2003 Dodge Caravan

This defect petition evaluates July 7, 2014 allegations from an owner of a model year (MY) 2007 Dodge Grand Caravan minivan that engine stall occurs in these vehicles without warning after refueling.The petitioner's vehicle is a Chrysler RS platform minivan.The RS platform includes MY 2003 through 2007 Dodge Grand Caravan, Dodge Caravan, Chrysler Town and Country and Chrysler Voyager minivans.NHTSA evaluated the petition by analyzing consumer complaints submitted to the Agency, analyzing field data, reviewing technical information provided in Chrysler's response to an Agency information request and testing an RS minivan identified by its owner as experiencing post-refuel engine stalls.After completing this evaluation, NHTSA has concluded that further investigation is unlikely to result in a finding that a defect related to motor vehicle safety exists.The stalls occurring in these vehicles only occur immediately after filling up the fuel tank and happen at low engine speeds. The failure rate is low, even after 8 to 13 years of the vehicles being in service, and there are no reports of crashes or injuries resulting from the stall condition.In the Agency's view, additional investigation is unlikely to result in finding the existence of a safety-related defect in the subject vehicles.Given the need to allocate and prioritize NHTSA's limited resources to best accomplish the Agency's safety mission, the petition is denied.This action does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency will take further action if warranted by future circumstances. More details concerning our review can be found in the Federal Register Notice for this action.The following 161 VOQs are included in the petition evaluation: 10209242, 10229468, 10240708, 10260923, 10275939, 10276532, 10296487, 10298175, 10328669, 10330144, 10346517, 10349789, 10354758, 10363689, 10372112, 10372368, 10372514, 10378031, 10379764, 10382938, 10387448, 10394063, 10398877, 10413918, 10418652, 10420924, 10427063, 10437525, 10445392, 10446902, 10470028, 10471249, 10473733, 10502231, 10503114, 10504260, 10509862, 10511988, 10512120, 10512385, 10512650, 10513147, 10538154, 10549841, 10551763, 10555188, 10555418, 10556754, 10565367, 10574012, 10574398, 10586555, 10587212, 10587559, 10593433, 10607841, 10607913, 10608922, 10615810, 10622468, 10628141, 10632112, 10632128, 10632172, 10632175, 10632231, 10632262, 10632266, 10632270, 10632305, 10632316, 10632326, 10632370, 10632385, 10632399, 10632492, 10632542, 10632765, 10632833, 10632928, 10633197, 10633281, 10633409, 10633421, 10633483, 10633507, 10637752, 10637804, 10637950, 10637975, 10638032, 10638289, 10638290, 10638401, 10638968, 10639218, 10639623, 10641157, 10641603, 10641614, 10641836, 10644339, 10644705, 10649713, 10649895, 10649932, 10650313, 10652590, 10653147, 10653783, 10654533, 10655226, 10658900, 10659679, 10660320, 10662588, 10662645, 10662662, 10663473, 10667056, 10667437, 10668081, 10668094, 10668131, 10668612, 10668969, 10668970, 10669584, 10669678, 10669729, 10669775, 10669866, 10669895, 10669992, 10670422, 10670506, 10676348, 10676732, 10677120, 10679795, 10679934, 10680057, 10680290, 10680342, 10680714, 10681512, 10682584, 10682906, 10683022, 10683114, 10683549, 10683620, 10683697, 10683743, 10689898, 10690761, 10691284, 10691556, 10691751, 10693061, 10694300

DRIVING DOWN THE HIGHWAY AT REGULAR SPEED AND ENGINE COMPRESSION SHUT DOWN AND VEHICLE STALLED, AS I BARELY COASTED OFF TO THE SIDE OF THE HIGHWAY, AS THIS SITUATION WAS VERY DANGEROUS..

