Safety Recall Y76 Intake Air Heater Relay – 2021-2022 Ram 2500-5500

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October 14, 2021 NHTSA CAMPAIGN NUMBER: 21V798000

Electrical Short in Relay May Cause Fire

A vehicle fire increases the risk of injury.

 

NHTSA Campaign Number: 21V798

Manufacturer Chrysler (FCA US, LLC)

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 131,177

 

Summary

Chrysler (FCA US, LLC) is recalling certain 2021-2022 Ram 3500, 2500 pickup trucks, and Ram 3500, 4500, and 5500 cab chassis vehicles equipped with Cummins 6.7L Turbo Diesel engines. An electrical short in the relay may cause a vehicle fire with the ignition on or off.

 

Remedy

Owners are advised to park these vehicles outside of buildings or structures, and not near other vehicles, until the vehicle has been remedied. Dealers will inspect and, if needed, replace the Solid State Intake Heater Grid Relay (“Relay”); if FCA US Recall ID Y08 (NHTSA Recall ID 21V-163) is open, then insulating material will be applied to the Relay after inspection. Owner notification letters were mailed November 10, 2021. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC’s number for this recall is Y76.

 

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.nhtsa.gov.

 

Check if your Vehicle has a Recall

 


New Safety Recall Advanced Communication – Y76

FCA US LLC (FCA US) has announced a safety recall on certain 2021 and 2022 Model Year (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup, (DD) Ram 3500 Cab Chassis and (DP) Ram 4500/5500 Cab Chassis vehicles equipped with a 6.7L Cummins Engine.

 

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 condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods.

 


Revision 3 November 2021

Dealer Service Instructions for:

Safety Recall Y76 / NHTSA 21V-798 Intake Air Heater Relay

 

NOTE: Updated information in the “Repair” section highlighted in red.

 

Remedy Available

2021 – 2022 (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 137,946 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.

 

Repair

For all vehicles involved, check Engine Run Hours in the Instrument Panel Cluster:

 

For 2022 MY and 2021 MY, built ON or AFTER January 08, 2021:

  • If the total engine hours are GREATER than 600, this recall can be marked complete and vehicle returned to the customer.
  • If total engine hours are LESS than 600, perform Section A: Grid Heater Temperature Test Procedure.
    • Pass this recall can be marked complete and vehicle returned to the customer.
    • Fail – grid heater relay exceeds the specified surface temperature; contact STAR Center for additional directions and replacement relay. Reference Section B: Grid Heater Relay Replacement Procedure if relay replacement is directed by STAR Center.

 

For 2021 MY, built BEFORE January 8, 2021:

  • If the total engine hours are GREATER than 600 and service history shows Y08 was previously completed, this recall can be marked complete and vehicle returned to the customer
  • If the total engine hours are GREATER than 600 and service history does not show Y08 was previously completed, perform Section C: Intake Air Heater Relay RTV Application Procedure.
  • If the total engine hours are LESS than 600, regardless of Y08 completion or not, perform Section A: Grid Heater Temperature Test Procedure.
    • Pass – If Y08 was NOT previously completed, perform Section C: Intake Air Heater Relay RTV Application Procedure. If Y08 was previously completed this recall can be marked complete.
    • Fail – grid heater relay exceeds the specified surface temperature; contact STAR Center for additional directions and replacement relay. Reference Section B: Grid Heater Relay Replacement Procedure if relay replacement is directed by STAR Center.

 

Parts Information

NOTE: The below part number is only applicable to 2021 vehicles, built before January 8, 2021 and no service history of recall Y08 remedy completion.

*Part Number Qty. Description
04883971AC 1 RTV, Silicone Rubber Adhesive (MS-GF44B)

NOTE: 1 Tube of RTV will cover approximately 4 relays

 

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
  • NPN
Laser Infrared Thermometer MINIMUM specifications:

Range: -30C to 200C
Resolution: +/- 0.2C
Accuracy; +/- 3C
Spot Size Ratio: 8:1
Response Time: < 1.5s

 

Service Procedure

A. Intake Air Heater Relay Temperature Test Procedure

WARNING: Do NOT leave the vehicle unattended while performing this test. NOTE: Position the vehicle on a NONFLAMMABLE surface.  

