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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:
|
wiTECH MicroPod II |
|
Laptop Computer |
|
wiTECH Software |
|
Laser Infrared Thermometer MINIMUM specifications:
Range: -30C to 200C |
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.
- Open the hood.
- Connect the wiTECH micro pod II to the vehicle data link connector.
- Open the wiTECH 2.0 website.
- Enter your “User id” and “Password” and your “Dealer Code”, then select “Sign In” at the bottom of the screen. Click “Accept”.
- From the “Vehicle Selection” screen, select the vehicle to be updated.
- Turn the ignition to the “ON”
- From the “Topology” tab, select the “PCM” icon.
- Select “System Tests”.
- Select “Grid Heater Relay Test”.
- Select “Continue” (Figure 1).
- Place check mark in box then select “Continue” (Figure 2).
- Follow and complete all wiTECH screen prompts; through 9 test sequences.
- Using an Infrared Thermometer, set measurement to read temperature in Celsius ONLY.
- Take an initial surface temperature of the grid heater relay, in Celsius, for your reference.
- 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.
- Select view the DTCs.
- If no DTCs are present, the procedure is complete.
- Place the ignition in the “OFF” position and then remove the wiTECH micro pod II device from the vehicle.
- 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.
- Disconnect the Intelligent Battery Sensor (IBS) wire harness connector (Figure 5).
- Loosen the air intake hose clamp and remove the clean air hose from turbocharger (Figure 6).
- Loosen the air hose clamp from the air cleaner housing and remove the clean air hose (Figure 6).
- Disconnect the intake air heater relay wire harness connector (Figure 7).
- Remove the nuts and the cables from intake air heater relay. Note position of cables before removing (Figure 7).
- 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).
- Install the NEW intake air heater relay in the bracket (Figure 7).
- Install the cables to the intake air heater relay and tighten nuts to 15N·m (11ft. lbs.). (Figure 5).
- Connect the intake air heater relay wire harness connector (Figure 6).
- Install the clean air hose and securely tighten the clamp (Figure 6).
- 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 5).
- Connect the IBS wire harness connector (Figure 5).
- Close the hood and return the vehicle to the customer or vehicle inventory.
C. Intake Air Heater Relay RTV Application Procedure
- Disconnect the Intelligent Battery Sensor (IBS) wire harness connector (Figure 8).
- Loosen the air intake hose clamp and remove the clean air hose from turbocharger (Figure 9).
- Loosen the air hose clamp from the air cleaner housing and remove the clean air hose (Figure 9).
- Disconnect the intake air heater relay wire harness connector (Figure 10).
- Remove the nuts and the cables from intake air heater relay. Note position of cables before removing (Figure 10).
- 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).
- 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 11).
- 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).
- Allow the RTV to cure (Approximately 15min).
- Install the intake air heater relay in the bracket (Figure 12).
- Install the cables to the intake air heater relay and tighten nuts to 15N·m (11ft. lbs.). (Figure 10).
- Connect the intake air heater relay wire harness connector (Figure 10).
- Install the clean air hose and securely tighten the clamp (Figure 9).
- 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 8).
- Connect the IBS wire harness connector (Figure 8).
- 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
ISSUED Owner Notification Letter(Part 577)
RCONL-21V798-8294.pdf 586.521KB
Recall 573 Report
RCLRPT-21V798-1210.PDF 217.41KB
Recall 573 Report
RCLRPT-21V798-7930.PDF 217.514KB
Recall Quarterly Report #1, 2021-4
RCLQRT-21V798-7515.PDF 211.153KB
ISSUED Owner Notification Letter(Part 577)
RCONL-21V798-8588.pdf 583.327KB
Recall 573 Report
RCLRPT-21V798-6365.PDF 217.514KB
ISSUED Owner Notification Letter(Part 577)
RCONL-21V798-8127.pdf 585.953KB
Recall Acknowledgement
RCAK-21V798-3027.pdf 645.397KB
Remedy Instructions and TSB
RCRIT-21V798-5883.pdf 2309.809KB
Remedy Instructions and TSB
RCRIT-21V798-3085.pdf 2309.23KB
Recall 573 Report
RCLRPT-21V798-9650.PDF 217.41KB
Defect Notice 573 Report
RCLRPT-21V798-8942.PDF 217.33KB
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
Renotification Notice
RCRN-21V798-1000.pdf 1537.491KB
ISSUED Renotification Notice
RCRN-21V798-9633.pdf 134.356KB
Recall 573 Report
RCLRPT-21V798-2583.PDF 217.514KB
Recall Quarterly Report
RCLQRT-21V798-6070.PDF 211.258KB
Recall Quarterly Report #3, 2022-2
RCLQRT-21V798-4344.PDF 211.354KB
Recall Quarterly Report #4, 2022-3
RCLQRT-21V798-6030.PDF 211.465KB
Latest Recalls Documents
https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V798&docType=RCL
