Investigations
Engine Electrical Wiring Harness Chafe
NHTSA Preliminary Evaluation PE21004 — closed, opened 2021-02-25.
NHTSA investigation PE21004 is a Preliminary Evaluation opened on 2021-02-25 and currently closed. The subject is tracked inside the Office of Defects Investigation queue. Latest activity on this investigation was logged on 2025-01-14 — NHTSA updates that field whenever an Information Request goes out, a supplement is filed, or a status change is recorded in the public docket.
A Preliminary Evaluation like PE21004 is the entry point of the federal defect-investigation process. NHTSA engineers scan complaint databases, field reports, and manufacturer data to decide whether an Engineering Analysis is warranted, whether a voluntary recall is already sufficient, or whether the pattern does not rise to a defect finding.
Investigators summarized the matter as follows: "The Office of Defects Investigation (ODI) opened this Preliminary Evaluation to investigate reports of engine electrical wiring harness chafe on the subject vehicles. ODI analysis found thousands of unique harness part n..." Investigations are the early-warning layer of the federal auto-safety system, sitting upstream of formal recalls and defect orders. Whether this one closes without action or escalates into an Engineering Analysis, the full history stays in the ODI archive so researchers, litigators, and buyers can pull the paper trail at any time.
Investigation Summary
The Office of Defects Investigation (ODI) opened this Preliminary Evaluation to investigate reports of engine electrical wiring harness chafe on the subject vehicles. ODI analysis found thousands of unique harness part numbers, spanning the two generations of vehicle chassis assembled at multiple vehicle assembly plants in two different countries, with multiple sub-models, incorporating over thirty powertrain choices. Each wiring harness could contain several dozen individual wires for power, ground and communication purposes depending on the multitude of equipment options available for custom vehicle configuration. ODI identified three primary areas where a wiring harness bundle may chafe: the air compressor support bracket, the transmission case, or the coolant surge tank. In each case, the root cause was some combination of inadequate design clearance, installation variability and relative motion between the wiring harness and the point of contact, such as from vibration. The chafing could result in a range of consequences from none to various diagnostic fault codes, telltale illumination, driver warning center messages, erratic electrical component operation, difficult or no engine start condition, engine de-rate (power reduction), engine shut down, inoperative transmission gear selection, or an unexpected shift to neutral. These potential consequences vary depending on the specific damaged wire in the harness and the exact failure mode, such as intermittent short circuit to ground or open circuit. Generally, the chafing resulted in a progressive series of driver warnings with high levels of detectability over the course of several days and ignition cycles. Drivers usually heed warnings before an engine shutdown condition occurs and the driver may override an engine shutdown countdown timer using the override switch. If the driver allows the shutdown event to occur, the engine can almost always be immediately restarted. Incident rates for an engine shutdown with
About This Investigation Type
A Preliminary Evaluation (PE) is the first phase of NHTSA's investigation process. It is opened when the agency identifies a potential safety defect pattern, usually triggered by consumer complaints, manufacturer reports, or field monitoring. During a PE, NHTSA gathers information to determine whether a formal engineering analysis is warranted.
Data from NHTSA Office of Defects Investigation. Cross-references: NHTSA recall campaign API and NHTSA FARS where fatality records overlap. PlainCars does not rate or recommend vehicles. Learn more.
Read our methodology — how this data is sourced, computed, and verified.