Z87 – Internal ECM Short May Cause Loss of Drive Power – 2022 Ram 3500, 3500 Cab Chassis, Ram 2500, & 4500/5500 Cab Chassis

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August 26, 2022 NHTSA CAMPAIGN NUMBER: 22V642000

Internal ECM Short May Cause Loss of Drive Power

An internal loss of communication can result in a loss of drive power, increasing the risk of a crash.

 

NHTSA Campaign Number: 22V642

Manufacturer Chrysler (FCA US, LLC)

Components ENGINE AND ENGINE COOLING

Potential Number of Units Affected 4,907

 

Summary

Chrysler (FCA US, LLC) is recalling certain 2022 Ram 3500, 3500 Cab Chassis, Ram 2500, and 4500 and 5500 Cab Chassis vehicles equipped with Cummins 6.7L turbo diesel engines. The engine control module (ECM) may have been built with a misaligned capacitor that can short-circuit, resulting in an internal loss of communication.

 

Remedy

Dealers will replace the ECM, free of charge. Owner notification letters were mailed October 20, 2022. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC’s number for this recall is Z87.

 

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 – Z87

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

 

REASON FOR THIS SAFETY RECALL

Some of the above vehicles may have been built with a Powertrain Control Module (PCM) with a misaligned capacitor which could create a short to ground and cause an internal PCM loss of communication. An internal loss of communication could result in a loss of motive power, which can cause a vehicle crash without prior warning.

 

SERVICE ACTION

FCA US will conduct a voluntary safety recall to replace and reprogram the PCM. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 3rd Quarter of 2022.

 


October 2022

Dealer Service Instructions for:

Safety Recall Z87 / NHTSA 22V-642 Powertrain Control Module

 

NOTE:  4500/5500 Cab Chassis repairs can only be performed by BusinessLink Dealers.  Non BusinessLink Dealers should not order parts or perform the repair.

 

Remedy Available

2022 (DJ) Ram 2500 Pickup
(DD) Ram 3500 Cab Chassis
(DP) Ram 4500/5500 Cab Chassis
(D2) Ram 3500 Pickup

 

NOTE:  This recall applies only to the above vehicles equipped with a 6.7L Diesel Engine (sales codes ETL/ETM/ETN).

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 toapply 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 Powertrain Control Module (PCM) on about 5,000 of the above vehicles may have been built with a misaligned capacitor which could create a short to ground and cause an internal PCM loss of communication. An internal loss of communication could result in a loss of motive power, which can cause a vehicle crash without prior warning.

 

Repair

Replace and reprogram the PCM.

 

Alternate Transportation

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if the vehicle must be held overnight.

 

Parts Information

Part Number Description
CSANZ871AA Powertrain Control Module

 

Parts Return

This recall part will be subject to parts return.

Return the Powertrain Control Module to the PDC following the standard core return policy. Dealers will be reimbursed for the core once received by the PDC.

 

Special Tools

The following special tools are required to perform this repair:

➢ NPN wiTECH MicroPod II
➢ NPN Laptop Computer
➢ NPN wiTECH Software

 

Service Procedure

A Powertrain Control Module Removal Procedure

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

 

  1. Loosen the ground terminal nut and remove the negative battery cable with IBS from the battery and isolate it.

 

  1. Raise and support the vehicle.

 

  1. Remove the left front tire and wheel.

 

  1. Remove the left wheelhouse splash shield screws and remove the splash shield (Figure 2).

 

  1. Loosen the charge air cooler hose from the air flow control valve.

 

  1. Remove the fasteners securing the transmission wire harness to the PCM (Figure 3).

 

  1. Remove the fasteners securing the engine wire harness to the PCM (Figure 3).

 

  1. Disconnect the engine (1) and transmission (2) wire harness connectors from the PCM (Figure 4).

 

CAUNTION: If the connector latch is packed with dirt or debris, clean connector latch first with electrical contact cleaner otherwise damage to the connector housing may result when trying to open a dirty connector.

 

  1. Remove the (4) fasteners attaching the PCM to the engine block bracket (Figure 5).

 

  1. Rotate the PCM as shown and remove the PCM (Figure 6).

 

  1. Proceed to section Powertrain Control Module Installation Procedure

 

B. Powertrain Control Module Installation Procedure

NOTE: Do not apply paint to the PCM or a poor ground will result.

 

  1. Align and install the PCM to the mounting bracket and tighten the fasteners to 24N∙m (18ft. Lbs.) (Figure 5).

 

  1. Check pins in wire harness connectors for corrosion, damage or dirt intrusion. Also, check all the PCM pins for being bent. Repair as necessary.  Damaged, dirty, bent or corroded pins could result in poor conductivity, causing intermittent electrical issues or DTCs.

 

  1. Clean pins in the wire harness connectors with an electrical contact cleaner.

 

  1. Connect the engine and transmission wire harness connectors to the PCM and rotate the latches closed (Figure 4).

 

  1. Install the fasteners securing the engine wire harness to the PCM and tighten them securely.

 

  1. Install the fasteners securing the transmission wire harness to the PCM and tighten them securely.

 

  1. Install the charge air cooler hose to the air flow control valve.

 

  1. Install the wheelhouse splash shield.

 

  1. Install the push-pins and install the screws tighten the screws securely.

 

  1. Install the left front tire and wheel and tighten the wheel lug nuts in a star pattern to to Cone Lug 176N∙m (130ft. Lbs.) Flanged Lug 175N∙m (129ft. Lbs.).

