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November 23, 2022 NHTSA CAMPAIGN NUMBER: 22V865000
Communication Loss May Cause Engine Shutdown
An engine shutdown can cause a loss of drive power, increasing the risk of a crash.
NHTSA Campaign Number: 22V865
Manufacturer Chrysler (FCA US, LLC)
Components ENGINE
Potential Number of Units Affected 62,909
Summary
Chrysler (FCA US, LLC) is recalling certain 2021-2023 Jeep
Wrangler 4xe vehicles equipped with 2.0L Plug-In Hybrid Electric Vehicle engines. A loss of communication may cause an engine shutdown.
Remedy
There is more than one involved component and calibration software. Updating the calibration software in the Transmission Control Module, Hybrid Control Processor and Auxiliary Hybrid Control Processor that changes fail safe from shut down to limp home. Dealers will update the transmission control module software, Hybrid Control Processor and Auxiliary Hybrid Control Processor, free of charge. Owner notification letters were mailed December 22, 2022. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC’s number for this recall ZB7.
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 – ZB7
FCA US LLC (FCA US) has announced a safety recall on certain 2021 through 2023 Model Year (JL) Jeep® Wrangler 4xe PHEV vehicles equipped with a 2.0L engine (sales code ECX).
REASON FOR THIS SAFETY RECALL
Some of the above vehicles may experience an engine shut down condition caused by diagnostic reactions to faults caused by loss of communication. An engine shut down condition may result in an unexpected loss of motive power while driving, which can cause a vehicle crash without prior warning.
SERVICE ACTION
FCA US will conduct a voluntary safety recall on all affected vehicles to update vehicle control software. 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. This recall is estimated to launch in 1st Quarter of 2023.
(Revision 2) February 2023
Dealer Service Instructions for:
Safety Recall ZB7 / NHTSA 22V-865 Loss of Motive Power
NOTE: BPCM flash added to procedure and need to disable contactors removed.
Remedy Available
2021-2023 (JL) Jeep Wrangler 4xe
NOTE: This recall applies only to the above vehicles equipped with a 2.0L Plug-in Hybrid Electric Vehicle (“PHEV”) engine.
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
About 62,900 of the above vehicles may experience an engine shut down condition caused by diagnostic reactions to faults caused by loss of communication. An engine shut down condition may result in an unexpected loss of motive power while driving, which can cause a vehicle crash without prior warning.
Repair
IMPORTANT: Make sure the Battery Pack Control Module (BPCM) calibration software is up to date BEFORE starting the repair process.
Repair process: Update the calibration software in the Power Inverter Module (PIM), comprised of the Hybrid Control Processor (HCP) and Auxiliary Hybrid Control Processor (AHCP), then update the calibration software in the Transmission Control Module (TCM).
IMPORTANT: Software update sequence outlined is CRITICAL!
1. BPCM – MUST be up to date BEFORE starting the repair process.
2. PIM comprised of the HCP and AHCP.
3. TCM
Do NOT deviate from that order or vehicle software will not update properly.
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
No parts are required to perform this service procedure.
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 |
Service Procedure
NOTE: The wiTECH scan tool must be used to perform this Safety Recall. The wiTECH software is required to be at the latest release level before performing this procedure.
NOTE: The Battery Pack Control Module (BPCM), Hybrid Control Processor (HCP), Auxiliary Hybrid Control Processor (AHCP) and Transmission Control Module (TCM) must be updated to the latest available software calibration level after completing this Safety Recall. This flash sequence is critical.
NOTE: If this software update flash process is interrupted/aborted, the flash should be restarted.
NOTE: It is normal for the high voltage charging lamp on the dash to flash like there is a charging system failure while performing software updates.
- 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.
- Connect the wiTECH micro pod II to the vehicle data link connector
- Place the ignition in the “RUN” position.
- Open the wiTECH 2.0 website.
- Enter your “User id” your “Password” and your “Dealer Code”, then select “Finish” at the bottom of the screen.
- Starting at the “Vehicle Selection” screen, select the vehicle to be updated.
