2012 Dodge RAM 1500 Exterior Lighting Problems, Complaints and Defects, Recalls and Failures

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2012 Dodge RAM 1500 Exterior Lighting Problems, Complaints and Defects

 Issue ID1007571
 Internal NHTSA #10538353
 ManufacurerChrysler Group LLC
 ModelRAM 1500
 Model Year2012
 File date01/09/13
Product type codeVEHICLE
 Description of the problemThe right headlight on my 2012 dodge ram 1500 failed while driving. The vehicle uses separate low and high beam bulbs. Test showed that both low and high beam were affected on the failed side. I had recently purchased the truck used. When i called the previous owner he informed me that he had experienced the same problem at different times with each headlight. He had simply unplugged and replugged the headlight connectors to "fix" the problem. I removed the failed right headlight assembly. Test showed that manipulating the wires (push, pull, stress to one side or the other) coming into the male side of the connector could cause the headlight work or fail. I performed a similar test on the (working) left side headlight with the same results - i could force failure at will, even though the connector was fully assembled and locked. Upon inspection of the connectors, both appeared clean inside. I sprayed each with contact cleaner anyway, and reassembled only to find the same problem. Manipulating the pins on the female side of the connector in effort to increase contact pressure resulted in no improvement when the connector was replugged. As a former failure analysis engineer i can tell you that there is a design / application problem with the headlight connectors used on this truck. Short of contact plating analysis, it appears there is insufficient contact area and / or contact pressure on the small pins used. As a work-around, i used long nose pliers to reach inside the male connector body, and twisted the small, flat, male pins approximately 45 degrees to increase contact pressure. After reassembling both connectors in this manner, i can no longer force failure on either side. The stock headlight connectors used on this truck present a serious design flaw and safety issue since as designed, headlight failure may occur at any time. *js
 Vehicle Mileage at Failure61503
Number of Occurences2
Source of the issueNHTSA WEB SITE
 City and StateROUND ROCK, TX
 Was vehicle invloved in a crash?N
 Was vehicle involved in a fire?N
 Was incedent reported to police?N
 Was medical attention required?
 Was part original equipment?
No. of injured persons0
No. of fatalities0
 Date of purchase26/05/20
Was original owner?N
Anti-lock brakesN
Cruise controlN
Number of cylinders8
Drive train type4WD
Transmission type
 Vehicle speed45
 DoT tire identifier
 Tire size
 Location of tire code
 Type of tire failure code
 Was defective tire repaired?
 Date of manufacture
Type of child seat code
Type of restraint
 Dealer's name
 Dealer's telephone number
 Dealer's city
 Dealer's state code
 Dealer's ZIP code
  • What is Recall?

    A recall is when a product is removed from the market or a correction is made to the product because it is either defective or potentially harmful.
  • What is Failure?

    Failure is the state or condition of not meeting a desirable or intended objective, and may be viewed as the opposite of success. Product failure ranges from failure to sell the product to fracture of the product, in the worst cases leading to personal injury, the province of forensic engineering.
  • What is Defect?

    Non-conformance of a car component with the specified requirements, or non-fulfillment of user expectations, including the safety aspects.
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