Recall 03A An unexpected engine shut down resulting in a loss of motive power can cause a vehicle crash without prior warning.

ryedaddy said:

Apparently there are three separate federal investigations into Stellantis.

If someone knows how to explain the PIM control and wiring harness in plain english and what the issue is I would love to hear it.

There is a YouTube guy named Scotty something who talked about this issue over a year ago and his video has like millions of hits... but to me he came across as a raving lunatic.

I can't believe that this is happening in 2023. It feels like a 1970s class action suit creeping up on a relic of a brand.

Anyone on this forum who has tried to argue about American builds being up to Japanese/German standards can open 👄 and stick 🦶 in 👄

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jnads said:

This is the first time we've learned exactly how many PacHys Chrysler has produced.

Only 67,000.

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ThisSuckersElectrical said:

The issue is not Chrysler's fault unless the engineers designed the part with a flaw or software voltage parameters are burning out the wire over time causing the short. Otherwise, the blame for this is on the company sourced to manufacture the part and the lack of quality assurance inspections.

Supplier Identification :
Component Manufacturer
Name : General Cable Industries Inc.
Address : Industrial de las Maquiladoras 11
Nueva Nogales Foreign States 84094
Country : Mexico

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js607191 said:

I was thinking that too. They have never shared sales numbers for the hybrid (not that I've been able to find anyway). It's a tiny number. If Chrysler had a better reputation, this should be one of the best selling 3-row vehicles anywhere, including SUVs.

If this problem is only point-2 percent of vehicles, I'll eat my hat.

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jnads said:

I think it's more of a matter of parts / battery supply than reputation.

They probably don't have the supply chain built up for this vehicle.

Also Chrysler likely is (or was) making a very slim profit margin on these vehicles and their true value was the CARB / CAFE credits offsetting the trucks. For a while Chrysler was keeping Tesla alive because were buying CAFE offset credits from them.


CAFE has rules on fleetwide MPG and rather than make trucks more efficient it's probably easier to sell a 126 MPGe minivan.

For every PacHy they sell they can sell 4 guzzling trucks.

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js607191 said:

I was thinking that too. They have never shared sales numbers for the hybrid (not that I've been able to find anyway). It's a tiny number. If Chrysler had a better reputation, this should be one of the best selling 3-row vehicles anywhere, including SUVs.

If this problem is only point-2 percent of vehicles, I'll eat my hat.

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js607191 said:

Sure, but the buck stops with Chrysler. That means they are not vetting their suppliers well enough or have standards that are too loose regarding the parts they accept. If most issues were all tied to suppliers, then vehicle problems would be spread out equally among all brands.

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ThisSuckersElectrical said:

Run your VIN to see if you are part of the recall.

Check for Recalls: Vehicle, Car Seat, Tire, Equipment | NHTSA

Jan 17,2023
Manufacturer Recall Number03A
NHTSA Recall Number23V-010
Recall StatusRecall Incomplete, remedy not yet available
SummaryAn internal transmission wiring connector short could result in an unexpected engine shutdown under certain conditions.

Safety RiskAn unexpected engine shut down resulting in a loss of motive power can cause a vehicle crash without prior warning.

RemedyFCA US will conduct a voluntary safety recall on all affected vehicles to update the Power Inverter Module ("PIM") software and, if necessary, update the instrument panel cluster ("IPC") software.

"Manufacturer's Notes"For more information, visit recalls.mopar.com or call 1-800-853-1403. Please have your VIN ready when calling.

Chrysler (FCA US, LLC) is recalling certain 2017-2023 Pacifica Plug-In Hybrid Electric vehicles
(PHEVs). An internal transmission wiring connector may short circuit, resulting in an
unexpected engine shutdown.

Number of potentially involved : 67,118

Estimated percentage with defect : 100 %

Vehicle Information :
Vehicle 1 : 2017-2023 Chrysler Pacifica
Vehicle Type :
Body Style : VAN
Power Train : NR
Descriptive Information : Some 2017-2023 MY Chrysler Pacifica Plug-In Hybrid Electric Vehicles ("PHEVs")
may experience a loss of motive power.
The suspect period began on August 12, 2016, when production of the Chrysler
Pacifica began, and ended on January 9, 2023, when FCA US LLC ("FCA US") began
containing suspect vehicles under plant control. The suspect period was determined
using field data and engineering change records.
Similar vehicles not included in this recall are not PHEVs or were built after the
suspect period.
Production Dates : AUG 12, 2016 - JAN 09, 2023