- From the “Action Items” screen, select the “All Flashes” tab. Inspect if new software flashes are available for the “BPCM” and/or “HCP” and/or “TCM”.
- If no modules have new software available, then proceed to Step 26 and claim the inspection LOP to complete this recall.
- If one or more modules have new software available, then continue with Step 8 and follow the flash sequence of BPCM, HCP, TCM.
- Create a Vehicle Scan Report (VSR) before proceeding with software updates.
- Ensure there are no current DTCs that could cause concern with modules being flashed. If any questions, please share the VSR with the STAR center.
- From the “Action Items” screen, select the “All Flashes” tab.
- Select “BPCM” by clicking the arrow on the right side of the screen. Read the special flash instructions, then select “OK”. Continue with Step 11.
- If “BPCM” is not displayed as one of the available flashes, the BPCM software is already at the current software level and does not require updating. Proceed to Step 15.
- From the “Flash ECU Agreement” page, agree to terms by “Checking the Box”.
- Select “Flash ECU” and then follow the wiTECH screen instructions to complete the flash.
- Once the software is confirmed to be at the latest available calibration level, select “View DTCs”.
- Select the “Clear All DTCs” tab, then click “Clear All DTCs” and then select “Close”. It may be necessary to cycle the ignition OFF to RUN to clear the codes.
NOTE: The PIM contains two processors, Hybrid Control Processor (HCP) and Auxiliary Hybrid Control Processor (AHCP). The HCP and AHCP are combined into one PIM software update. The software update must begin with updating the HCP. The AHCP will update immediately following the HCP.
- From the “Action Items” screen, select the “All Flashes” tab.
- Select “HCP” by clicking the arrow on the right side of the screen. Read the special flash instructions, then select “OK”. Continue with Step 16.
- If “HCP” is not displayed as one of the available flashes, the PIM software is already at the current software level and does not require updating. Proceed to Step 20.
- From the “Flash ECU Agreement” page, agree to terms by “Checking the Box”.
- Select “Flash ECU” and then follow the wiTECH screen instructions to complete the flash.
- Once the software is confirmed to be at the latest available calibration level, select “View DTCs”.
- Select the “Clear All DTCs” tab, then click “Clear All DTCs” and then select “Close”. It may be necessary to cycle the ignition OFF to RUN to clear the codes.
- From the “Action Items” screen, select the “All Flashes” tab.
- Select “TCM” by clicking the arrow on the right side of the screen. Read the special flash instructions, then select “OK”. Continue with Step 21.
- If “TCM” is not displayed as one of the available flashes, the TCM software is already at the current software level and does not require updating. Proceed to Step 25.
- From the “Flash ECU Agreement” page, agree to terms by “Checking the Box”.
- Select “Flash ECU” and then follow the wiTECH screen instructions to complete the flash.
- Once the software is confirmed to be at the latest available calibration level, select “View DTCs”.
- Select the “Clear All DTCs” tab, then click “Clear All DTCs” and then select “Close”. It may be necessary to cycle the ignition OFF to RUN to clear the codes.
- Create a VSR to ensure P0AA4/P0AA1 or any DTC is not active or pending.
- Turn the ignition to the “OFF” position and then remove the wiTECH micro pod II device from the vehicle.
- Remove the battery charger from the vehicle.
- Return the vehicle to the customer or inventory.
Owner Notification and Service Scheduling
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.
Chronology :
- On September 8, 2021, FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) opened an investigation into 2021-2023 MY Wrangler 4xe PHEVs for a loss of motive power.
- From September 2021, through October 2022, FCA US TSRC conducted an analysis of stall reports and vehicle history and determined that the affected vehicles reported multiple cause and correction details with varied commonality.
- As of November 3, 2022, FCA US is aware of 112 customer assistance records, 196 warranty claims, and 65 field reports potentially related to this issue for all markets with dates of receipt ranging from December 17, 2020, to October 26, 2022.
- As of November 3, 2022, FCA US is aware of two accidents and one injury potentially related to this issue for all markets.
- On November 17, 2022, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.
