March 11, 2021 NHTSA CAMPAIGN NUMBER: 21V163000
Relay May Short and Cause Fire
A vehicle fire increases the risk of injury.
NHTSA Campaign Number: 21V163
Manufacturer Chrysler (FCA US, LLC)
Components ELECTRICAL SYSTEM
Potential Number of Units Affected 19,214
Summary
Chrysler (FCA US, LLC) is recalling certain 2021 Ram 2500, 3500, and 3500, 4500, and 5500 Cab Chassis vehicles equipped with a Cummins 6.7L Turbo Diesel engine. An electrical short may occur in the Solid State Intake Heater Grid Relay, which could result in a vehicle fire.
Remedy
Toe remedy your vehicle, your dealer will install a protective barrier on the relay, free of charge. Owners may contact FCA US LLC customer service at 1-800-853-1403. FCA US LLC’s number for this recall is Y08.
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
New Safety Recall Advanced Communication – Y08
FCA US LLC (FCA US) has announced a safety recall on certain 2021 Model Year (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup, (DD) Ram 3500 Cab Chassis, (DP) Ram 4500/5500 Cab Chassis vehicles equipped with a 6.7L Cummins engine.
VINs identified as being involved in this campaign are currently live and searchable. Stop sale is in effect for the above-identified vehicles.
Vehicles impacted by a stop sale are eligible for reimbursement allowance through the Recall Floorplan Reimbursement Policy (RFPRP), which can be requested upon recall claim submission.
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. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Involved vehicles can be determined by using the VIP inquiry process.
REASON FOR THIS SAFETY RECALL
Some of the above vehicles may experience an engine compartment fire originating from an electrical short in the Intake Air Heater Relay, which can potentially lead to a vehicle fire with the ignition in the “ON” or “OFF” position. A vehicle fire can result in increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage.
It is advised to exercise the following precautions until the vehicle has the final repair completed: do not park these vehicles inside of buildings or structures, or near other vehicles.
SERVICE ACTION
The remedy for this recall has been suspended. Dealers will be notified of future required action for this safety recall by way of established communication methods.
NOTE: Safety Recall Y08 has been superseded by Safety Recall Y76, please see Safety Recall Y76 for service repair instructions.
2021-2022 Ram 2500-5500 Safety Recall Y76 Intake Air Heater Relay
2021-2022 Ram 2500-5500 Safety Recall Y76 Intake Air Heater Relay
Revision 1 April 2021
Dealer Service Instructions for:
Safety Recall Y08 / NHTSA 21V-163 Intake Air Heater Relay
NOTE: Added additional information in the “Completion Reporting and Reimbursement” section.
Remedy Available
| 2021 | (DJ) | Ram 2500 Pickup |
| (D2) | Ram 3500 Pickup | |
| (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, ETL, ETM).
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 intake air heater relay on about 20,000 of the above vehicles may experience an engine compartment fire originating from an electrical short in the Intake Air Heater Relay, which can potentially lead to a vehicle fire with the ignition in the “ON” or “OFF” position. A vehicle fire can result in increased risk of occupant
has this repair completed: do not park these vehicles inside of buildings or injury and/or injury to persons outside the vehicle, as well as property damage.
Customers are advised to exercise the following precautions until the vehicle
structures and avoid parking near other vehicles.
Repair
Follow service procedure as described below.
Parts Information
| Qty. | Description | Part Number |
| 1 | RTV, Silicone Rubber Adhesive (MS-GF44B) | 04883971AC |
NOTE: 1 Tube of RTV will cover approximately 4 relays
Parts Return
No parts return required for this campaign.
Special Tools
No special tools are required to perform this service procedure.
Service Procedure
- Disconnect the Intelligent Battery Sensor (IBS) wire harness connector (Figure 1).
- Loosen the ground terminal nut and remove the negative battery cables with
- Loosen the air intake hose clamp and remove the clean air hose from turbocharger (Figure 2).
- Loosen the air hose clamp from the air cleaner housing and remove the clean air hose (Figure 2).
- Disconnect the intake air heater relay wire harness connector (Figure 3).
- Remove the nuts and the cables from intake air heater relay. Note position of cables before removing (Figure 3).
- Remove the intake air heater relay by tilting relay forward and away from the studs then set on a clean surface with the back of the relay facing up (Figure 4).
- Using isopropyl alcohol and a clean cloth wipe the back of the relay clean of any dirt or residue.
