Another Recall Sends Owners to the Dealer

The Recall Notice is back with your 2023 second quarter update. As a reminder, this series unpacks some of the National Highway Traffic Safety Administration's (NHTSA) most recent software-related recalls. We explore both why they happened and how connectivity, such as over-the-air updates and remote data logging, could have streamlined the recall rollout process. Now let’s dive in!  

RAM Recall 23V265

NHTSA Campaign Number: 23V265000

OEM: Chrysler (FCA US, LLC)

Components: Power Train

Estimated Vehicles Affected: 131,700

Remedy: Free Software Update at the Dealership

Estimated Cost to OEM: $39.5M - $65.8M

NHTSA Recall 23V265 is related to a powertrain control module calibration fault that may result in an engine stall while driving. It impacts certain RAM 150 vehicles with 5.7L eTorque engines from the 2021 model year. Initial investigations began in January 2023. Since then, over 636 relevant warranty claims have been identified, as well as 53 field reports and one traffic collision. 

RAM, which is part of the automotive conglomerate Stellantis, has over the air (OTA) capabilities limited to firmware updates to the infotainment system. Without access to real-time data, it took several months for the manufacturer to both identify the fault and announce the recall, which was issued on April 6th, 2023. Additionally, RAM has yet to implement the technology necessary to remedy the software fault remotely. As such, all 131,700 potentially impacted vehicles will have to return to the dealership to for the new software version.   

Volkswagen Recall 23V040

NHTSA Campaign Number: 23V040000

OEM: Volkswagen Group of America, Inc.

Components: Electrical System 

Estimated Vehicles Affected: 20,904

Remedy: Free Software Update at the Dealership

Estimated Cost to OEM: $6.2M - $10.5M

Investigation into NHTSA Recall 23V040 began a year and a half before the recall was issued. In July 2021, Volkswagen Group of America started receiving reports from Europe about a potential software problem in the high voltage (HV) battery management system of certain Volkswagen ID.4 vehicles from the 2021 model year. After further investigation, the manufacturer determined that the fault might cause the HV battery control module to reset or in rare cases deactivate the pulse inverter. Both of these conditions might result in a sudden loss of propulsion, thus increasing the driver’s risk of a traffic collision. 

The ID.4 is equipped with OTA updates that expand beyond just infotainment and navigation. However, some larger, safety-critical updates, such as fixing the HV battery management control fault in Recall 23V040, still require a visit to the local dealer. 

Shyft Recall 23V062

NHTSA Campaign Number: 23V062000

OEM: Shyft Group

Components: Electrical System

Estimated Vehicles Affected: 2,336

Remedy: Free Software Update

Estimated Cost to OEM: $700,800 - $1.2M

Software related recalls are not limited to passenger vehicles and two-wheelers, which our blog series traditionally covers. They also impact agricultural and construction equipment, buses, medium to heavy vehicles, and even vehicle chassis. NHTSA Recall 23V062 impacts certain 2022 to 2024 K1, K2, K3, and K4 model Spartan RV chassis which are manufactured by the Shyft Group. This recall is the result of a software fault in the vehicle control module which may lead to a sudden loss of drive power or key safety features. 

Since Shyft Group doesn’t have dealerships or the OTA update capabilities necessary to remedy this fault, owners will have to wait for directions from the manufacturer. These will tell them which local service station they may go to for the software update fix. 

Impact and Savings With Sibros

With a fully embedded connectivity solution that enables over-the-air updates, flexible data logging, and remote commands, these three manufacturers could have saved millions in recall-related costs. However, building, testing, and implementing such a solution is rarely practical or cost-effective. An alternative is to outsource connectivity solutions to realize savings sooner and bypass all the trial and error associated with in-house development. Even OEMs that do manage to create a viable OTA solution, such as Volkswagen, often find themselves backtracking to address functionalities they might not have considered during development. 

For both the Volkswagen and RAM recalls, having flexible data logging capabilities, like those provided by Sibros Deep Logger, would have expedited fault identification. These OEMs would have been able to target and collect real-world data from the relevant vehicles for advanced analysis and troubleshooting. With Sibros Deep Updater, all three manufacturers would have been able to send remote updates with ISO 26262 ASIL-D-level functional safety assurance. 

The rate of evolution in the automotive industry is accelerating. To survive the shift to more autonomous and software defined vehicles, OEMs must adapt. Gone are the days where OEMs make their own tires, brakes, and other vehicle components. Software solutions will soon follow in this vien, as partnerships with connected vehicle platform providers replace in-house development. 

To learn more about how Sibros’ Deep Connected Platform can help power your connected vehicles and software-defined vehicles, talk to us!