3 Affected Products
Vehicle
MAKE | MODEL | YEAR |
JEEP![]() | WRANGLER | 2021-2023 |
15 Associated Documents
Manufacturer Notices(to Dealers,etc) – New Safety Recall Advanced Communication – ZB7
Defect Notice 573 Report
RCLRPT-22V865-9895.PDF 213.973KB
Manufacturer Notices(to Dealers,etc) – New Safety Recall Advanced Communication – ZB7
Recall Acknowledgement
RCAK-22V865-1952.pdf 692.321KB
Remedy Instructions and TSB
RCRIT-22V865-0023.pdf 337.965KB
Remedy Instructions and TSB
RCRIT-22V865-4394.pdf 338.914KB
Recall 573 Report – 12/22/22
RCLRPT-22V865-2005.PDF 214.014KB
ISSUED Owner Notification Letter(Part 577)
RCONL-22V865-8324.pdf 175.258KB
Recall Quarterly Report #1, 2022-4
RCLQRT-22V865-1606.PDF 211.151KB
Manufacturer Notices(to Dealers,etc) – Dealer Bulletin re RETRACTED Dealer Service Instructions for: Safety Recall ZB7 / NHTSA 22V-865 Loss of Motive Power
RCMN-22V865-7501.pdf 400.413KB
ISSUED Renotification Notice
RCRN-22V865-8853.pdf 138.051KB
Recall Quarterly Report #2, 2023-1
RCLQRT-22V865-1220.PDF 211.258KB
Miscellaneous Document – FCA USA LLC ZB7 Involved Component Part Numbers Jeep Wrangler PHEV Vehicle Control Calibrations
RMISC-22V865-9808.pdf 101.353KB
Recall 573 Report – 7/13/23
RCLRPT-22V865-1647.PDF 214.298KB
Recall Quarterly Report #3, 2023-2
RCLQRT-22V865-7965.PDF 211.353KB
Latest Recalls Documents
Reprogramming
Chrysler J2534 Application Overview
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
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CarDAQ-Plus 3 All Makes J2534 Reprogramming Tool |
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CarDAQ-Plus 2 Diagnostic Code Reader and J2534 Programming Tool |
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CarDAQ-Plus |
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CarDAQ-M |
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VSI J2534 ECU Reprogrammer |
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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
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SEOCONTENT-START
11/24/2022 New Safety Recall Advanced Communication – ZB7 FCA US LLC (FCA US) has announced a safety recall on certain 2021 through 2023 Model Year (JL) Jeep® Wrangler 4xe PHEV vehicles equipped with a 2.0L engine (sales code ECX). REASON FOR THIS SAFETY RECALL Some of the above vehicles may experience an engine shut down condition caused by diagnostic reactions to faults caused by loss of communication. An engine shut down condition may result in an unexpected loss of motive power while driving, which can cause a vehicle crash without prior warning. SERVICE ACTION FCA US will conduct a voluntary safety recall on all affected vehicles to update vehicle control software. 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. This recall is estimated to launch in 1st Quarter of 2023. 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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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-865 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Chrysler (FCA US, LLC) Submission Date : NOV 23, 2022 NHTSA Recall No. : 22V-865 Manufacturer Recall No. : ZB7 Manufacturer Information : Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive CIMS 482-00-91 Auburn Hills MI 48326-2757 Company phone : 1-800-853-1403 Population : Number of potentially involved : 62,909 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2023 Jeep Wrangler Vehicle Type : Body Style : SUV Power Train : NR Descriptive Information : Some 2021-2023 MY Jeep Wrangler 4xe vehicles equipped with the 2.0L Plug-in Hybrid Electric Vehicle (“PHEV”) engine. The suspect period began on September 2, 2020, when the 2021 MY production began, and ended on August 17, 2022, when the 2023 MY production began with updated vehicle control software. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the PHEV engine or were built after the suspect period. Production Dates : SEP 02, 2020 – AUG 17, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Some 2021-2023 MY Jeep Wrangler 4xe vehicles equipped with the 2.0L PHEV may experience an engine shut down condition caused by diagnostic reactions to faults caused by loss of communication. