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

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 ChryslereBay logo (FCA US, LLC)

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 131,177

 

Summary

ChryslereBay logo (FCA US, LLC) is recalling certain 2021-2022 RameBay logo 3500, 2500 pickup trucks, and RameBay logo 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) RameBay logo 2500 Pickup, (D2) RameBay logo 3500 Pickup, (DD) RameBay logo 3500 Cab Chassis and (DP) RameBay logo 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)RameBay logo 2500 Pickup
(D2)RameBay logo 3500 Pickup
(DD)RameBay logo 3500 Cab Chassis
(DP)RameBay logo 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 NumberQty.Description
04883971AC1RTV, 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 IIeBay logo
  • 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 RameBay logo 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

MAKEMODELYEAR
RAMeBay logo25002021-2022
RAMeBay logo35002021-2022
RAMeBay logo45002021-2022
RAMeBay logo55002021-2022

 


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) RameBay logo 2500 Pickup, (D2) RameBay logo 3500 Pickup, (DD) RameBay logo 3500 Cab Chassis and (DP) RameBay logo 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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