NOTE: Please have a fire extinguisher available while performing the test.

 

  1. Open the hood.

 

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

 

  1. Open the wiTECH 2.0 website.

 

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

 

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

 

  1. Turn the ignition to the “ON”

 

  1. From the “Topology” tab, select the “PCM” icon.

 

  1. Select “System Tests”.

 

  1. Select “Grid Heater Relay Test”.

 

  1. Select “Continue” (Figure 1).

 

  1. Place check mark in box then select “Continue” (Figure 2).

 

  1. Follow and complete all wiTECH screen prompts; through 9 test sequences.

 

  1. Using an Infrared Thermometer, set measurement to read temperature in Celsius ONLY.

 

  1. Take an initial surface temperature of the grid heater relay, in Celsius, for your reference.

 

  1. Measure the temperature of the Grid Heater Relay during the test in the specific location as illustrated in Figure 3 when prompted by wiTECH.

NOTE: Measure the relay temperature from the same distance for each test sequence (Figure 3).

NOTE: Verify Celsius is selected for EACH reading, by testing a known ambient temperature surface. Some equipment will default back to a Fahrenheit setting.

 

➢ If the Grid Heater Temperature exceeds 80°C abort the test, make selection in wiTECH for the report to be sent to you via email, hold the vehicle, and contact STAR Center for additional direction. B. Intake Air Heater Relay Replacement Procedure.

➢ If test is aborted accidently, return to step 8.

➢ If the Grid Heater Relay does not exceed 80°C, proceed to step 16.

 

  1. Select view the DTCs.

 

  1. If no DTCs are present, the procedure is complete.

 

  1. Place the ignition in the “OFF” position and then remove the wiTECH micro pod II device from the vehicle.

 

  1. If this is a 2022 MY or 2021 MY, built ON or AFTER January 08, 2021, close the vehicle hood and return the vehicle to the customer or inventory, otherwise consult the “Repair” section for additional information.

 

B. Intake Air Heater Relay Replacement Procedure.

  1. Disconnect the Intelligent Battery Sensor (IBS) wire harness connector (Figure 5).

 

  1. Loosen the air intake hose clamp and remove the clean air hose from turbocharger (Figure 6).

 

  1. Loosen the air hose clamp from the air cleaner housing and remove the clean air hose (Figure 6).

 

  1. Disconnect the intake air heater relay wire harness connector (Figure 7).

 

  1. Remove the nuts and the cables from intake air heater relay. Note position of cables before removing (Figure 7).

 

  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. Install the NEW intake air heater relay in the bracket (Figure 7).

 

  1. Install the cables to the intake air heater relay and tighten nuts to 15N·m (11ft. lbs.). (Figure 5).

 

  1. Connect the intake air heater relay wire harness connector (Figure 6).

 

  1. Install the clean air hose and securely tighten the clamp (Figure 6).

 

  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 5).

 

  1. Connect the IBS wire harness connector (Figure 5).

 

  1. Close the hood and return the vehicle to the customer or vehicle inventory.

 

C. Intake Air Heater Relay RTV Application Procedure

  1. Disconnect the Intelligent Battery Sensor (IBS) wire harness connector (Figure 8).

 

  1. Loosen the air intake hose clamp and remove the clean air hose from turbocharger (Figure 9).

 

  1. Loosen the air hose clamp from the air cleaner housing and remove the clean air hose (Figure 9).

 

  1. Disconnect the intake air heater relay wire harness connector (Figure 10).

 

  1. Remove the nuts and the cables from intake air heater relay. Note position of cables before removing (Figure 10).

 

  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 10).

 

  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 11).

 

  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 12).

 

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

 

  1. Install the intake air heater relay in the bracket (Figure 12).

 

  1. Install the cables to the intake air heater relay and tighten nuts to 15N·m (11ft. lbs.). (Figure 10).

 

  1. Connect the intake air heater relay wire harness connector (Figure 10).

 

  1. Install the clean air hose and securely tighten the clamp (Figure 9).

 

  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 8).