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : An engine shut down condition may result in an unexpected loss of motive power while driving, which can cause a vehicle crash without prior warning. Description of the Cause : NR Part 573 Safety Recall Report 22V-865 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : None Involved Components : Component Name 1 : Unknown. Root cause is under investigation. Component Description : Unknown. Root cause is under investigation. Component Part Number : Unknown. Root cause is under investigation. Supplier Identification : Component Manufacturer Name : Not a different manufacturer Address : NR NR Country : NR Chronology : • On September 8, 2021, FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) opened an investigation into 2021-2023 MY Wrangler 4xe PHEVs for a loss of motive power. • From September 2021, through October 2022, FCA US TSRC conducted an analysis of stall reports and vehicle history and determined that the affected vehicles reported multiple cause and correction details with varied commonality. • As of November 3, 2022, FCA US is aware of 112 customer assistance records, 196 warranty claims, and 65 field reports potentially related to this issue for all markets with dates of receipt ranging from December 17, 2020, to October 26, 2022. • As of November 3, 2022, FCA US is aware of two accidents and one injury potentially related to this issue for all markets. • On November 17, 2022, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles. Part 573 Safety Recall Report 22V-865 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to update vehicle control software. FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense. How Remedy Component Differs from Recalled Component : Remedy is updated calibration software in the Transmission Control Module, Hybrid Control Processor and Auxiliary Hybrid Control Processor Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : **11/23/2022: FCA US will notify dealers and begin notifying owners on or about 01/12/2023. Planned Dealer Notification Date : JAN 12, 2023 – JAN 12, 2023 Planned Owner Notification Date : JAN 12, 2023 – JAN 12, 2023 * NR – Not Reported
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12/01/2022 New Safety Recall Advanced Communication – ZB7 FCA US LLC (FCA US) has announced a safety recall on certain 2021 through 2023 Model Year (JL) Jeep® Wrangler 4xe PHEV vehicles equipped with a 2.0L engine (sales code ECX). VINs identified as being involved in this campaign are currently live and searchable. Stop sale is in effect for the above-identified vehicles. Vehicles impacted by a stop sale are eligible for reimbursement allowance through the Recall Floorplan Reimbursement Policy (RFPRP), which can be requested upon recall claim submission. REASON FOR THIS SAFETY RECALL Some of the above vehicles may experience an engine shut down condition caused by diagnostic reactions to faults caused by loss of communication. An engine shut down condition may result in an unexpected loss of motive power while driving, which can cause a vehicle crash without prior warning. SERVICE ACTION FCA US will conduct a voluntary safety recall on all affected vehicles to update vehicle control software. 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. This recall is estimated to launch in 1st Quarter of 2023. 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 IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Violation of this requirement by a dealer could result in a civil penalty of up to $21,000 per vehicle. Involved vehicles can be determined by using the VIP inquiry process.
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© Copyright 2023, FCA US LLC, All Rights Reserved (tdb) (Revision 2) February 2023 Dealer Service Instructions for: Safety Recall ZB7 / NHTSA 22V-865 Loss of Motive Power NOTE: BPCM flash added to procedure and need to disable contactors removed. 2021-2023 (JL) Jeep Wrangler 4xe NOTE: This recall applies only to the above vehicles equipped with a 2.0L Plug-in Hybrid Electric Vehicle (“PHEV”) engine. NOTE: Some vehicles above may have been identified as not involved in this recall and therefore have been excluded from this recall. About 62,900 of the above vehicles may experience an engine shut down condition caused by diagnostic reactions to faults caused by loss of communication. An engine shut down condition may result in an unexpected loss of motive power while driving, which can cause a vehicle crash without prior warning. 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 ZB7 — Software Updates Page 2 IMPORTANT: Make sure the Battery Pack Control Module (BPCM) calibration software is up to date BEFORE starting the repair process. Repair process: Update the calibration software in the Power Inverter Module (PIM), comprised of the Hybrid Control Processor (HCP) and Auxiliary Hybrid Control Processor (AHCP), then update the calibration software in the Transmission Control Module (TCM). IMPORTANT: Software update sequence outlined is CRITICAL! 1. BPCM – MUST be up to date BEFORE starting the repair process. 