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Schedule your FREE repair today! URGENT SAFETY RECALL INTAKE AIR HEATER RELAY — Y76/NHTSA 21V-798 [MY Make Model] AA111111 Dear CUSTOMER NAME: Please bring your vehicle and this card to your scheduled appointment. We apologize for any inconvenience and do appreciate your attention to this urgent matter. Safety recall campaign Y76/NHTSA 21V-798 is open on your [MY Make Model]. ATENCIÓN! La unidad descrita en esta carta tiene un llamado a revisión pendiente por realizer. Para protegerlo a usted y a su familia, es urgente que se comunique con el grupo FCA US al teléfono 1-800-853-1403 con el fin de programar una cita y se reparada su unidad sin costo para usted. 0000150/#102894/Y76-FST Call 1-800-853-1403 Visit recalls.mopar.com to locate your closest dealer Download the Mopar Owner’s Companion App at either the App or Google Play Stores LOGO VEHICLE PICTURE
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Schedule your FREE repair today! URGENT SAFETY RECALL INNER FENDER LINERS — K13/10V-236 Dear : Please bring your vehicle and this card to your scheduled appointment. We apologize for any inconvenience and do appreciate your attention to this urgent matter. Safety recall campaign K13/10V-236 is open on your ® . ATENCIÓN! La unidad descrita en esta carta tiene un llamado a revisión pendiente por realizer. Para protegerlo a usted y a su familia, es urgente que se comunique con el grupo FCA US al teléfono 1-800-853-1403 con el fin de programar una cita y se reparada su unidad sin costo para usted. 0000046/#102666/K13-SPC Call 1-800-853-1403 Visit recalls.mopar.com to locate your closest dealer Download the Mopar Owner’s Companion App at either the App or Google Play Stores
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Copyright 2021, FCA US LLC, All Rights Reserved (kka) 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. 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. 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. Remedy Available 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 Safety Recall Y76 – Intake Air Heater Relay Page 2 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. o 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. o 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. Repair Safety Recall Y76 – Intake Air Heater Relay Page 3 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 No parts return required for this campaign. 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 Parts Information Parts Return Special Tools Safety Recall Y76 – Intake Air Heater Relay Page 4 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. 2. Connect the wiTECH micro pod II to the vehicle data link connector. 3. Open the wiTECH 2.0 website. 4. Enter your “User id” and “Password” and your “Dealer Code”, then select “Sign In” at the bottom of the screen. Click “Accept”. 5. From the “Vehicle Selection” screen, select the vehicle to be updated. 6. Turn the ignition to the “ON” position. 7. From the “Topology” tab, select the “PCM” icon. 8. Select “System Tests”. 9. Select “Grid Heater Relay Test”. 10. Select “Continue” (Figure 1). Service Procedure Figure 1 – Grid Heater Test Selection Select Continue Safety Recall Y76 – Intake Air Heater Relay Page 5 11. Place check mark in box then select “Continue” (Figure 2). 12. Follow and complete all wiTECH screen prompts; through 9 test sequences. 13. Using an Infrared Thermometer, set measurement to read temperature in Celsius ONLY. 14. Take an initial surface temperature of the grid heater relay, in Celsius, for your reference. 15. 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. Service Procedure [Continued] Figure 3 – Temperature Measurement Location Measure Temperature Here Figure 2 – Check Box Safety Recall Y76 – Intake Air Heater Relay Page 6 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. 16. Select view the DTCs. 17. If no DTCs are present, the procedure is complete. 18. Place the ignition in the “OFF” position and then remove the wiTECH micro pod II device from the vehicle. 19. 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. Service Procedure [Continued] Safety Recall Y76 – Intake Air Heater Relay Page 7 B. Intake Air Heater Relay Replacement Procedure. 1. Disconnect the Intelligent Battery Sensor (IBS) wire harness connector (Figure 5). 2. Loosen the ground terminal nut and remove the negative battery cables with IBS from the battery and isolate it (Figure 5). 3. Loosen the air intake hose clamp and remove the clean air hose from turbocharger (Figure 6). 4. Loosen the air hose clamp from the air cleaner housing and remove the clean air hose (Figure 6). Service Procedure [Continued] Figure 6 – Air Intake Hose Figure 5 – Engine Compartment INTELLIGENT BATTERY SENSOR (IBS) WIRE HARNESS CONNECTOR NEGATIVE BATTERY CABLE (A) NEGATIVE BATTERY CABLE (B) AIR INTAKE HOSE CLAMPS Safety Recall Y76 – Intake Air Heater Relay Page 8 5. Disconnect the intake air heater relay wire harness connector (Figure 7). 6. Remove the nuts and the cables from intake air heater relay. Note position of cables before removing (Figure 7). 7. 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). 8. Install the NEW intake air heater relay in the bracket (Figure 7). 9. Install the cables to the intake air heater relay and tighten nuts to 15N·m (11ft. lbs.). (Figure 5). 10. Connect the intake air heater relay wire harness connector (Figure 6). 11. Install the clean air hose and securely tighten the clamp (Figure 6). Service Procedure [Continued] Figure 7 – Intake Air Heater Relay NUTS WIRE HARNESS CONNECTOR CABLES RELAY Safety Recall Y76 – Intake Air Heater Relay Page 9 12. Install the clean air hose to the turbocharger and securely tighten the clamp. 