Attention: TDR Forum Junkies 
TDRComm
Staff Member
HYPE AND SUCH – JUST SAY “FIRE”
For our next TDR magazine (due out in May), TDR writer John Holmes does a “Last Issue Recap.” In his column he mentions that he “liked the editor’s response to the recall on ‘fires.’”
Hell’s bells, I wrote it. What did I have to say?
Briefly, it was a rant about the media, sensationalism, and automatic transmission fluid (“a pressure buildup inside the transmission can cause transmission fluid to leak from the dipstick tube. If the fluid contacts are ignition source, the vehicle could catch fire.”). The recall number is ZA3.
My conclusion: Perhaps I would have a concern if the 68RFE was new on the market. Ram has been using this transmission since 2007.5. However, the thought does come to my mind, “what changed on the transmission that has created this latest headline and concern?” Now, 90 days later, I still do not have an answer for you. And, I’m still not the least bit concerned.
INTAKE GRID HEATER/HOT NUTS:
JUST SAY “FIRE,” PART TWO
For the current “fire” subject, let’s talk about Recall Y76, Intake Air Heater Relay. Here is the text from Issue 119
Date: January 2022
Models/Production:
’21-’22 DJ Ram 2500 Pickup
’21-’22 D2 Ram 3500 Pickup
’21-’22 DD Ram 3500 Cab Chassis
’21-’22 DP Ram 4500/5500 Cab Chassis
Subject: The intake air heater relay on about 137,946 of the above vehicles may experience an electrical short in the Intake Air Heater Relay.
Repair: Perform replacement or repair of the grid heater relay as outlined in the 15-page repair procedure document.
Now, 90 days later, what is the latest news on Y76? The problem has escalated.
ADVANCE COMMUNICATIONS, BAD RELAYS AND HOT NUTS
Advance Communication – 18A
Mopar Part Recall
On February 10, 2023, the folks at FCA (Stellantis) announced a recall for Mopar “Generation 1 Intake Grid Heater Relays” part number 68444169AB. Here is the text of the communication:
“Reason for this Safety Recall: Some Generation 1 solid state intake air grid heater relays were improperly designed and could fail internally. An electrical short in the relay, when installed on a vehicle, can potentially lead to a vehicle fire with the ignition on or off. A vehicle fire can result in increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage.”
I can’t describe what the “Generation 1” means. However, if you purchased/installed 68444169AB or have had one installed on your truck, I would disconnect the wiring to the relay and make do with an illuminated “check engine” light.
The summer months are now here. This is good news.
Advance Communication – 13A
2021-2023 Vehicle Recall
On February 16, 2023, the folks at FCA (Stellantis) announced a recall for 2021-2023 Turbo Diesel trucks. Here is the text of the communication.
“Reason for this Safety Recall: Some of the above vehicles can experience an engine compartment fire originating from the Generation 1 solid state intake air grid heater relay. An electrical short in the relay can potentially lead to a vehicle fire with the ignition on or off. A vehicle fire can result in increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage.
“Service Action: FCA US will conduct a voluntary safety recall on all affected vehicles to replace the suspect relay. 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.”
A Major Event?
This advance communication is directed to 2021-2023 model year Ram 2500-5500 diesel-powered trucks. This is a major event for the dealer network, “VINs identified as being involved in this campaign are currently live and searchable. Stop sale is in effect for the above-identified vehicles.”
Stop the sale of new vehicles.
This is a big deal.
Is this a big deal to you, Mr. 2021-2023 owner? Should you be concerned?
My truck is a 2020 model year. Rumor has it that it will also be involved in the recall. So, I’m in the same boat. Here is my take on the situation.
If I were overly concerned, I’d disconnect the hot wire to the grid heater, wrap the terminal end and secure it out of the way. I am not overly concerned. I did not disconnect the grid heater cable.
Yes, I would then have to suffer-through the check engine light being illuminated. But, summer is upon us, and the grid heaters will not have to function. This is a bit of good news.
Further Information: Press Release From Stellantis
Subsequently, there was a press release from Stellantis that zeros-in on the recall and the scope of the problem Here is the text:
“FCA US LLC is recalling an estimated 306,165 US-market vehicles to replace an electrical connector.
“An FCA US investigation discovered the intake heater-grid relays on certain vehicles may exhibit overheating. In rare instances, this condition may pose a fire risk.
“The Company is unaware of any related injuries or accidents. There are reports of six potentially related fires—five occurred while the vehicles’ engines were still on; the remaining incident was reported after the ignition was turned off.
“Affected are certain model-year Ram 2500 and 3500 pickups, and 3500/4500/5500 cab chassis trucks from model years 2021-2023. The recall population is limited to vehicles equipped with 6.7-liter Cummins diesel engines and prior-generation heater-grid relays, which were the focus of two previous but smaller campaigns.
“Despite the minimal risk, the Company advises custodians of these models, not to park their vehicles indoors.
“FCA expects to begin notifying affected customers next month. But as of February 16, customers may determine if their vehicles are included in the campaign by inputting their Vehicle Identification Numbers (VINs) on search engines such as mopar.com/recalls, checktoprotect.org, or nhtsa.gov.”