2. PIM comprised of the HCP and AHCP. 3. TCM Do NOT deviate from that order or vehicle software will not update properly. Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if the vehicle must be held overnight. No parts are required to perform this service procedure. No parts return required for this campaign. Repair Alternate Transportation Parts Information Parts Return Safety Recall ZB7 — Software Updates Page 3 The following special tools are required to perform this repair: ➢ NPN wiTECH MicroPod II ➢ NPN Laptop Computer ➢ NPN wiTECH Software Special Tools Safety Recall ZB7 — Software Updates Page 4 NOTE: The wiTECH scan tool must be used to perform this Safety Recall. The wiTECH software is required to be at the latest release level before performing this procedure. NOTE: The Battery Pack Control Module (BPCM), Hybrid Control Processor (HCP), Auxiliary Hybrid Control Processor (AHCP) and Transmission Control Module (TCM) must be updated to the latest available software calibration level after completing this Safety Recall. This flash sequence is critical. NOTE: If this software update flash process is interrupted/aborted, the flash should be restarted. NOTE: It is normal for the high voltage charging lamp on the dash to flash like there is a charging system failure while performing software updates. 1. 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. 2. Connect the wiTECH micro pod II to the vehicle data link connector 3. Place the ignition in the “RUN” position. 4. Open the wiTECH 2.0 website. 5. Enter your “User id” your “Password” and your “Dealer Code”, then select “Finish” at the bottom of the screen. 6. Starting at the “Vehicle Selection” screen, select the vehicle to be updated. 7. From the “Action Items” screen, select the “All Flashes” tab. Inspect if new software flashes are available for the “BPCM” and/or “HCP” and/or “TCM”. ➢ If no modules have new software available, then proceed to Step 26 and claim the inspection LOP to complete this recall. ➢ If one or more modules have new software available, then continue with Step 8 and follow the flash sequence of BPCM, HCP, TCM. Service Procedure Safety Recall ZB7 — Software Updates Page 5 8. Create a Vehicle Scan Report (VSR) before proceeding with software updates. 9. Ensure there are no current DTCs that could cause concern with modules being flashed. If any questions, please share the VSR with the STAR center. 10. From the “Action Items” screen, select the “All Flashes” tab. ➢ Select “BPCM” by clicking the arrow on the right side of the screen. Read the special flash instructions, then select “OK”. Continue with Step 11. ➢ If “BPCM” is not displayed as one of the available flashes, the BPCM software is already at the current software level and does not require updating. Proceed to Step 15. 11. From the “Flash ECU Agreement” page, agree to terms by “Checking the Box”. 12. Select “Flash ECU” and then follow the wiTECH screen instructions to complete the flash. 13. Once the software is confirmed to be at the latest available calibration level, select “View DTCs”. 14. Select the “Clear All DTCs” tab, then click “Clear All DTCs” and then select “Close”. It may be necessary to cycle the ignition OFF to RUN to clear the codes. NOTE: The PIM contains two processors, Hybrid Control Processor (HCP) and Auxiliary Hybrid Control Processor (AHCP). The HCP and AHCP are combined into one PIM software update. The software update must begin with updating the HCP. The AHCP will update immediately following the HCP. Service Procedure [Continued] Safety Recall ZB7 — Software Updates Page 6 15. From the “Action Items” screen, select the “All Flashes” tab. ➢ Select “HCP” by clicking the arrow on the right side of the screen. Read the special flash instructions, then select “OK”. Continue with Step 16. ➢ If “HCP” is not displayed as one of the available flashes, the PIM software is already at the current software level and does not require updating. Proceed to Step 20. 16. From the “Flash ECU Agreement” page, agree to terms by “Checking the Box”. 17. Select “Flash ECU” and then follow the wiTECH screen instructions to complete the flash. 18. Once the software is confirmed to be at the latest available calibration level, select “View DTCs”. 19. Select the “Clear All DTCs” tab, then click “Clear All DTCs” and then select “Close”. It may be necessary to cycle the ignition OFF to RUN to clear the codes. 20. From the “Action Items” screen, select the “All Flashes” tab. ➢ Select “TCM” by clicking the arrow on the right side of the screen. Read the special flash instructions, then select “OK”. Continue with Step 21. ➢ If “TCM” is not displayed as one of the available flashes, the TCM software is already at the current software level and does not require updating. Proceed to Step 25. 