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2022 Aisin Failure Tracking Sheet

I have it in good authority that the issue started at Aisin. It wasn’t an assembly error but rather a batch of snap rings that were out of spec. Somehow made it past quality control. They fail internally and fall out of position on the K1 drum. When this happens you lose 1-4 gears instantly.

They initially were rectifying the failed transmissions by installing completely new transmissions but that was suspended starting around 1/11/23 when they released the TSB (21-002-23) for this particular issue. There have been numerous cases where trucks that received replacement transmissions suffered another failure of the same type and are subsequently out of service again. The current method to address the issue is ordering a “parts kit” that includes all necessary components to fix the failed transmissions. Some of the parts in the kit are on extended backorder causing significant delays.

If you would like, I can add your truck to the tracking spreadsheet I have going. There are currently 132 trucks on there with confirmed K1 failures.
I was checking your tracking sheet my 22 3500 HO was built in March 2022. I noticed on your sheet there is only one failure before March 2022. Am I correct in saying that?
 
I was checking your tracking sheet my 22 3500 HO was built in March 2022. I noticed on your sheet there is only one failure before March 2022. Am I correct in saying that?
I believe there are 4 failures for trucks built prior to March 2022

Two January 2022 trucks
One October 2021
One December 2021

Generally speaking the earlier built 2022’s seem far less susceptible to this failure but it is not a guarantee as far as I can tell. Keep in mind they’re a bunch of build dates missing. Normally you could figure out a rough built date based on the delivery date, but with the lengthy backlogs in shipping for 2022 trucks, it’s very hard to nail the build date down without a ViN or directly from the trucks driver door sticker.
 
I believe there are 4 failures for trucks built prior to March 2022

Two January 2022 trucks
One October 2021
One December 2021

Generally speaking the earlier built 2022’s seem far less susceptible to this failure but it is not a guarantee as far as I can tell. Keep in mind they’re a bunch of build dates missing. Normally you could figure out a rough built date based on the delivery date, but with the lengthy backlogs in shipping for 2022 trucks, it’s very hard to nail the build date down without a ViN or directly from the trucks driver door sticker.
 
I have it in good authority that the issue started at Aisin. It wasn’t an assembly error but rather a batch of snap rings that were out of spec. Somehow made it past quality control. They fail internally and fall out of position on the K1 drum. When this happens you lose 1-4 gears instantly.

They initially were rectifying the failed transmissions by installing completely new transmissions but that was suspended starting around 1/11/23 when they released the TSB (21-002-23) for this particular issue. There have been numerous cases where trucks that received replacement transmissions suffered another failure of the same type and are subsequently out of service again. The current method to address the issue is ordering a “parts kit” that includes all necessary components to fix the failed transmissions. Some of the parts in the kit are on extended backorder causing significant delays.

If you would like, I can add your truck to the tracking spreadsheet I have going. There are currently 132 trucks on there with confirmed K1 failures.
Please add me and thanks
 
Please add me and thanks
I just added you. See line # 141 on the sheet. The only info I need to have a complete data set for you is:

Did you order it? (If so what was the order date)
What is the trucks build date? (This will be on the driver door sticker)
Serial number of failed transmission (this is on a blue stamped metal tag on side of transmission)
Date the transmission failed?

I appreciate you adding your info to the tracking sheet!
 
Stellantis needs to do like they did on the CP4/CP3 debacle and authorize aftermarket repair reimbursement. Even if you had to get approval first, at least you have a fighting chance that's better than waiting for a dealer fix on a broken down truck.

Only issue there is you're likely to lose that part of the warranty...
 
If you want to add me to the growing list. My truck went down last weekend and I'm waiting for parts. According to the dealership, they are on national backorder and my vehicle is #361 on the list.

Build Date 10/2022
Delivery/Aquistion Date 12/2022
Mileage at failure 6447
Failed while Towing No
Forward 1-4 gear works No
Revers works Yes
Transmission failed waiting on parts. 3/11/2023
 
If you want to add me to the growing list. My truck went down last weekend and I'm waiting for parts. According to the dealership, they are on national backorder and my vehicle is #361 on the list.

Build Date 10/2022
Delivery/Aquistion Date 12/2022
Mileage at failure 6447
Failed while Towing No
Forward 1-4 gear works No
Revers works Yes
Transmission failed waiting on parts. 3/11/2023
I’m in front of my laptop right now and will add you. Here is a complete list of the data I collect, if you don’t have some of it now, I can add it whenever you’re able to get. If it is redundant from what you posted above, please disregard.

