Extreme Measures

4 years ago Showcase

FCA US LLC puts vehicles and products through high-pressure “stress tests” before you take the wheel, so you can deal with whatever Mother Nature dishes out.

You may never drive your FCA US LLC vehicle during the dead of winter, or take a cruise in searing 110-degree heat – but if you are so inclined to attempt such an endeavor, it’s reassuring to know your FCA US vehicle is built to handle extreme temperature swings. That’s because FCA US runs all of its vehicles through a rigorous set of extreme conditions – from frigid treks through northern Minnesota and North Dakota to scorching drives through unforgiving western deserts – in order to take the measure of every vehicle component through the ultimate “stress tests.”

FCA US tests vehicles in a variety of situations and scenarios, which vary by vehicle type and duty cycle. A significant portion of testing is done virtually, via computer simulation, while other validation is performed with actual vehicles in real-world conditions or laboratory simulation. FCA US engineers and technicians conduct these “stress tests” armed with a plethora of data and specs that must be validated for a vehicle to pass muster – all FCA US vehicles must meet or exceed the requirements of applicable Federal Motor Vehicle Safety Standards.

“Performing these extreme tests is one of our key enablers before the vehicle goes to the customer,” explains Rod Romain, Vehicle Integration Manager for Heavy Duty Truck, FCA US. “They have to pass these tests. If a vehicle doesn’t pass, it doesn’t ship. These are the core tests that help us in the development of all vehicles. These tests are paramount for what we do as a company.”

A battery of in-depth, extreme tests is conducted to satisfy the objectives set out by the design and engineering teams at FCA US. Here’s a look at some of the specifics – and how the tests take FCA US vehicles to the extreme.


Much of the extreme vehicle testing conducted by FCA US takes place in static facilities at the FCA Technology Center headquarters in Auburn Hills, Michigan, or at company proving grounds in Michigan and Arizona. Real-world testing locations vary, from North Dakota, Minnesota and Canada in the north to Arizona in the south and California in the west.


Punishing heat testing is conducted during the hottest time of the day in July and August in the deserts of Nevada and Arizona. Vehicles are run full-out to ensure that there are no overheating issues, and that the engine, oil, coolant and transmission temperatures remain at operable levels.

Vehicles are also put to the ultimate stop-and-go test – Las Vegas traffic on The Strip in the heat of the day, with the air conditioning on full blast. The main objective is to make sure the HVAC (Heating, Ventilation and Air Conditioning) system performs to its full function and that cool air continues to circulate through the cabin of the vehicle.


FCA US engineers routinely chase the cold, seeking out temperatures of 20 below zero and colder in the northern reaches of Minnesota, North Dakota and Canada. In such arctic temperatures, the main objective is to make sure a vehicle will start unassisted, so a customer can put it in Drive and be on their way. To test for driveability and handling, a vehicle is put through a slush trough, a mixture of 32-degree ice and water. The vehicle is then frozen at 20 below zero to make sure it will start up under such conditions and to ensure no loss of function from ice and snow buildup.

In regards to the “white stuff,” snow packing tests are conducted to simulate a vehicle caught in a whiteout. For Ram trucks, a day of snowplowing in extreme cold and snow is implemented to make sure those vehicles are ready for a full day of work in any condition.


FCA US can make it rain, and more – engineers have the capability of producing artificial rain, fog, snow and ice in controlled settings. These are called chamber tests and are conducted at the FCA Technology Center at home base.

Tests are used to simulate the most severe conditions a customer may ever face while driving. The main objective is to make sure vehicle systems do not freeze up, ice over or fill with water. While vehicles are frozen during outdoor tests, the same is done during chamber testing; vehicles are also baked in triple-digit, man-made heat.


Many grades (inclines and declines) are used to validate FCA US vehicles, depending on the vehicle type and its functional objectives. Engineers have the capability to simulate any grade required in the lab, combined with varying temperature, humidity and even attitude. Tests are conducted on the road itself, in hot temperature locations filled with hills and mountains, such as the Denver area. Engineers drive vehicles up and down grades, with a max grade of 32 degrees. Temperatures of major vehicle systems are observed to ensure operation at full potential, with functionality of brakes and suspension tested.


The FCA US state-of-the-art wind tunnel is capable of generating wind speeds of 160 mph, the highest of any domestic original equipment manufacturer. The wind tunnel was used extensively in development of the Ram 1500, and as a result, the truck’s drag coefficient (0.36) is best-in-class – equaling that of the SRT® Viper.

Increased fuel economy is a key result of wind tunnel tests, as vehicles are streamlined to more efficiently slip through the air, resulting in improved gas mileage. Noise reduction is also a key outcome from wind tunnel testing.


Bone-chilling arctic cold or Death Valley-levels of heat may never be encountered while shuttling the kids to soccer practice or hauling the groceries home. But when such punishing weather conditions do arise, owners can feel confident that FCA US has cared enough to make sure their rides are up to the task, thanks to “stress tests” that ensure vehicles are ready to perform under extreme pressure.



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