Context
Got it. Now it is an electrical connector that will be replaced. Regardless of the parts or the repair technique, let’s do the math: 6 ÷ 306,165 = .000195.
Context.
The bottom line for me: If I was really concerned (and I’m not—look at the numbers) I could install a “Stan Gozzi: LED” from Issue 115, page 96. I could monitor the operation of the heater and, should it remain “on” for too long of a period, I’d start the truck (to flow cool air), open the hood and remove the battery cable with a 10mm wrench stashed close to the battery terminal(s). Turn the engine off. Disconnect the hot wire to the grid heater. Wrap the hot wire. Go on about my business.
Out of Warranty Trucks
TDR writers Joe Donnelly, Stan Gozzi and I did an exchange of text messages back on 2/27/23 to discuss the situation. Now, in fairness to Joe or Stan (owners of 2013 and 2018 trucks respectively) perhaps I should give some additional thought to the big picture situation that has the potential to exist on 6.7-liter trucks from 2007.5 to current.
These trucks are out of warranty. Part of the problem identified in the Y78 15-page recall was “loose nuts.” They opined that they would first inspect and tighten the grid bolt. Joe may reconsider the “Gozzi LED.” Both Joe and Stan may consider a disconnect “knife” switch at the battery or at the power wire to the grid heater.
Details on their solutions will be in the next magazine.
Additional “context” for you to consider: Should you try a Stan Gozzi or Joe Donnelly repair or modification you will become this t-shirt design: “I am my own warranty station.” And, considering that 2007.5-2020 trucks have eclipsed the basic 3/36 warranty period, you are your own warranty station.
Fault Code P2609
For now, I took the opportunity to research the code “P2609 Intake Air Heater Performance,” the code that may/may not appear prior to the hot nut dropping into the air intake. Here are the possible causes of P2609:
Faulty heater element relay
Defective heater element
Faulty temperature sensor
Corroded or damaged connector
Damaged or restricted air duct
Faulty or damaged wiring
Defective Blower motor
Faulty PCM
Funny, it does not mention the “Ram Specific” problem of bad electrical connectors and hot nuts.
Summary
A closing opinion/summary: Context has been provided. Year model 2021-2023 trucks are under warranty. Older 6.7-liter engine owners (’07.5 to the 2020 trucks) that are out of warranty: Inspect the grid heater nuts, tighten as needed. Hang with us through these summer months as we discuss different options for preventive maintenance.
Thank you for supporting the TDR.
TDR Staff
For our next TDR magazine (due out in May), TDR writer John Holmes does a “Last Issue Recap.” In his column he mentions that he “liked the editor’s response to the recall on ‘fires.’”
Hell’s bells, I wrote it. What did I have to say?
Briefly, it was a rant about the media, sensationalism, and automatic transmission fluid (“a pressure buildup inside the transmission can cause transmission fluid to leak from the dipstick tube. If the fluid contacts are ignition source, the vehicle could catch fire.”). The recall number is ZA3.
My conclusion: Perhaps I would have a concern if the 68RFE was new on the market. Ram has been using this transmission since 2007.5. However, the thought does come to my mind, “what changed on the transmission that has created this latest headline and concern?” Now, 90 days later, I still do not have an answer for you. And, I’m still not the least bit concerned.
INTAKE GRID HEATER/HOT NUTS:
JUST SAY “FIRE,” PART TWO
For the current “fire” subject, let’s talk about Recall Y76, Intake Air Heater Relay. Here is the text from Issue 119
Date: January 2022
Models/Production:
’21-’22 DJ Ram 2500 Pickup
’21-’22 D2 Ram 3500 Pickup
’21-’22 DD Ram 3500 Cab Chassis
’21-’22 DP Ram 4500/5500 Cab Chassis
Subject: The intake air heater relay on about 137,946 of the above vehicles may experience an electrical short in the Intake Air Heater Relay.
Repair: Perform replacement or repair of the grid heater relay as outlined in the 15-page repair procedure document.
Now, 90 days later, what is the latest news on Y76? The problem has escalated.
ADVANCE COMMUNICATIONS, BAD RELAYS AND HOT NUTS
Advance Communication – 18A
Mopar Part Recall
On February 10, 2023, the folks at FCA (Stellantis) announced a recall for Mopar “Generation 1 Intake Grid Heater Relays” part number 68444169AB. Here is the text of the communication:
“Reason for this Safety Recall: Some Generation 1 solid state intake air grid heater relays were improperly designed and could fail internally. An electrical short in the relay, when installed on a vehicle, can potentially lead to a vehicle fire with the ignition on or off. A vehicle fire can result in increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage.”
I can’t describe what the “Generation 1” means. However, if you purchased/installed 68444169AB or have had one installed on your truck, I would disconnect the wiring to the relay and make do with an illuminated “check engine” light.
The summer months are now here. This is good news.