NHTSA ID

11404631

Incident

Mar 23, 2021

Mileage

154,000 mi

TL* THE CONTACT OWNS A 2003 DODGE CARAVAN. THE CONTACT STATED WHILE DRIVING AT 25 MPH, THE POWER STEERING STARTED TO FAIL WHICH MADE THE VEHICLE DIFFICULT TO STEER. THE CONTACT STATED NO WARNING LIGHT WAS ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED WITH THE UPPER POWER STEERING COOLER HOSE NEEDING TO BE REPLACED. THE CONTACT RELATED THE FAILURE TO NHTSA CAMPAIGN NUMBER: 04V386000 (STEERING) WHICH WAS PREVIOUSLY PERFORMED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER HAD NOT BEEN INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 108,000.

NHTSA ID

11403052

Incident

Jun 11, 2018

Mileage

108,000 mi

I WAS DRIVING AND HIT A POT HOLE AND THE REAR AXLE BROKE CAUSE BY CHEAP DESIGN REAR AXLE SUPPORT. AFTER CHECKING OUT YOU TUBE IT IS E COMMON PROBLEM WITH DODGE AND CHRYSLER VANS. IF THIS HAPPENED ON THE HIGHWAY ONE CAN END UP UNDER A 18 WHEELER.

NHTSA ID

11308740

Incident

Jan 21, 2020

Mileage

137,000 mi

TL* THE CONTACT OWNS A 2003 DODGE CARAVAN. WHILE DRIVING 15 MPH AND ATTEMPTING TO MAKE A RIGHT OR LEFT TURN, THE STEERING WHEEL BECAME DIFFICULT TO MANEUVER. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE DEALER AND MANUFACTURER WERE NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 100,000. THE VIN WAS NOT AVAILABLE.

NHTSA ID

11099032

Incident

May 31, 2018

Mileage

100,000 mi

AFTER REFUELING ENGINE DIES WHEN PULLING OUT IN TRAFFIC. HAPPENED LAST THREE TIMES AFTER REFUELING.

NHTSA ID

11065549

Incident

Jan 15, 2018

Mileage

92,052 mi

I HAD ALREADY SENT INFO TO DOL (BELOW) ON 03 CARAVAN I FROM UNLICENSED DEALER MICHAEL RANKIN. PLEASE SEE COMPLAINT FORM INATTACHMENT -IT'S TOO LONG TO ADD. THEY'RE IN PROCESS OF CHARGING MICHAEL RANKIN ON 12 COUNTS FOR DIFFERENT VEHICLES SOLD,AND ASESSING MONETARY FINES. I HAVE DONE TRANSMISSION REPAIRS TO THIS POSTAL FLEET VEHICLE.ACCORDING TO EXPERIENCED MECHANISS AT 32,300 MILES THE TRANSMISSION HAD ALREADY BEEN REBUILT -IMPROPERLY. I'M COMPLAINING BECAUSE I WAS STUCK ON FAST MOVING ARTERIAL WITH LEAKING TRANSMISSION (UNSAFE CONDITION) BECAUSE OF IMPROPER REPAIRS ,AND COULD NOT MOVE THE VEHICLE IN CONJESTED TRAFFIC 1621-72ND ST EAST,TACOMA,WA 98404. VEHICLE WAS STATIONARY AT THAT MOMENT AND AT ANOTHER DIFFERENT TIME WHEN DRIVING.THIS IS THE UNSAFE PART. THE MECHANIC CHARGED ME APPROXIMATELY $1500 AND ALSO TOLD ME IT HAD TRANSMISSION ALREADY REBUILT AND (4) LOOSE BOLTS ON PUMP SEAL, ALSO HAD A "PRE OWNED" USED? WRECKING YARD TORQUE CONVERTER WHICH WAS PAINTED BLACK INDICATING THE REBUILD OCURRED. HE ALSO STATED HOW THE 2 FRONT HALF SHAFTS (AXELS) WERE WORN OUT AND I HAD TO REPLACE THOSE, ABOUT $250. IT HAS BAD POWER STEERING PUMP-AND GROANING NOISES CURRENTLY (UNSAFE CONDITION) JUST LIKE WHEN I GOT IT (32.3K MILES) VEHICLE HAS A BAD AIR CONDITIONER NOT UNSAFE. *I HAVE JPEG PHOTOS AND RECEIPS FOR PARTS,AXELS, TRANSMISSION REPAIR AND FLUID I HAD TO BUY TO KEEP FLUID IN TRANSMISSION. PLEASE SEE ATTACHMENT FOR COMPLAINT SENT TO WASHINGTON DOL , JOSH IS THE CONTACT.