13. Install the negative battery cables with IBS to the negative posts and tighten to 7N·m (62 In. lbs.) (Figure 5). 14. Connect the IBS wire harness connector (Figure 5). 15. Close the hood and return the vehicle to the customer or vehicle inventory. Service Procedure [Continued] Safety Recall Y76 – Intake Air Heater Relay Page 10 C. Intake Air Heater Relay RTV Application Procedure 1. Disconnect the Intelligent Battery Sensor (IBS) wire harness connector (Figure 8). 2. Loosen the ground terminal nut and remove the negative battery cables with IBS from the battery and isolate it (Figure 8). 3. Loosen the air intake hose clamp and remove the clean air hose from turbocharger (Figure 9). 4. Loosen the air hose clamp from the air cleaner housing and remove the clean air hose (Figure 9). Service Procedure [Continued] Figure 9 – Air Intake Hose Figure 8 – Engine Compartment INTELLIGENT BATTERY SENSOR (IBS) WIRE HARNESS CONNECTOR NEGATIVE BATTERY CABLE (A) NEGATIVE BATTERY CABLE (B) AIR INTAKE HOSE CLAMPS Safety Recall Y76 – Intake Air Heater Relay Page 11 5. Disconnect the intake air heater relay wire harness connector (Figure 10). 6. Remove the nuts and the cables from intake air heater relay. Note position of cables before removing (Figure 10). 7. 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). 8. 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. Service Procedure [Continued] Figure 10 – Intake Air Heater Relay NUTS WIRE HARNESS CONNECTOR CABLES RELAY Safety Recall Y76 – Intake Air Heater Relay Page 12 9. 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). Service Procedure [Continued] Figure 11 – RTV Application Procedure RTV APPLICATION STEPS A) BUSS-BAR HOLES B) OUTER SIDES OF BUSS-BARS C) RELAY SURFACE B) OUTER BUSS-BAR SIDES C) RELAY SURFACE A) Buss-Bar Holes Safety Recall Y76 – Intake Air Heater Relay Page 13 10. 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). 11. Allow the RTV to cure (Approximately 15min). 12. Install the intake air heater relay in the bracket (Figure 12). 13. Install the cables to the intake air heater relay and tighten nuts to 15N·m (11ft. lbs.). (Figure 10). 14. Connect the intake air heater relay wire harness connector (Figure 10). 15. Install the clean air hose and securely tighten the clamp (Figure 9). 16. Install the clean air hose to the turbocharger and securely tighten the clamp. 17. Install the negative battery cables with IBS to the negative posts and tighten to 7N·m (62 In. lbs.) (Figure 8). 18. Connect the IBS wire harness connector (Figure 8). 19. Close the hood and return the vehicle to the customer or vehicle inventory. Service Procedure [Continued] Figure 12 – Skimming Excessive RTV Safety Recall Y76 – Intake Air Heater Relay Page 14 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 the following labor operation numbers and time allowances: Labor Operation Time Number Allowance Inspect Vehicle Engine Hours 08-Y7-61-81 0.2 hours Inspect and Perform Grid Heater Relay Test 08-Y7-61-82 0.8 hours Apply Protective Layer on Relay 08-Y7-61-60 0.6 hours (Applies to 2021 vehicles that have NOT completed Y08 recall) NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. To view this notification on DealerCONNECT, select “Global Recall System” on the Service tab, then click on the description of this notification. 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. Completion Reporting and Reimbursement Dealer Notification Owner Notification and Service Scheduling Safety Recall Y76 – Intake Air Heater Relay Page 15 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. 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 Vehicle Lists, Global Recall System, VIP and Dealer Follow Up Additional Information This notice applies to your vehicle, Y76/NHTSA 21V-798 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 recalls.mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App. 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 Y76. IMPORTANT SAFETY RECALL Intake Air Heater Relay Dear [Name], This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Owners of vehicles previously notified of the Y08 recall (NHTSA 21V-163) will need to bring their vehicle in for recall completion, regardless of having the Y08 repair performed. FCA US has decided that a defect, which relates to motor vehicle safety, exists in certain [2021 – 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. 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? Your vehicle [1] may experience an engine compartment fire originating from an electrical short in the Intake Air Heater Relay, which can potentially lead to the risk of 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. Customers are advised to not park these vehicles inside of buildings or structures, or near other vehicles until the vehicle has the final repair completed. 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 the Intake Air Heater Relay. The estimated repair time is about one 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. 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 [Model Year and Model] VIN XXXXXXXXXXXXXXXXX LOGO VEHICLE PICTURE QR Code [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 1-800-424- 9153), 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. Mr. Mrs. Customer 1234 Main Street Hometown, MI 48371
