Safety Recall IY08 – Intake Air Heater Relay – 2021 Ram 2500, 3500, 3500, 4500, 5500 Cab Chassis

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

 

  1. Disconnect the Intelligent Battery Sensor (IBS) wire harness connector (Figure 1).

 

  1. Loosen the ground terminal nut and remove the negative battery cables with

 

  1. Loosen the air intake hose clamp and remove the clean air hose from turbocharger (Figure 2).

 

  1. Loosen the air hose clamp from the air cleaner housing and remove the clean air hose (Figure 2).

 

  1. Disconnect the intake air heater relay wire harness connector (Figure 3).

 

  1. Remove the nuts and the cables from intake air heater relay. Note position of cables before removing (Figure 3).

 

  1. 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).

 

  1. 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.

 

  1. 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).

 

  1. 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).

 

  1. Allow the RTV to cure (Approximately 15min).

 

  1. Install the intake air heater relay in the bracket (Figure 3).

 

  1. Install the cables to the intake air heater relay and tighten nuts to 6N·m (53In. lbs.). (Figure 3).

 

  1. Connect the intake air heater relay wire harness connector (Figure 3).

 

  1. Install the clean air hose and securely tighten the clamp (Figure 2).

 

  1. Install the clean air hose to the turbocharger and securely tighten the clamp.

 

  1. Install the negative battery cables with IBS to the negative posts and tighten to 7N·m (62 In. lbs.) (Figure 1).

 

  1. Connect the IBS wire harness connector (Figure 1).

 

  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.pdf 202.88KB

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

RCRIT-21V163-0593

 


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.pdf 743.25KB

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

RCMN-21V163-8745

 


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

RCLQRT-21V163-6568

 


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

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V163&docType=RCL

 


 

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  • [Full OBDII Functions Code Reader]----LAUNCH CRP123 scan tool supports all 10 modes of OBDII standard to ensure complete, accurate, system diagnosis. Read and Clear DTCs, do smog tests , I/M readiness and O2 sensor tests, Mode 06 EVAP system test, Mode 08 on-board test component test. And OBDII Code lookup tool and acronym database to assist and speed diagnosis and repair time.
  • [Live Data Graphing + Read/Record/Playback Data stream + Lifetime Free Update] Live Data Graphing ,more intuitive to know your vehicle’s problem. Large size Color Screen; Print Function; Print the diagnose result easily; With user manual and register & update tutorial video uploaded in the link by us, you can look up it anytime by ONE-CLICK. Lifetime free update by windows.
  • [Extensive Vehicle Coverage + 9 Languages]----The LAUNCH CRP123 reads data from ENGINE, TRANSMISSION, ABS and SRS systems from Asian, US and European manufacturers. Coverage includes Suzuki, Honda, Mitsubishi, Nissan, Toyota, Mazda, Hyundai, Kia, Subaru, Infiniti, Lexus, Acura, Isuzu, Ford, GM, Chrysler, Benz, BMW, VW, Opel, Volvo, Fiat, Land Rover, Seat, Skoda, Audi, Porsche, Saab, Jaguar and many others. Support 9 different languages.
SaleBestseller No. 10
OBD2 Scanner Code Reader AL600 - ABS & SRS Diagnostics with Active Test, Car Diagnostic Scan Tool with Oil/ BMS/ SAS Reset, Full OBD2 Functions, Lifetime Free Update, LED Lights - by TOPDON
  • 【ABS & SRS Scan Tool 】 Help you diagnose issues with both anti-lock braking system (ABS) and internal airbag system (SRS); test their sensors, valves, or solenoids; and keep track of any threats in real time to prevent unexpected damage with these 2 essential safety systems, which a normal OBD2 scanner cannot do. Compatible with GM, Nissan, Fiat, Benz, Volvo, LandRover, BMW, USAFord.
  • 【3 Reset Services 】Easy to set up 3 regular reset services for Oil Light, Battery Management System, and Steering Angle Position. With this diagnostic tool, you can reset the oil service light and reset pre-programmed mileage intervals for energy efficiency; adjust or reset the steering angle position to keep steering aligned; and clear the original low battery fault information. No need to leave home for shop-quality car maintenance.
  • 【All OBD2 Test Modes 】 Quickly tell you the exact cause behind the check engine warning light. This ABS & SRS scan tool is also a fully-featured obd2 code reader; can read/clear engine light codes, show live data, and do I/M readiness test ... to solve emission issues, and help pass smog test for most post-1996 OBD2/CAN vehicles. Plus, it has the now-popular DTC lookup library to save searching repair materials online.
  • 【User-Oriented 】 Physically, you will like the feel of this obd2 scanner with the black rubber grip thing all around the outside edge. Durable enough to stand the accidental drop. Thanks to its easily accessible menu, you can operate all functions in minutes, with the press of a few buttons. 3-color LEDs intuitively indicate if everything's good, there's a warning, or there's a serious issue. There’s even an LED integrated into the connector port so you can hook it up in darkness.
  • 【Worry-Free Purchase 】 You can update this scan tool through an internet USB to have the latest software for its optimized performance, with no extra costs throughout all its using life. We offer you 1-year quality backup period with 30-day unconditional return & replacement policy. TOPDON offers reliable customer support on Facebook during weekdays. Search “TOPDON Official” on Facebook and contact us via message. Multilingual Menu: EN, FR, ES, DE, IT, RU, PT, and JP.

Last update on 2023-01-19 / Affiliate links / Images from Amazon Product Advertising API

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