Dodge Trucks, Clutch Switches, and Springs

Chrysler (now Fiat Chrysler Automobiles - FCA) has announced a recall of some 2006-2007 Dodge trucks:

An investigation by FCA US engineers discovered switches in certain model-year 2006 and 2007 pickups may be equipped with spring wire that differs from wire used in previous switches. The alternate wire may break and, as a result, the vehicles may not start. In rare cases, a vehicle may – if recommended starting procedures are not followed – exhibit unintended movement when its ignition key is turned.

The recall covers certain Dodge Dakota, Dodge Ram 1500, 2500, 3500 and Mitsubishi Raider pickups. Switches with the alternate wire were not used in any vehicles produced before July of 2005, or after June of 2006. The Dakota and Raider are no longer in production. (The latter was built for Mitsubishi under terms of an assembly contract.) 

Reading the NHTSA investigations page, Chrysler has decided to recall certain manual transmission applications. (NHTSA Action Number: PE14013)

Chrysler's Safety Report states that: 1) the clutch ignition interlock switch return springs may experience fatigue failure due to material issues; 2) if the return springs are broken, the switch contacts may not reflect actual clutch pedal position; and 3) the failures could result in a vehicle experiencing unintended movement if the ignition is cranked when the clutch pedal is not being pressed. Chrysler's recall remedy will replace the clutch ignition interlock switch on all affected vehicles with a switch with a more robust design. 

One of the MY 2006 complaints involved a fatality that occurred when a young child was able to start a MY 2006 Ram 3500 truck that was parked with the transmission in gear, without depressing the clutch. The diesel engine started and the vehicle moved forward under power running over another child resulting in fatal injuries.

NHTSA's Office of Defect Investigations has more detail: (Investigation: PE 14-013)

ODI has received three vehicle owner complaints (VOQs) alleging incidents of engine crank or start when the clutch was not engaged due to clutch interlock switch failure. The complaints involved 1 model year (MY) 2004 Dodge Ram 2500 truck and 2 MY 2006 Dodge Ram 3500 trucks equipped with manual transmissions. One complaint (VOQ
10566076) involved an incident that occurred when a child was able to enter the vehicle and start the ignition without depressing the clutch. The vehicle then moved forward striking another child resulting in a fatality. A second complaint (10533996) described an incident that occurred when the engine was cranked without the clutch pedal
depressed while an individual was standing directly in front of the vehicle performing work under the hood. The clutch interlock failed to prevent the engine from cranking, which resulted in vehicle movement into the pedestrian performing work under the hood. The individual was knocked to the ground, but did not report any injuries. 

Based on what is available, it seems that a new ignition interlock switch included a spring with a different steel than in previous switches. It is not clear to me if the new switch was a new design, or a new supplier's switch, or if the switch was a carry over but the spring contained the defect of having the wrong steel.
The problem does not seem to have been a production quality issue, but rather a design related failure. Here are some of the questions I would have:

• Is the new spring steel a "normal" selection?  In other words, has the new steel been used before, or on an approved list? If the steel was "new" there should have been a heightened test schedule.
• Was the new switch with the new spring steel tested to confirm it meets durability targets? What was the test schedule?
• How open to Chrysler was the new switch design?

These types of failures seem to fall back on the old tried and true system failures.