21. From the “Flash ECU Agreement” page, agree to terms by “Checking the Box”. 22. Select “Flash ECU” and then follow the wiTECH screen instructions to complete the flash. Service Procedure [Continued] Safety Recall ZB7 — Software Updates Page 7 23. Once the software is confirmed to be at the latest available calibration level, select “View DTCs”. 24. Select the “Clear All DTCs” tab, then click “Clear All DTCs” and then select “Close”. It may be necessary to cycle the ignition OFF to RUN to clear the codes. 25. Create a VSR to ensure P0AA4/P0AA1 or any DTC is not active or pending. 26. Turn the ignition to the “OFF” position and then remove the wiTECH micro pod II device from the vehicle. 27. Remove the battery charger from the vehicle. 28. Return the vehicle to the customer or inventory. Service Procedure [Continued] Safety Recall ZB7 — Software Updates Page 8 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 BPCM, PIM, TCM Software up to Date 18-ZB-71-81 0.2 hours Inspect/Update Applicable Module Software. 18-ZB-71-85 0.2 hours (Use Related Operation LOPs for Applicable Updates) Related Operations Update BPCM software 18-ZB-71-50 0.2 hours Update PIM software 18-ZB-71-51 0.4 hours Update TCM software 18-ZB-71-52 0.2 hours Floor Plan Reimbursement 95-95-95-97 Calculate See Below Floor Plan Reimbursement represents the vehicle’s average daily allowance (see table below) multiplied by the number of days the vehicle was in dealer inventory and not available for sale. This reimbursement is limited to the number of days from the date of the stop sale to the date that the remedy was made available. Note: If the vehicle was received by your dealership (KZX date) AFTER the stop sale date, you will use the KZX date instead of the stop sale date. For this Recall, the stop sale was initiated on 12/01/2022 and the remedy was made available on 12/15/2022, therefore, the number of days cannot exceed 14 days. Vehicle Average Daily Allowance 2021-2023 (JL) Jeep Wrangler 4xe $9.74 NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Completion Reporting and Reimbursement Safety Recall ZB7 — Software Updates Page 9 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. 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. Dealer Notification Owner Notification and Service Scheduling Vehicle Lists, Global Recall System, VIP and Dealer Follow Up Safety Recall ZB7 — Software Updates Page 10 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 Additional Information This notice applies to your vehicle, ZB7/NHTSA 22V-865 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 ZB7. IMPORTANT SAFETY RECALL Loss of Motive Power Dear [Name], This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. FCA US LLC has decided that a defect, which relates to motor vehicle safety, exists in certain [2021 through 2023 Model Year (JL) Jeep® Wrangler 4xe PHEV] vehicles. 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 shut down condition caused by diagnostic reactions to faults caused by loss of communication. An engine shut down condition may result in an unexpected loss of motive power while driving, which can cause a vehicle crash without prior warning. 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 update vehicle control software on all affected vehicles. The estimated repair time is 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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FCA USA LLC ZB7 Involved Component Part Numbers Jeep Wrangler PHEV Vehicle Control Calibrations Submitted on July 13, 2023 Calibration Part Numbers by Model Year 2021 2022 2023 68451035AU 68540072AE 68614244AB 68451036AU 68540073AE 68614245AB 68451040AU 68540074AE 68614246AB 68451042AU 68540075AE 68614247AB 68451043AU 68540076AE 68614248AB 68451044AU 68540077AE 68614249AB 68477940AU 68540078AE 68614250AB 68477941AU 68540079AE 68614251AB 68477942AU 68540080AE 68614252AB 68477943AU 68540081AE 68614253AB 68477944AU 68540082AE 68614254AB 68477945AU 68540083AE 68614255AB Part number by Model Year Hybrid Control Processor 2021 2022 2023 68478030AP 68563824AD 68620361AB 68478033AP 68563827AD 68620364AB 68478031AP 68563825AD 68620362AB 68478037AP 68563829AD 68620366AB 68478032AP 68563826AD 68620363AB 68478034AP 68563828AD 68620365AB Part number by Model Year Transmission Control Processor 2021 2022 2023 68498791AU 68540084AE 68614243AB Auxiliary Hybrid Control Processor Part number by Model Year