Description of Defect :
Description of the Defect : An internal transmission wiring connector short could result in an unexpected
engine shutdown under certain conditions.
FMVSS 1 : NR
FMVSS 2 : NR
Description of the Safety Risk : An unexpected engine shut down resulting in a loss of motive power can
cause a vehicle crash without prior warning.
Description of the Cause : NR

Involved Components :
Component Name 1 : Harness Assembly
Component Description : Low Voltage Wiring
Component Part Number : 05062444AI / 05062444AH / 05062444AG / 05062444AF / 05062444AE
Component Name 2 : Harness Assembly
Component Description : Low Voltage Wiring
Component Part Number : 05062444AD / 05062444AC / 05062444AB / 05062444AA

Supplier Identification :
Component Manufacturer
Name : General Cable Industries Inc.
Address : Industrial de las Maquiladoras 11
Nueva Nogales Foreign States 84094
Country : Mexico

Description of Remedy :

Description of Remedy Program : FCA US will conduct a voluntary safety recall on all affected vehicles to
update the Power Inverter Module ("PIM") software and, if necessary,
update the instrument panel cluster ("IPC") 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 a PIM and IPC software update for 2017-2018 model year
vehicles and a PIM software update for 2019-2023 model year vehicles
providing messaging to the customer and sufficient drive time to exit
traffic.

Identify How/When Recall Condition was Corrected in Production : NR

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SKPacHy said:

Good info from @alphawolff in another thread about this defect. I will copy his post here and provide a link.

Post


Hey everyone, factory tech here whose personally diagnosed these a decent amount of times this year.

To keep it simple the A drive motor has three resolvers: sin, cos, and excitement. In all cases I’ve seen, the cos resolver is shorting to the transmission case and causing a short to ground condition. It is either intermittent, and will cause a random stall, or shorts in such a way that you can instantly see it on a DMM and the vehicle won’t start and the code will be active

I believe the above poster is right is condemning the internal harness as faulty. It’s probably bad routing or some such.

I don’t see how a flash will solve this unless the flash is just to prevent the immediate stall condition. The problem isn’t common, but I do get about one of these a month coming into the shop and this is in socal with a **** high amount of hybrids on the road.

They might just send the recall flash and deal with the transmission failures as they come as they aren’t exactly common. The trans is covered under the 10 yr/150k mile hybrid warranty


Also, for those concerned with the dealers replacing the PIM, the reason for that is if the short isn’t present during testing the diagnostic flow chart leads to the replacement of the PIM. The first two I had we replaced the PIM first before replacing the transmission. Now when you go to make a Star case to order a PIM the star center will just tell you it’s the transmission and order that first to avoid that waste of time

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spirotot said:

Anyone happen to have even a guesstimate on when the software update may be available to dealers? Dealers in my area don't seem to know//won't give an answer.

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dmj said:

According to the NHTSA information Chrysler is planning to start notifying owners and dealers on March 8. I'm not certain whether they'll just be notifying of future availability or whether they'll have the fix in hand ready to apply. I would expect they'd put a certain priority on applying the change to vehicles which are otherwise stuck on dealer lots...

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jnads said:

I already explained it here:

2021 Pacifica hybrid failure while driving on highway

Recorded for reference: While driving with over 20 mile for electric range the car decides to cut all propulsion and heating. The dash reported charging system failure and to switch the car to park. I managed to coast from the furthest left lane to the the curb lane as traffic was pretty...

www.pacificaforums.com

Recap: For those wondering, the part mentioned is here: YOUTUBE As an engineer I'd guess the part that fails is that in-line SIP wire connector (edit: the 90 degree black plastic connector on ring / resolver assembly). It looks like the part is meant to be protected against failure by that robust bracketing system, but I'd guess that plastic cracks due to the lateral stress on the connector (or maybe people are swinging it around by the wire harness at the factory... which would explain why some vehicles are breaking and some are not [my 2020 has 30k miles and has never had this issue]). It's also possible since the pins are exposed in that SIP connector that something conductive gets lodged in there and shorts against the metal bracket (like I said that's a dumb connector). The resolver is the electric motor equivalent to a crankshaft position sensor. Essentially the vehicle is shutting down because the sensor goes faulty and the vehicle doesn't know the position of the motors / how fast they are spinning, which could lead to fighting between the motors (burn out the PIM) or fighting with the engine (which would cause excess gear or bearing wear). These sensors are more or less key to making the whole PHEV planetary transmission work since you have to carefully match the motor speeds to the engine speed or they all fight each other. I'm guessing the software update allows everything to keep working for a limited amount of time if such an error occurs since there's nothing physically keeping from the motors working, just if the drivetrain gets too out of sync it can lead to damage. Disclaimer: Keep in mind this is all speculation by an engineer. I'm working off what another tech said and my own knowledge of the vehicle.

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