 

  1. Connect the IBS wire harness connector (Figure 8).

 

  1. Close the hood and return the vehicle to the customer or vehicle inventory.

 


Chronology :

  • On February 17, 2021, FCA US Vehicle Safety and Regulatory Compliance (“VSRC”) opened an investigation into 2021 MY Ram 2500, 3500, and 4500/5500 trucks as a result of a detected trend of engine compartment fires.
  • During February 2021, FCA US VSRC conducted analysis of fire patterns, witness statements, and vehicle history and determined all of the affected vehicles were equipped with the Solid State Intake Heater Grid Relay, and determined it was the origin of the fires.
  • On March 4, 2021, the FCA US Vehicle Regulations Committee (VRC) determined to conduct a voluntary safety recall on vehicles equipped with an unprotected Relay.
  • On May 17, 2021, FCA US became aware of a vehicle fire in a vehicle with a protected Relay.
  • From March 2021, to October 2021, FCA US and the Relay supplier continued to conduct root cause analysis and examined photographic evidence, witness statements, and vehicle history data.
  • From May 2021, through September 2021, FCA US became aware of seven additional fires in vehicles with a protected Relay.
  • As of October 8, 2021, FCA US identified seven customer assistance records, one warranty claim, and seven field reports potentially related to this issue for all markets with dates of receipt ranging from August 5, 2020 to October 8, 2021.
  • As of October 8, 2021, FCA US is aware of zero accidents and zero injuries potentially related to this issue for all markets.
  • On October 08, 2021, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.

 


8 Affected Products

Vehicles

MAKE MODEL YEAR
RAM 2500 2021-2022
RAM 3500 2021-2022
RAM 4500 2021-2022
RAM 5500 2021-2022

 


20 Associated Documents

Remedy Instructions and TSB

RCRIT-21V798-0840.pdf 2235.94KB

RCRIT-21V798-0840

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V798-8294.pdf 586.521KB

RCONL-21V798-8294

 


Recall 573 Report

RCLRPT-21V798-1210.PDF 217.41KB

RCLRPT-21V798-1210

 


Recall 573 Report

RCLRPT-21V798-7930.PDF 217.514KB

RCLRPT-21V798-7930

 


Recall Quarterly Report #1, 2021-4

RCLQRT-21V798-7515.PDF 211.153KB

RCLQRT-21V798-7515

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V798-8588.pdf 583.327KB

RCONL-21V798-8588

 


Recall 573 Report

RCLRPT-21V798-6365.PDF 217.514KB

RCLRPT-21V798-6365

 


ISSUED Owner Notification Letter(Part 577)

RCONL-21V798-8127.pdf 585.953KB

RCONL-21V798-8127

 


Recall Acknowledgement

RCAK-21V798-3027.pdf 645.397KB

RCAK-21V798-3027

 


Remedy Instructions and TSB

RCRIT-21V798-5883.pdf 2309.809KB

RCRIT-21V798-5883

 


Remedy Instructions and TSB

RCRIT-21V798-3085.pdf 2309.23KB

RCRIT-21V798-3085

 


Recall 573 Report

RCLRPT-21V798-9650.PDF 217.41KB

RCLRPT-21V798-9650

 


Defect Notice 573 Report

RCLRPT-21V798-8942.PDF 217.33KB

RCLRPT-21V798-8942

 


Manufacturer Notices(to Dealers,etc) – NSRAC re FCA US LLC (FCA US) has announced a safety recall on certain 2021 and 2022 Model Year (DJ) Ram 2500 Pickup, (D2) Ram 3500 Pickup, (DD) Ram 3500 Cab Chassis and (DP) Ram 4500/5500 Cab Chassis vehicles equipped with a 6.7L Cummins Engine.