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Schedule your FREE repair today! URGENT SAFETY RECALL LOSS OF MOTIVE POWER — ZB7/22V-865 [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 ZB7/22V-865 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. 0000109/#105890/ZB7-FSP 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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This notice applies to your vehicle, ZB7/NHTSA 22V-865 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 ZB7. IMPORTANT SAFETY RECALL Loss of Motive Power Dear [Name], This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act. FCA US LLC has decided that a defect, which relates to motor vehicle safety, exists in certain [2021 through 2023 Model Year (JL) Jeep® Wrangler 4xe PHEV] vehicles. 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 shut down condition caused by diagnostic reactions to faults caused by loss of communication. An engine shut down condition may result in an unexpected loss of motive power while driving, which can cause a vehicle crash without prior warning. 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 update vehicle control software on all affected vehicles. The estimated repair time is 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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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-865 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Chrysler (FCA US, LLC) Submission Date : DEC 22, 2022 NHTSA Recall No. : 22V-865 Manufacturer Recall No. : ZB7 Manufacturer Information : Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive CIMS 482-00-91 Auburn Hills MI 48326-2757 Company phone : 1-800-853-1403 Population : Number of potentially involved : 62,909 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2023 Jeep Wrangler Vehicle Type : Body Style : SUV Power Train : NR Descriptive Information : Some 2021-2023 MY Jeep Wrangler 4xe vehicles equipped with the 2.0L Plug-in Hybrid Electric Vehicle (“PHEV”) engine. The suspect period began on September 2, 2020, when the 2021 MY production began, and ended on August 17, 2022, when the 2023 MY production began with updated vehicle control software. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the PHEV engine or were built after the suspect period. Production Dates : SEP 02, 2020 – AUG 17, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Some 2021-2023 MY Jeep Wrangler 4xe vehicles equipped with the 2.0L PHEV may experience an engine shut down condition caused by diagnostic reactions to faults caused by loss of communication between the Transmission Control Module and the Hybrid Control Processor. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : An engine shut down condition may result in an unexpected loss of motive power while driving, which can cause a vehicle crash without prior warning. Description of the Cause : NR Part 573 Safety Recall Report 22V-865 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : None Involved Components : Component Name 1 : Unknown. Root cause is under investigation. Component Description : Unknown. Root cause is under investigation. Component Part Number : Unknown. Root cause is under investigation. Supplier Identification : Component Manufacturer Name : Not a different manufacturer Address : NR NR Country : NR Chronology : • On September 8, 2021, FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) opened an investigation into 2021-2023 MY Wrangler 4xe PHEVs for a loss of motive power. • From September 2021, through October 2022, FCA US TSRC conducted an analysis of stall reports and vehicle history and determined that the affected vehicles reported multiple cause and correction details with varied commonality. • As of November 3, 2022, FCA US is aware of 112 customer assistance records, 196 warranty claims, and 65 field reports potentially related to this issue for all markets with dates of receipt ranging from December 17, 2020, to October 26, 2022. • As of November 3, 2022, FCA US is aware of two accidents and one injury potentially related to this issue for all markets. • On November 17, 2022, FCA US determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles. Part 573 Safety Recall Report 22V-865 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Remedy : Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to update vehicle control software. FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense. How Remedy Component Differs from Recalled Component : Remedy is updated calibration software in the Transmission Control Module, Hybrid Control Processor and Auxiliary Hybrid Control Processor Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : **11/23/2022: FCA US will notify dealers and begin notifying owners on or about 01/12/2023. Planned Dealer Notification Date : JAN 12, 2023 – JAN 12, 2023 Planned Owner Notification Date : JAN 12, 2023 – JAN 12, 2023 * NR – Not Reported