Advance Communication – 13A
2021-2023 Vehicle Recall
On February 16, 2023, the folks at FCA (Stellantis) announced a recall for 2021-2023 Turbo Diesel trucks. Here is the text of the communication.
“Reason for this Safety Recall: Some of the above vehicles can experience an engine compartment fire originating from the Generation 1 solid state intake air grid heater relay. An electrical short in the relay can potentially lead to a vehicle fire with the ignition on or off. A vehicle fire can result in increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage.
“Service Action: FCA US will conduct a voluntary safety recall on all affected vehicles to replace the suspect relay. 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.”
A Major Event?
This advance communication is directed to 2021-2023 model year Ram 2500-5500 diesel-powered trucks. This is a major event for the dealer network, “VINs identified as being involved in this campaign are currently live and searchable. Stop sale is in effect for the above-identified vehicles.”
Stop the sale of new vehicles.
This is a big deal.
Is this a big deal to you, Mr. 2021-2023 owner? Should you be concerned?
My truck is a 2020 model year. Rumor has it that it will also be involved in the recall. So, I’m in the same boat. Here is my take on the situation.
If I were overly concerned, I’d disconnect the hot wire to the grid heater, wrap the terminal end and secure it out of the way. I am not overly concerned. I did not disconnect the grid heater cable.
Yes, I would then have to suffer-through the check engine light being illuminated. But, summer is upon us, and the grid heaters will not have to function. This is a bit of good news.
Further Information: Press Release From Stellantis
Subsequently, there was a press release from Stellantis that zeros-in on the recall and the scope of the problem Here is the text:
“FCA US LLC is recalling an estimated 306,165 US-market vehicles to replace an electrical connector.
“An FCA US investigation discovered the intake heater-grid relays on certain vehicles may exhibit overheating. In rare instances, this condition may pose a fire risk.
“The Company is unaware of any related injuries or accidents. There are reports of six potentially related fires—five occurred while the vehicles’ engines were still on; the remaining incident was reported after the ignition was turned off.
“Affected are certain model-year Ram 2500 and 3500 pickups, and 3500/4500/5500 cab chassis trucks from model years 2021-2023. The recall population is limited to vehicles equipped with 6.7-liter Cummins diesel engines and prior-generation heater-grid relays, which were the focus of two previous but smaller campaigns.
“Despite the minimal risk, the Company advises custodians of these models, not to park their vehicles indoors.
“FCA expects to begin notifying affected customers next month. But as of February 16, customers may determine if their vehicles are included in the campaign by inputting their Vehicle Identification Numbers (VINs) on search engines such as mopar.com/recalls, checktoprotect.org, or nhtsa.gov.”
Context
Got it. Now it is an electrical connector that will be replaced. Regardless of the parts or the repair technique, let’s do the math: 6 ÷ 306,165 = .000195.
Context.
The bottom line for me: If I was really concerned (and I’m not—look at the numbers) I could install a “Stan Gozzi: LED” from Issue 115, page 96. I could monitor the operation of the heater and, should it remain “on” for too long of a period, I’d start the truck (to flow cool air), open the hood and remove the battery cable with a 10mm wrench stashed close to the battery terminal(s). Turn the engine off. Disconnect the hot wire to the grid heater. Wrap the hot wire. Go on about my business.
Out of Warranty Trucks
TDR writers Joe Donnelly, Stan Gozzi and I did an exchange of text messages back on 2/27/23 to discuss the situation. Now, in fairness to Joe or Stan (owners of 2013 and 2018 trucks respectively) perhaps I should give some additional thought to the big picture situation that has the potential to exist on 6.7-liter trucks from 2007.5 to current.
These trucks are out of warranty. Part of the problem identified in the Y78 15-page recall was “loose nuts.” They opined that they would first inspect and tighten the grid bolt. Joe may reconsider the “Gozzi LED.” Both Joe and Stan may consider a disconnect “knife” switch at the battery or at the power wire to the grid heater.
Details on their solutions will be in the next magazine.
Additional “context” for you to consider: Should you try a Stan Gozzi or Joe Donnelly repair or modification you will become this t-shirt design: “I am my own warranty station.” And, considering that 2007.5-2020 trucks have eclipsed the basic 3/36 warranty period, you are your own warranty station.
Fault Code P2609
For now, I took the opportunity to research the code “P2609 Intake Air Heater Performance,” the code that may/may not appear prior to the hot nut dropping into the air intake. Here are the possible causes of P2609:
Faulty heater element relay
Defective heater element
Faulty temperature sensor
Corroded or damaged connector
Damaged or restricted air duct
Faulty or damaged wiring
Defective Blower motor
Faulty PCM
Funny, it does not mention the “Ram Specific” problem of bad electrical connectors and hot nuts.
Summary
A closing opinion/summary: Context has been provided. Year model 2021-2023 trucks are under warranty. Older 6.7-liter engine owners (’07.5 to the 2020 trucks) that are out of warranty: Inspect the grid heater nuts, tighten as needed. Hang with us through these summer months as we discuss different options for preventive maintenance.
Thank you for supporting the TDR.
TDR Staff