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This notice applies to your vehicle, Y76/NHTSA 21V-798 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 recalls.mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App. 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 Y76. IMPORTANT SAFETY RECALL Intake Air Heater Relay Dear [Name], This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Owners of vehicles previously notified of the Y08 recall (NHTSA 21V-163) will need to bring their vehicle in for recall completion, regardless of having the Y08 repair performed. FCA US has decided that a defect, which relates to motor vehicle safety, exists in certain [2021 – 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. 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? Your vehicle [1] may experience an engine compartment fire originating from an electrical short in the Intake Air Heater Relay, which can potentially lead to the risk of 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. Customers are advised to not park these vehicles inside of buildings or structures, or near other vehicles until the vehicle has the final repair completed. 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 the Intake Air Heater Relay. Depending on inspection results, your dealer will install a protective barrier on the relay, replace the relay, or close the recall without further action. The estimated repair time is about two hours. 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. 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 [Model Year and Model] VIN XXXXXXXXXXXXXXXXX LOGO VEHICLE PICTURE QR Code FCA US LLC Mr. Mrs. Customer 1234 Main Street Hometown, MI 48371
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This notice applies to your vehicle, Y76/NHTSA 21V-798 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 recalls.mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App. 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 Y76. IMPORTANT SAFETY RECALL Intake Air Heater Relay Dear [Name], This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. Owners of vehicles previously notified of the Y08 recall (NHTSA 21V-163) will need to bring their vehicle in for recall completion, regardless of having the Y08 repair performed. FCA US has decided that a defect, which relates to motor vehicle safety, exists in certain [2021 – 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. 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? Your vehicle [1] may experience an engine compartment fire originating from an electrical short in the Intake Air Heater Relay, which can potentially lead to the risk of 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. Customers are advised to not park these vehicles inside of buildings or structures, or near other vehicles until the vehicle has the final repair completed. 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 the Intake Air Heater Relay. The estimated repair time is about one 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. 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 [Model Year and Model] VIN XXXXXXXXXXXXXXXXX LOGO VEHICLE PICTURE QR Code [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 1-800-424- 9153), 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. Mr. Mrs. Customer 1234 Main Street Hometown, MI 48371
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This notice applies to your vehicle, Y76/NHTSA 21V-798 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 recalls.mopar.com, scan the QR code below, or download the Mopar Owner’s Companion App. 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 Y76. IMPORTANT SAFETY RECALL Intake Air Heater Relay 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 [2021 – 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. 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? Your vehicle [1] may experience an engine compartment fire originating from an electrical short in the Intake Air Heater Relay, which can potentially lead to the risk of 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. Customers are advised to not park these vehicles inside of buildings or structures, or near other vehicles until the vehicle has the final repair completed. 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 the Intake Air Heater Relay. Depending on inspection results, your dealer will either replace the relay or close the recall without further action. The estimated repair time is about one 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. 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 [Model Year and Model] VIN XXXXXXXXXXXXXXXXX LOGO VEHICLE PICTURE QR Code [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 1-800-424- 9153), 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. Mr. Mrs. Customer 1234 Main Street Hometown, MI 48371
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10/15/2021 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. 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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