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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 22V-865 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Chrysler (FCA US, LLC) Submission Date : JUL 13, 2023 NHTSA Recall No. : 22V-865 Manufacturer Recall No. : ZB7 Manufacturer Information : Manufacturer Name : Chrysler (FCA US, LLC) Address : 800 Chrysler Drive CIMS 482-00-91 Auburn Hills MI 48326-2757 Company phone : 1-800-853-1403 Population : Number of potentially involved : 62,909 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2023 Jeep Wrangler Vehicle Type : Body Style : SUV Power Train : NR Descriptive Information : Some 2021-2023 MY Jeep Wrangler 4xe vehicles equipped with the 2.0L Plug-in Hybrid Electric Vehicle (“PHEV”) engine. The suspect period began on September 2, 2020, when the 2021 MY production began, and ended on August 17, 2022, when the 2023 MY production began with updated vehicle control software. The suspect period was determined using supplier and vehicle production records. Similar vehicles not included in the recall population are not equipped with the PHEV engine or were built after the suspect period. Production Dates : SEP 02, 2020 – AUG 17, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : Some 2021-2023 MY Jeep Wrangler 4xe vehicles equipped with the 2.0L PHEV may experience an engine shut down condition caused by diagnostic reactions to faults caused by loss of communication between the Transmission Control Module and the Hybrid Control Processor. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : An engine shut down condition may result in an unexpected loss of motive power while driving, which can cause a vehicle crash without prior warning. Description of the Cause : NR Part 573 Safety Recall Report 22V-865 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Identification of Any Warning that can Occur : None Involved Components : Component Name 1 : ZF Transmission Control Calibration Component Description : Please see the attached supplemental information titled “FCA USA LLC ZB7 Involved Component Part Numbers Jeep Wrangler PHEV Vehicle Control Calibrations – 07132023.pdf” Component Part Number : See attached document referenced above for the vehicle control calibration part numbers. Supplier Identification : Component Manufacturer Name : ZF Group Address : 12001 Tech Center Drive Livonia Michigan 48150 Country : United States Chronology : • On September 8, 2021, FCA US LLC (“FCA US”) Technical Safety and Regulatory Compliance (“TSRC”) opened an investigation into 2021-2023 MY Wrangler 4xe PHEVs for a loss of motive power. • From September 2021, through October 2022, FCA US TSRC conducted an analysis of stall reports and vehicle history and determined that the affected vehicles reported multiple cause and correction details with varied commonality. • As of November 3, 2022, FCA US is aware of 112 customer assistance records, 196 warranty claims, and 65 field reports potentially related to this issue for all markets with dates of receipt ranging from December 17, 2020, to October 26, 2022. • As of November 3, 2022, FCA US is aware of two accidents and one injury potentially related to this issue for all markets. • On November 17, 2022, FCA US determined, through the Vehicle Regulations Committee, to conduct a Part 573 Safety Recall Report 22V-865 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 voluntary safety recall of the affected vehicles. Description of Remedy : Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to update vehicle control software. FCA US has a longstanding policy and practice of reimbursing owners who have incurred the cost of repairing a problem that subsequently becomes the subject of a field action. To ensure consistency, FCA US, as part of the owner letter, will request that customers send the original receipt and/or other adequate proof of payment to the company for confirmation of the expense. How Remedy Component Differs from Recalled Component : Root cause unknown. There is more than one involved component and calibration software. Remedy is updated calibration software in the Transmission Control Module, Hybrid Control Processor and Auxiliary Hybrid Control Processor that changes fail safe from shut down to limp home. Identify How/When Recall Condition was Corrected in Production : NR Recall Schedule : Description of Recall Schedule : **11/23/2022: FCA US will notify dealers and begin notifying owners on or about 01/12/2023. Planned Dealer Notification Date : JAN 12, 2023 – JAN 12, 2023 Planned Owner Notification Date : JAN 12, 2023 – JAN 12, 2023 * NR – Not Reported
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