RCMN-21V798-1463.pdf 199.746KB

RCMN-21V798-1463

 


Renotification Notice

RCRN-21V798-1000.pdf 1537.491KB

RCRN-21V798-1000

 


ISSUED Renotification Notice

RCRN-21V798-9633.pdf 134.356KB

RCRN-21V798-9633

 


Recall 573 Report

RCLRPT-21V798-2583.PDF 217.514KB

RCLRPT-21V798-2583

 


Recall Quarterly Report

RCLQRT-21V798-6070.PDF 211.258KB

RCLQRT-21V798-6070

 


Recall Quarterly Report #3, 2022-2

RCLQRT-21V798-4344.PDF 211.354KB

RCLQRT-21V798-4344

 


Recall Quarterly Report #4, 2022-3

RCLQRT-21V798-6030.PDF 211.465KB

RCLQRT-21V798-6030

 


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=21V798&docType=RCL

 


 

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  • [Get The Right Fix] - Much more than a car code reader, BlueDriver is a diagnostic tool. Get unlimited specific repair reports containing possible causes, reported fixes, and more for virtually every vehicle make and model.
  • [Wireless & Bluetooth Enabled] - Say goodbye to wires. BlueDriver connects with Bluetooth via your phone/tablet to a sensor that plugs into your car's OBDII port. Get all of the capabilities of an expensive code reader & scan tool without any annoying wires.
  • [User-Friendly App and Repair Videos] - BlueDriver gives you more ways to scan and fix your vehicle. Our iOS & Android app connects you to a large database of repair videos with step-by-step directions of repairs.
Bestseller No. 8
ANCEL FX2000 OBD2 Scanner Diagnostic Tool, ABS SRS Transmission Airbag Car Scanner, Check Engine Car Code Reader, Automotive Scan Tool for All Cars
  • 🔧【PLUG AND PLAY - EASY TO USE】 : ANCEL FX2000 car scanner only takes 3 steps to connect to the car for diagnosis without cumbersome operations. The latest FX2000 scan tool is equipped with a one-key diagnosis function, which can automatically identify the model and year of your car, and automatically diagnose the car. Even beginners can use it to read the data and find out what the fault codes mean.
  • 🚗【FULL OBD-LEVEL DIAGNOSTICS TOOL】: Quickly determines the cause of engine system faults, reads current, permanent and pending codes. After the repair, clears the codes and turns off the warning light. In addition, the FX2000 engine code reader also displays important OBD II advanced data such as fuel, live data and other manufacturer-specific parameters in real time to ensure that the engine ECU is operating correctly and safely, saving vehicle owners a lot of time and money in maintenance.
  • 🚙【TRANSMISSION FAULT DIAGNOSTIC TOOL】: Some noises come from the transmission? Ancel obd2 scanner will read fault codes, display live transmission system data (fluid temperature, fluid pump, clutch actuation, pressure, etc.), and ensures transmission performance is optimal for vehicle speed and load. It provides detailed TCM data of the vehicle, so you can quickly and accurately find existing or potential problems.
  • 🚐【FIND OUT SRS WRONG】: ANCEL FX2000 automotive scanner is able to read and clear fault codes in the SRS (airbag) and turn off the warning light to make sure the system is working correctly and safely. This odb2 scanner also displays a live graphical data stream of the supplemental restraint system (air bag), which allows you to analyze and verify that the air bag system is working properly.
  • 🚌【ABS OBD2 SCANNER】:The FX2000 diagnostic scanner for all vehicles can read and clear the Diagnostic Trouble Codes (DTC) data stream transmitted from the ABS. By retrieving the ABS code data, the obd scanner can check the various brake components and accurately diagnose problems.
Bestseller No. 9
OBD2 Scanner TOPDON AL600, ABS SRS Code Reader, Diagnostic Scan Tool, Active Test for ABS/SRS, with Car Maintenance Reset Service of Oil, BMS, SAS
  • ABS/SRS OBD2 Scanner > Enjoy this ABS OBD2 code reader to reveal exact issues underlying in your brake, airbag, and engine systems, test individual ABS/SRS sensors, valves, or solenoids to quickly locate malfunctions (compatible with GM, Nissan, Fiat, Benz, Volvo, Land Rover, BMW, USA Ford, please reach us for details.), making sure critical safety systems work in perfect harmony together against accidents to be safe than sorry. NOTE: Only support upgrade on windows.
