient temperatures above 0°F (-18°C), we recommend using 10W-30 engine oil that meets the API CK-4 engine oil category.  In ambient temperatures below 0°F (-18°C), we recommend using 5W-40 synthetic engine oil that meets the API CK-4 engine oil category.

 

TO SCHEDULE YOUR FREE REPAIR,
CALL YOUR CHRYSLER, DODGE, JEEP OR RAM DEALER TODAY

 

WHAT IF I ALREADY PAID TO HAVE THIS REPAIR COMPLETED?

If you have already experienced this specific condition and have paid to have it repaired, you may visit www.fcarecallreimbursement.com to submit your reimbursement request online. ^[3] Once we receive and verify the required documents, reimbursement will be sent to you within 60 days.  If you have had previous repairs performed and/or already received reimbursement, you may still need to have the recall repair performed.

 

We apologize for any inconvenience, but are sincerely concerned about your safety.  Thank you for your attention to this important matter.

Customer Assistance/Field Operations

FCA US LLC

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Mr. Mrs. Customer
1234 Main Street
Hometown, MI 48371

[1] If you no longer own this vehicle, please help us update our records. Call the FCA Recall Assistance Center at 1-800-853-1403 to update your information.

[2] If your dealer fails or is unable to remedy this defect without charge and within a reasonable time, you may submit a written complaint to the Administrator, National Highway Traffic Safety Administration, 1200 New Jersey Ave., S.E., Washington, DC  20590, or you can call the toll-free Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-4249153), or go to safercar.gov.

[3] You can also mail in your original receipts and proof of payment to the following address for reimbursement consideration: FCA Customer Assistance, P.O. Box 21-8004, Auburn Hills, MI 48321-8007, Attention: Recall Reimbursement.

 

Note to lessors receiving this recall notice: Federal regulation requires that you forward this recall notice to the lessee within 10 days.

 

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FCA US LLC Recall Part Numbers

W57 Cummins 6.7L High Output Engine Calibration Submitted on August 27, 2020

 

CUMMINS ENGINE CALIBRATION PART NUMBERS BY MODEL AND MODEL YEAR

Model	Part Numbers by Model Year
	2019		2020
Ram 3500 Cab Chassis – 50 States	51360932AA	51360932AH	51360032AE
	51360932AC	51360932AI	51360032AF
	51360932AD	51360932AJ	S5360032SA
	51360932AE	51360932AF
	51360932AF	S5360932SA
	51360932AG
Ram 3500 Cab Chassis – Emergency Vehicle	51360972AA	51360972AG	51360072AE
	51360972AC	51360972AH	51360072AF
	51360972AD	51360972AI	51360072SA
	51360972AE	51360972AJ
	51360972AF	S5360972SA
Ram 4500/5500 Cab Chassis – 50 States	51361932AA	51361932AH	51361032AE
	51361932AC	51361932AI	51361032AF
	51361932AD	51361932AJ	S5361032SA
	51361932AE	S5361932SA
	51361932AF
Ram 4500/5500 Cab Chassis – Emergency Vehicle	51361972AA	51361972AH	51361072AE
	51361972AC	51361972AI	51361072AF
	51361972AD	51361972AJ	S5361072SA
	51361972AE	S5361972SA
	51361972AF

 

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08/28/2020

New Safety Recall Advanced Communication – W57

 

FCA US LLC (FCA US) has announced a safety recall on certain 2019 and 2020 Model Year (DD) Ram 3500 Cab Chassis and (DP) 4500/5500 Cab Chassis vehicles equipped with a Cummins 6.7L high output engine.  

 

REASON FOR THIS SAFETY RECALL

Some of the above vehicles may have been built with engine calibration software that does not provide adequate engine warm up protection. Inadequate warmup protection can cause a lack of oil film on the main bearings while the engine is reaching operating temperature, resulting in engine damage and potential connecting rod failure, which may puncture the engine block, and result in oil contacting a competent ignition source and vehicle fire may occur. A vehicle fire may increase the risk of injury or occupants and persons outside the vehicle, as well as property damage.

 

SERVICE ACTION

FCA US will conduct a voluntary safety recall to reprogram the Powertrain Control Module. Dealers will be notified of the launch of this safety recall by way of established communication methods.  This recall is estimated to launch in 3rd Quarter of 2020.