Date you ordered it
Date of manufacture
Date purchased
Miles at the time of failure
Towing when it failed?
Lost forward gears?
Reverse still worked?
Date transmission failed ?
Serial number of failed transmission
Serial number of replacement transmission
 
Stellantis needs to do like they did on the CP4/CP3 debacle and authorize aftermarket repair reimbursement. Even if you had to get approval first, at least you have a fighting chance that's better than waiting for a dealer fix on a broken down truck.

Only issue there is you're likely to lose that part of the warranty...
Agreed. There have been quite a few on the list who have requested this, unfortunately it was met with an obvious denial from corporate.

I’ve been at this for 66 days now and then trend of 2 failures per day continues. Up to 134 trucks as of 8am this morning. 70% of those are down, out of service waiting for repair. The most recent successful return-to-service I updated was a truck which went down in November 22. They opted for a transmission replacement in this instance. The truck was out of service 112 days. That is an unacceptable length of time for any vehicle repair.
 
Well I'm back on the road. Transmission is shifting smooth. I still don't know how they got a complete transmission for me but they did. I'll try too keep everyone updated as we put miles on it. Hopefully they sent a known good one.
 
I bought mine off the lot so no order date. It's currently 600 miles from me but I did text the dealer to see if they can grab the transmission serial number for me. If I get it I'll let you know.
 
I bought mine off the lot so no order date. It's currently 600 miles from me but I did text the dealer to see if they can grab the transmission serial number for me. If I get it I'll let you know.
That would be very helpful. If you can get it I would greatly appreciate it!
 
So, for those of you with whom I’ve been discussing the Aisin serial numbers: I have to apologize, as your theories were correct regarding how the numbering system worked. I had mistakenly typed a “3” instead of a “2” at the beginning of one of the transmission serial numbers on the tracking spreadsheet. That was throwing off what we thought might be how Aisin used their serial numbers. Indeed your hypothesis was correct. Pretty certain the Aisin serial numbers are determined as follows:

Example: “2H-1234”

First character is the last digit of year of manufacture
So in the example above the “2” would be “2022”

Second character is the month of manufacture
So in the example above “H” would be “August”

The last four characters are (I’m assuming) the sequence number. I’m still sorting that out.

I’ve cross checked this theory against multiple trucks on the tracking sheet and it worked for every one.

I appreciate those of you who have been helping to figure all of this out. The goal here continues: Find out as much about this issue as possible in the hopes of assisting others to understand this problem, as well as help others avoid dangerous situations if possible.
98463E94-E880-4523-887F-1ACC6972DD8F.jpeg
 
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I am not broken down truck has 1300 miles on it. Build date 3-22 here is a picture of the serial number. hopefully it helps.1E0E9D40-06A9-4A2E-A889-54C82D908A0C.jpeg
 
I am not broken down truck has 1300 miles on it. Build date 3-22 here is a picture of the serial number. hopefully it helps.View attachment 53558
Thanks, I appreciate it as a reference. So a March 22 built truck with a March 22 built transmission under it if our theory on the serials is correct. That transmission didn’t sit around long!
 
If it helps for a data point, mine is currently not broken, have about 5200 miles on it, built May 15, trans serial # 2D-4189
4WD DRW
 
20230318_095444.jpg

Here's mine from the new one. Not very happy right now as I've discovered fluid all over my skid plates and what appears to be at least 2 leaks. You'd think when you have a truck for almost 50 days you'd triple check for leaks. Completely unacceptable.
 
View attachment 53559

Here's mine from the new one. Not very happy right now as I've discovered fluid all over my skid plates and what appears to be at least 2 leaks. You'd think when you have a truck for almost 50 days you'd triple check for leaks. Completely unacceptable.
Well that’s officially the first “real” serial with a “3” in front of it, and by the looks of the sequence number, a very early one.

That sucks about the fluid leaks, can you tell where it’s coming from??
 
**edit** dealer is ordering a new seal. They cleaned everything up hoping the other area was just residual. Almost wanted to argue with me about the rear seal leaking like you didn't drop the drives haft and tcase to remove the transmission. No matter what how are you going to let a truck with 2500 miles leave with any fluid underneath is baffling to me. Our 14 year old 242,000 mile camry is cleaner underneath.

Hopefully that means it's a good one. Time will tell there.

Rear tcase output seal is definitely leaking and it looks like the input seal is the other spot. Fluid is getting on the exhaust so I get a nice burnt Fluid smell when I get out. I'll be heading back to the dealer here in a bit. Unbelievable.
 
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