  • 3 Most Needed Service Functions > This OBD2 scanner guides you through step by step procedures to reset oil service light and programmed mileage intervals for engine efficiency (Oil Reset); to calibrate steering wheel position for vehicle’s traveling in a straight line (SAS Reset); to clear the original low battery fault information against coming battery failures or damage (BMS Reset); saving your needless visits to mechanics. NOTE: Not suitable for all models, please reach us for compatibility.
  • Full OBD2 Diagnostics > Say goodbye to the hassle of manual check-ups via this srs code reader. Quickly correct Check Engine Light warning on most OBD2/CAN compatible vehicles. Easily access to your smog status with one simple click I/M Readiness; and being filled with features for live data readings, freeze frame data, plus EVAP system, onboard monitor test means this scan tool checks all daily car care boxes.
  • Work Easier > Red-Yellow-Green LEDs in this OBD2 scanner quickly show the overall DTC status without toggling through menu selections. HELP hotkey takes you directly to detailed descriptions/tips. Read/Erase DTC, I/M readiness shortcuts are added for optimized operation, along with DTC Lookup library for interpreting codes, designing the SRS OBD2 code reader a pleasure to use right out of the package even for beginners.
  • Helpful Service > Get instant, free lifetime access to the most recent updates to add new car models and troubleshooting bugs making the OBD2 scanner a long-term investment for any home mechanics. The extended 1 years of quality assurance sweetens the worry-free deal even further. Multilingual Menu: EN, FR, ES, DE, IT, RU, PT, and JP. NOTE: Only support upgrade on windows.
Bestseller No. 10
Scan Tool, check engine light scanner, OBD2 Scanner car code reader, full OBDⅡ Modes, Read/Clear Codes, 5 yrs warran.,fr-ee update" title="Safety Recall Y76 Intake Air Heater Relay - 2021-2022 Ram 2500-5500 20">
OBD2 Scanner Diagnostic Tool, Code Reader LAUN CH CR529, 2024 ABS SRS Scan Tool, check engine light scanner, OBD2 Scanner car code reader, full OBDⅡ Modes, Read/Clear Codes, 5 yrs warran.,fr-ee update
  • Check Engine Light Killer ➤ Annoying engine error light keeps popping out? No frustrating. LAUN CH CR529 is born to kill the Check Engine Light on your dashboard. This obd2 scanner can clear the trouble codes in seconds, save you a bundle in unwanted repair cost, and help you make the proper repairs without any guess work.
  • Patented One-Click Smog Checker ➤ How effective this scan tool is? You will be completely blown away. With just one press of a button to run a quick check, you’ll see if the car is ready to pass the emission test, without the hassle of driving around endlessly, or continuously coming back to the repair shop for retest.
  • Effective Car Status Analyzer ➤ Want to get educated enough before hitting the dealer? Live Data shows clearly and vividly in graphical way, being super easy for you to ensure if the data are in normal conditions / ranges, or not. Red-Yellow-Green LEDs indicate vehicle’s status visually, to avoid unnecessary step-to-step operations.
  • Wide-Ranging Cars Supporter ➤ Doubt about the compatibility? The diagnostic scanner can be used regardless of the type of your vehicle, as long as it is OBD2 compliant (1996 and newer): KWP2000, ISO9141, J1850 VPW, J1850 PWM and CAN. Multiple language option is also packed: English, French, Spanish, German, Portuguese, Russian, Japanese.
  • A Necessity in Toolbox ➤ Classic and solid design to withstand everyday shocks; HELP shortcut key for quick access to commonly tips; Plug & Play, no battery required; AutoVin, DTC LookUp, Data Playback and Print etc. Whether you’re a home car owner or an auto mechanic, with CR529, you can save thousands of dollars on car maintenance, save time and effort on repairs, and dramatically improve your car’s lifespan / performance.

Last update on 2024-02-13 / Affiliate links / Images from Amazon Product Advertising API

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