 

We ask that you please take the time to ensure that your personnel are aware of this communication and are prepared to execute a customer friendly process for inquiries regarding involved vehicles.

 

 

Customer Services Field Operations

FCA US LLC

 

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6 Affected Products

Vehicles

MAKE	MODEL	YEAR
RAM	3500	2019-2020
RAM	4500	2019-2020
RAM	5500	2019-2020

 

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12 Associated Documents

Recall Quarterly Report #2, 2020-4

RCLQRT-20V511-9990.PDF 211.246KB

 

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Remedy Instructions and TSB

RCRIT-20V511-2667.pdf 1021.748KB

 

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Recall Quarterly Report #1, 2020-3

RCLQRT-20V511-0120.PDF 211.141KB

 

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Recall Quarterly Report #3, 2021-1

RCLQRT-20V511-2772.PDF 211.331KB

 

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Recall Quarterly Report #4, 2021-2

RCLQRT-20V511-9316.PDF 211.449KB

 

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ISSUED Renotification Notice

RCRN-20V511-7226.pdf 138.25KB

 

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Remedy Instructions and TSB

RCRIT-20V511-9127.pdf 1021.429KB

 

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Manufacturer Notices(to Dealers,etc) – Dealer Notification re New Safety Recall Advanced Communication – W57, FCA US LLC (FCA US) has announced a safety recall on certain 2019 and 2020 Model Year (DD) Ram 3500 Cab Chassis and (DP) 4500/5500 Cab Chassis vehicles equipped with a Cummins 6.7L high output engine.

RCMN-20V511-0041.pdf 97.766KB

 

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Miscellaneous Document – FCA US LLC Recall Part Numbers W57 Cummins 6.7L High Output Engine Calibration

RMISC-20V511-6667.pdf 340.155KB

 

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Recall Acknowledgement

RCAK-20V511-8223.pdf 244.137KB

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V511-6512.pdf 518.311KB

 

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Recall Quarterly Report #5, 2021-3

RCLQRT-20V511-4728.PDF 211.565KB

 

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V511&docType=RCL

 

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Reprogramming

Chrysler J2534 Application Overview

 

DRB III Emulator

Flash Availability - J2534/Pass Thru Device

Vehicle to Diagnostic Tool Reference Chart

 

Chrysler Recommended J2534 Devices

For Chrysler recommended J2534 device, see below table.

J2534 Device	Firmware Version
CTC Vehicle Box *	1.9
UCAN 2	1.0
Blue Streak -2534 Global Programmer	2.10
Actia I+ME Passthru	2.07

* Chrysler recommends the CTC Vehicle Box Device for Chrysler SCI ECU reprogramming. SCI reprogramming is used on most PCMs and TCMs prior to the introduction of CAN bus vehicles which began in 2004 (Durango).

 

Compatible J2534 Devices

	CarDAQ-Plus 3 All Makes J2534 Reprogramming Tool
	CarDAQ-Plus 2 Diagnostic Code Reader and J2534 Programming Tool
	CarDAQ-Plus
	CarDAQ-M
	VSI J2534 ECU Reprogrammer
	Bosch Automotive Tools MTECH2 Mastertech II J2534 VCI with Wired/Wireless Capability for OEM Reprogramming and Diagnostics on GM, Ford, FCA, Nissan/Infiniti, Honda/Acura, and Toyota/Lexus Vehicles
	RAP2 OEM J2534 Remote Reprogramming Tool
	BOSCH Automotive Tools MTECH2 Mastertech II J2534 VCI
	Autel MaxiFlash VCI Vehicle Communication Interface J2534 PassThru ECU Programming Device Bluetooth Connection Internet Update Support CAN FD, 4 CAN Channels, DoIP, D-PDU Works with PC or Autel MS909
	GODIAG J2534

 

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Click on the link below to:

Download J2534 Application

(Install the wiTECH 2.0 J2534 Application on your computer)

Download the Setup Utility

(Configure your microPod/MDP device)

Launch wiTECH 2.0

(Once subscription and users are assigned to a tool please follow this link to access wiTECH)

https://www.mopartsp.com/support

 

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Chrysler J2534 Manual

wiTECH Software

www.techauthority.com

 

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