NHTSA ID

11063819

Incident

Jun 10, 2017

Mileage

36,000 mi

FUEL WIRING HARNESS IS TO CLOSE TO EXHAUST CAUSED MELTING OF WIRES WHILE GOING DOWN THE ROAD. I NOTICED A BURNING SMELL IN THE CABIN OF CARAVAN. IT HAPPENED APPROX. A MILE FROM MY HOUSE AT APPROX 45MPH AND A STRONG ODOR OF GAS WAS NOTICEABLE. THIS IS A SERIOUS ISSUE THAT NEEDS TO BE CORRECTED. VEHICLE BEGAN TO STALL COMING UP DRIVE WAY. WE STILL HAVE THE CARAVAN BUT HAVE PARKED IT. WE BELIEVE WHEN THE MELTING OCCURRED IT CAUSED OTHER POSSIBLE ISSUES AND ARE SCARED TO HAVE IT FIXED, NOT KNOWING WHAT OTHER ISSUES THIS MAY HAVE CAUSED THAT WE WILL NOT KNOW UNTIL WE ARE GOING DOWN THE ROAD, IT'S NOT A RISK I'M WILLING TO TAKE...ESPECIALLY WITH GAS BEING FLAMMABLE AND SHORTENING OF FUEL ELECTRICAL WIRES. THAT'S A FIRE IN THE MAKING, IT'S NOT WORTH RISKING OUR LIVES OR ANYONE ELSE'S ON ROAD. I HAVE SEEN SEVERAL OTHER COMPLAINTS ON REVIEW PAGES AND MECHANICS BLOGS/POSTS. THIS SEEMS TO BE A CONTINUING ISSUE THAT HAS NOT BEEN ADDRESSED. I HAVE SEEN THAT OTHER YEAR MODELS WERE RECALLED DUE TO THE SAME ISSUE BUT NOT THE 2003 DODGE CARAVAN SPORT. CAN YOU PLEASE INVESTIGATE THIS MATTER? IT COULD BE A SIMPLE FIX BY MOVING WIRES AWAY FROM EXHAUST BUT YOU ARE UNAWARE THAT, IT'S A ISSUE, UNTIL IT HAPPENS. BECAUSE IT NOT A VISIBLE HARNESS THAT YOU CAN SEE JUST BY RAISING HOOD.IT'S ONLY WHEN YOU HAVE PROBLEMS THAT YOU REALLY GET TO LOOKING AND THAT'S WHEN YOU SEE IT MELTED AND BURNED WITH STRONG ODOR COMING OUT FROM UNDER HOOD WHEN WE CHECKED IT. ALSO CATALYTIC CONVERTER WAS HOT THIS SHOULD NOT BE A CONSUMER EXPENSE WHEN IT HAPPENS. DUE TO WIRES TO CLOSE TO EXHAUST IT SEEMS TO BE A ISSUE FOR DODGE, SINCE THIS IS DUE TO THEIR FAULT AND NOT THE CONSUMER, DODGE SHOULD BE HELD ACCOUNTABLE FOR COST WHEN FUEL HARNESS WIRES MELTS AND ANY FURTHER DAMAGE CAUSED BY THE WIRES SHORTENING OUT . THIS IS A DANGEROUS/SERIOUS ISSUE THAT I HOPE CAN BE ADDRESSED SOON...BEFORE A LIFE IS LOST.

NHTSA ID

10978732

Incident

Jan 23, 2017

Mileage

242,000 mi

WAS DRIVING DOWN THE ROAD AIR BAG LIGHT CAME ON TOOK TO MIDDAS HAD INSPECTION $200 LATER LIGHT STILL ON NO ONE KNOWS WHY SCARED IT'S GOING TO BUST WAS ON A STRAIGHT ROAD NO BUMPS

NHTSA ID

10969672

Incident

Mar 1, 2017

Mileage

200,000 mi

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicle, use the "AC" NIC level part and submit a part warranty.

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicle, use the "AC" NIC level part and submit a part warranty.

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