 

  1. Lower the vehicle and reconnect the negative battery cable with IBS to the negative post and tighten to 7N∙m (62In. Lbs.).

 

  1. Proceed to section: Reprogramming the PCM Procedure

 

C. Reprogramming the PCM Procedure

CAUTION: Do not interrupt the software update process in any way once it has begun. It may cause permanent damage to the PCM which will require replacement. 

 

NOTE: The wiTECH scan tool must be used to perform this recall.  The wiTECH software is required to be at the latest release level before performing this procedure.

 

  1. Open the hood. Install a battery charger and verify that the charging rate provides 13.0 to 13.5 volts.  Do not allow the charger to time out during the flash process.  Set the battery charger timer (if so equipped) to continuous charge.

 

NOTE:  Use an accurate stand-alone voltmeter.  The battery charger volt meter may not be sufficiently accurate.  Voltages outside of the specified range will cause an unsuccessful flash.  If voltage reading is too high, apply an electrical load by activating the park or headlamps and/or HVAC blower motor to lower the voltage.

 

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

 

  1. Place the ignition in the “RUN” position.

 

  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. Manually enter the VIN.

 

  1. From the “Action Items” screen, select the “Topology” tab.

 

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

 

  1. From the PCM tab, select the PCM flash part number. Read the flash special instructions page.  Select “OK” to continue.

 

  1. From the flash ECU agreement page, agree to terms by checking the box.

 

  1. Select “Flash ECU” and then follow the wiTECH screen instructions to complete the flash.

 

  1. Clear all DTC’s.

 

  1. From the “Home” screen, select “ECU View”.

 

  1. Select “PCM”.

 

  1. Select “ functions”.

 

  1. Select “Check PCM VIN” and follow the on-screen instructions. When complete, select “Finish”.

 

  1. Navigate back to the home screen and select the Body Control Module (BCM).

 

  1. Select the “ Functions” menu.

 

  1. Run the “Immobilizer ECU Replace” routine.

 

  1. Key OFF ignition for a minimum of 60 seconds (1 minute) and then Key ON ignition for a minimum of 60 seconds (1 minute) after running the Immobilizer ECU replace routine.

 

  1. Select PCM, then Function.

 

  1. Select PCM Configuration.

 

  1. Select “Oil Life Restore” follow screen prompts.

 

  1. Return to the topology screen.

 

  1. Select ABS module icon.

 

  1. Select functions.

 

  1. Perform the “Brake Pedal Calibration” procedure as follows:

a. Park the vehicle on level ground.

 

NOTE: When performing the Brake Pedal Calibration Learn routine, make sure the brake pedal is NOT pressed.

 

NOTE: Not all PCM’s support the Brake Pedal Learn. If the PCM supports, it the routine will be available.

 

b. With the scan tool, under the ABS “Miscellaneous Functions” menu, select and run the “Brake Pedal Learn” routine.

 

NOTE: Due to the PCM/ TCM programming procedure, a DTC may be set in other ECU’s within the vehicle. Some DTCs may cause the MIL to illuminate. From the “Home” screen select “System View”. Then select “All DTC’s”. Press “Clear All Stored DTC’s” if there are any DTC’s shown on the list.

 

NOTE: After Programming the PCM, the vehicle needs to be test driven for coolant temperature to reach 180 degrees Fahrenheit and then allow for 10 minutes (68 RFE) or 90 seconds (Aisin) power down to allow the Exhaust Gas Recirculation (EGR) system auto-zero to store and then key ON for it to learn.

 

  1. Remove the wiTECH micro pod II from the vehicle, disconnect the battery charger from the vehicle.

 

  1. Return the vehicle to the customer.

 


Chronology :

  • On August 2, 2022, the FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) organization opened an investigation into 2022 MY Ram 2500, 3500, and 3500/4500/5500 Cab Chassis vehicles based on information from the vehicle assembly plant regarding suspect ECMs.
  • During August 2022, FCA US TSRC reviewed traceability records and met with FCA US manufacturing and determined certain Ram 2500, 3500, and 3500/4500/5500 Cab Chassis vehicles may have been released from the assembly plant with suspect ECMs.
  • As of August 15, 2022, FCA US has identified zero customer assistance records, two warranty claims, and zero field reports potentially related to this issue for all markets with dates of receipt of July 6, 2022 and August 5, 2022.
  • As of August 15, 2022, FCA US is not aware of any accidents or injuries potentially related to this issue for all markets.
  • On August 19, 2022, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.