NOTE: It is extremely important to ensure the relay has been sufficiently cleaned before applying the RTV.
- Initiate the application of the RTV by: A) applying the RTV on the buss bar holes then B) apply to the outer sides of the buss-bars and C) finally on the remaining surface of the relay (approximately 2MM thickness) to cover the relay (Figure 4).
- Starting at the top of the Buss-Bars use a tongue depressor or equivalent and align it to the outer case of the relay and skim in the downward position to remove any excess RTV (Figure 5).
- Allow the RTV to cure (Approximately 15min).
- Install the intake air heater relay in the bracket (Figure 3).
- Install the cables to the intake air heater relay and tighten nuts to 6N·m (53In. lbs.). (Figure 3).
- Connect the intake air heater relay wire harness connector (Figure 3).
- Install the clean air hose and securely tighten the clamp (Figure 2).
- Install the clean air hose to the turbocharger and securely tighten the clamp.
- Install the negative battery cables with IBS to the negative posts and tighten to 7N·m (62 In. lbs.) (Figure 1).
- Connect the IBS wire harness connector (Figure 1).
- Close the hood and return the vehicle to the customer or vehicle inventory.
4 Affected Products
Vehicles
| MAKE | MODEL | YEAR |
| RAM | 2500 | 2021 |
| RAM | 3500 | 2021 |
| RAM | 4500 | 2021 |
| RAM | 5500 | 2021 |
18 Associated Documents
Manufacturer Notices(to Dealers,etc) – Media Release re FCA US LLC (FCA US) has announced a safety recall on certain 2021 Model Year (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup, (DD) Ram 3500 Cab Chassis, (DP) Ram 4500/5500 Cab Chassis vehicles equipped with a 6.7L Cummins engine
RCMN-21V163-8652
Recall Quarterly Report #1, 2021-2
RCLQRT-21V163-6693.PDF 211.138KB
RCLQRT-21V163-6693
Manufacturer Notices(to Dealers,etc) – Media Release re New Safety Recall Advanced Communication Y08
RCMN-21V163-7647.pdf 203.177KB
RCMN-21V163-7647
Remedy Instructions and TSB
RCRIT-21V163-9964.pdf 1448.114KB
RCRIT-21V163-9964
Remedy Instructions and TSB
RCRIT-21V163-0593.pdf 1447.644KB
ISSUED Owner Notification Letter(Part 577)
RCONL-21V163-7802.pdf 518.624KB
RCONL-21V163-7802
Manufacturer Notices(to Dealers,etc) – Media Release re FCA US LLC (FCA US) has announced a safety recall on certain 2021 Model Year (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup, (DD) Ram 3500 Cab Chassis, (DP) Ram 4500/5500 Cab Chassis vehicles equipped with a 6.7L Cummins engine
RCMN-21V163-6959.pdf 198.632KB
RCMN-21V163-6959
Recall Acknowledgement
RCAK-21V163-6551
Defect Notice 573 Report
RCLRPT-21V163-8370.PDF 216.964KB
RCLRPT-21V163-8370
Manufacturer Notices(to Dealers,etc) – Dealer Notification re Suspended Safety Recall Y08 R2
RCMN-21V163-8745.pdf 124.724KB
Manufacturer Notices(to Dealers,etc) – Media Release re FCA US LLC (FCA US) has announced a safety recall on certain 2021 Model Year (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup, (DD) Ram 3500 Cab Chassis, (DP) Ram 4500/5500 Cab Chassis vehicles equipped with a 6.7L Cummins engine
RCMN-21V163-4997.pdf 205.858KB
RCMN-21V163-4997
Recall 573 Report
RCLRPT-21V163-9243.PDF 216.997KB
RCLRPT-21V163-9243
Recall 573 Report
RCLRPT-21V163-4330.PDF 217.019KB
RCLRPT-21V163-4330
Recall 573 Report
RCLRPT-21V163-4879.PDF 217.006KB
RCLRPT-21V163-4879
Recall Quarterly Report #2, 2021-3
RCLQRT-21V163-6568.PDF 211.242KB
Recall 573 Report
RCLRPT-21V163-5906.PDF 217.005KB
RCLRPT-21V163-5906
Remedy Instructions and TSB
RCRIT-21V163-9791.pdf 26.726KB
RCRIT-21V163-9791
Recall Quarterly Report #3, 2021-4
RCLQRT-21V163-5798.PDF 211.33KB
RCLQRT-21V163-5798
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https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V163&docType=RCL
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