 


4 Affected Products

Vehicles

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

 


10 Associated Documents

Defect Notice 573 Report

RCLRPT-22V642-5484.PDF 216.969KB

RCLRPT-22V642-5484

 


Manufacturer Notices(to Dealers,etc) – NSRAC re New Safety Recall

RCMN-22V642-4637.pdf 49.023KB

RCMN-22V642-4637

 


Recall Acknowledgement

RCAK-22V642-6914.pdf 645.261KB

RCAK-22V642-6914

 


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

RCMN-22V642-0387.pdf 52.752KB

RCMN-22V642-0387

 


Remedy Instructions and TSB

RCRIT-22V642-6245.pdf 972.34KB

RCRIT-22V642-6245

 


ISSUED Owner Notification Letter(Part 577)

RCONL-22V642-9332.pdf 174.95KB

RCONL-22V642-9332

 


Recall Quarterly Report #1, 2022-4

RCLQRT-22V642-9444.PDF 211.152KB

RCLQRT-22V642-9444

 


ISSUED Renotification Notice

RCRN-22V642-8826.pdf 102.514KB

RCRN-22V642-8826

 


Miscellaneous Document – Email Blast re Details of the Recall

RMISC-22V642-0778.pdf 244.033KB

RMISC-22V642-0778

 


Recall Quarterly Report #2, 2023-1

RCLQRT-22V642-7390.PDF 211.257KB

RCLQRT-22V642-7390

 


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=22V642&docType=RCL

 


 

Reprogramming

Chrysler J2534 Application Overview

 

DRB III Emulator

Flash Availability - J2534/Pass Thru Device

Vehicle to Diagnostic Tool Reference Chart

 

Chrysler Recommended J2534 Devices

For Chrysler recommended J2534 device, see below table.

J2534 Device Firmware Version
CTC Vehicle Box * 1.9
UCAN 2 1.0
Blue Streak -2534 Global Programmer 2.10
Actia I+ME Passthru 2.07

* Chrysler recommends the CTC Vehicle Box Device for Chrysler SCI ECU reprogramming. SCI reprogramming is used on most PCMs and TCMs prior to the introduction of CAN bus vehicles which began in 2004 (Durango).

 

Compatible J2534 Devices

Z87 - Internal ECM Short May Cause Loss of Drive Power - 2022 Ram 3500, 3500 Cab Chassis, Ram 2500, & 4500/5500 Cab Chassis | small light CarDAQ-Plus 3 All Makes J2534 Reprogramming Tool
Z87 - Internal ECM Short May Cause Loss of Drive Power - 2022 Ram 3500, 3500 Cab Chassis, Ram 2500, & 4500/5500 Cab Chassis | small light CarDAQ-Plus 2 Diagnostic Code Reader and J2534 Programming Tool
Z87 - Internal ECM Short May Cause Loss of Drive Power - 2022 Ram 3500, 3500 Cab Chassis, Ram 2500, & 4500/5500 Cab Chassis | small light CarDAQ-Plus
Z87 - Internal ECM Short May Cause Loss of Drive Power - 2022 Ram 3500, 3500 Cab Chassis, Ram 2500, & 4500/5500 Cab Chassis | small light CarDAQ-M
Z87 - Internal ECM Short May Cause Loss of Drive Power - 2022 Ram 3500, 3500 Cab Chassis, Ram 2500, & 4500/5500 Cab Chassis | small light VSI J2534 ECU Reprogrammer
Z87 - Internal ECM Short May Cause Loss of Drive Power - 2022 Ram 3500, 3500 Cab Chassis, Ram 2500, & 4500/5500 Cab Chassis | small light

Bosch Automotive Tools MTECH2 Mastertech II J2534 VCI with Wired/Wireless Capability for OEM Reprogramming and Diagnostics on GM, Ford, FCA, Nissan/Infiniti, Honda/Acura, and Toyota/Lexus Vehicles

Z87 - Internal ECM Short May Cause Loss of Drive Power - 2022 Ram 3500, 3500 Cab Chassis, Ram 2500, & 4500/5500 Cab Chassis | small light

RAP2 OEM J2534 Remote Reprogramming Tool

Z87 - Internal ECM Short May Cause Loss of Drive Power - 2022 Ram 3500, 3500 Cab Chassis, Ram 2500, & 4500/5500 Cab Chassis | small light

BOSCH Automotive Tools MTECH2 Mastertech II J2534 VCI

Z87 - Internal ECM Short May Cause Loss of Drive Power - 2022 Ram 3500, 3500 Cab Chassis, Ram 2500, & 4500/5500 Cab Chassis | small light

Autel MaxiFlash VCI Vehicle Communication Interface J2534 PassThru ECU Programming Device Bluetooth Connection Internet Update Support CAN FD, 4 CAN Channels, DoIP, D-PDU Works with PC or Autel MS909

Z87 - Internal ECM Short May Cause Loss of Drive Power - 2022 Ram 3500, 3500 Cab Chassis, Ram 2500, & 4500/5500 Cab Chassis | small light

GODIAG J2534

 


Click on the link below to:

Download J2534 Application

(Install the wiTECH 2.0 J2534 Application on your computer)

Download the Setup Utility

(Configure your microPod/MDP device)

Launch wiTECH 2.0

(Once subscription and users are assigned to a tool please follow this link to access wiTECH)

https://www.mopartsp.com/support

 


Chrysler J2534 Manual

wiTECH Software

www.techauthority.com

 


 

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