2005 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

The subject vehicle (SV) population includes MY 2005-2006 vehicles built between March 2004 and December 2005 manufactured with a TRW supplied headlight switch assembly (HSA).The HSA was the primary focus of the investigation; earlier and later vehicles utilized different HSAs.Consumers complain that the headlights in the subject vehicles do not illuminate when the HSA is turned on, or that the headlights extinguish while on (subject failure).No other driving lights are affected.The front marker, tail, and instrument lamps operate.Also, the high beams can be illuminated by holding the turn signal stalk in the up position.As reported by consumers, turning the HSA off and on typically corrects the failure.Initially the failures occur infrequently but they become progressively more frequent with age.Chrysler has indicated its intention to offer of an extended lifetime warranty on the HSA, so that consumers with this problem can have their HSA replaced at no charge when they begin experiencing the subject failure.Commencing sometime in early 2013, Chrysler will send letters to SV owners notifying them of the lifetime warranty.The SV headlight system design is essentially the same as that described in EA 05-009, which involved headlight anomalies in earlier model Chrysler minivans; refer to it to for additional information.The subject failure is caused by friction between the plastic cam and metal surfaces of the electrical contacts in the HSA, which results in the production of plastic particles (debris).Analysis shows that debris can collect on the electrical contact that controls the headlights, resulting in an open circuit and preventing the headlights from turning on.Subsequent operation of the HSA may temporarily displace the debris, at which time the headlights operate correctly.Lubricant was applied to the plastic cam beginning in December 2005, reducing debris production.Consequently, subsequent failure levels were lower.The report counts shown above include only those that involve the subject failure.Reports involving other failure modes which were identified have not been included either because they were not safety related, or if they were safety related, because there was no defect trend.The single crash event listed in the Failure Report Summary Table above involved a deer strike allegedly due to loss of headlights in February 2006.No injuries were reported in this crash.An April 2004 non-crash incident (?Other? above) involved a momentary loss of headlights.The consumer drove into a ditch, and one minor injury was alleged. The subject vehicles experienced a 2.2% warranty claim rate.While standing alone this would appear to be significant, a portion of these warranty claims likely involve other problems with the HSA unrelated to the subject failure.In view of the on road experience of drivers in rapidly restoring headlight illumination by turning the headlight switch off and on again, the rate and particularly the recent trend in problems with the switch, and Chrysler?s extended lifetime warranty coupled with the owner notification of that extended warranty, further investigation does not appear to be warranted.Accordingly, the investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist, and the agency reserves the right to take additional action if warranted by new circumstances.Details on Chrysler?s lifetime HSA warranty extension for the SV population will be available in the public file for this investigation.

On November 18, 2010, NHTSA's Recall Management Division (RMD) opened an audit query (AQ10-001) to investigate recall remedy completion by rental car companies on safety recall campaigns.It was expected to provide the agency an indication of how completely and how quickly rental car fleets perform necessary recall-related remedies on the vehicles owned and then rented/leased for use on the roadways.RMD queried three (3) major motor vehicle manufacturers (Ford, Chrysler, and General Motors) and requested data regarding completion figures for fifteen (15) discreet safety recalls.Analysis of this data demonstrated that rental car recalls completion was neither complete nor consistent.The rental car companies representing the largest market share in the industry were then queried as to their respective policies for the rental, lease, and sale of vehicles with open recalls.The data and responses from the manufacturers and the rental car companies can be found in the document repository by accessing the ?Associated Documents link above.In December 2015, Congress enacted the Fixing America's Surface Transportation (FAST) Act.One section of the Act prohibits rental car companies from renting, leasing, or selling motor vehicles subject to open safety recalls.With the passage of the FAST Act and its prohibition, there is no continuing need for the agency to investigate rental car recall completions.Accordingly, this investigation is closed.The agency reserves the right to open any future investigations, including audits of individual recalls, or groups of recalls, or rental car companies, to examine more closely safety recalls performance and completion issues in this area.

To date, ODI has interviewed several complainants who confirmed that the headlights fully extinguish, and remain extinguished, on an intermittent basis.In most cases this occurred while the vehicle was in motion.The occurrences do not show a repeatable pattern, and the problem occurs at a low frequency, typically one or more weeks between failures.For this reason most complainants have not attempted diagnosis or repair of the problem, so the cause is unknown, and the problem continues to occur.In the cases where repairs have been attempted, which consisted mainly of headlight switch and body control module replacements, mixed success is reported.In interviews complainants advised ODI that they can usually toggle the headlight switch, or turn on the high beams by actuating the column stalk (pulling it upward), when the headlights unexpectedly turn off.Complainants report that toggling the switch is usually effective, and the high beams have always been available when the column is used.During the course of the interviews ODI was able to obtain a few suspect headlamp switches for further evaluation.No verifiable crashes or injuries have been identified in the vehicle owner complaints (VOQs).Chrysler notes that its complaints also include allegations of dimming or flickering of the headlights in addition to loss of headlamps, and that their analysis of available data indicates a declining trend occurring in the field.Chrysler data reports two alleged crash incidents; one where a consumers vehicle lost forward lighting and struck a deer, and one where a consumer alleged their lighting stopped working, causing them to depart the roadway and drive into a ditch.A minor injury is alleged in this second incident.Both incidents occurred several years ago, and neither allegation has been confirmed by ODI.ODI is upgrading this investigation to an Engineering Analysis (EA11-010) to continue its analysis of the alleged defect and its consequences, which will include additional analysis of consumer reports, their frequency and trend, and Chrysler's technical information for the headlight system and its components.Additionally testing will be conducted to evaluate possible root cause(s) of the alleged defect, and will include analysis of suspect components collected from the field, and/or assessment of subject vehicles that have reportedly experienced the condition.

Air bag Light stays On, even with seat belt attached, so this means air bag is not working, not sure driver side, or passenger. went to Dodge dealer, they would NOT fix it!!

NHTSA ID

11500887

Incident

Aug 4, 2022

The door locks do not work for the sliding doors or the passenger side of the vehicle. We tried to fix this issue by checking the door lock fuse out to make sure it was okay, and it was. The driver's side is the only one that locks. The passenger door lock will not push down and lock when pressed down manually. I feel this is a safety issue and I have seen that others online are having problems with their door locks not working or getting stuck and not unlocking. I don't understand why there is no recall on this issue with the 2005 Dodge Grand Caravan. This is a serious safe issue on any vehicle. My sliding doors have to be manually locked and as I said, the passenger side won't lock, so it's dangerous for me to have passengers. My local Dodge dealership offered to diagnose it, but it's $125.00 for them to just find out what's causing this if they could even do that. Clearly it is an issue of some kind since one door locks. Can you please look into this? Again, I know others have had door lock issues with the Dodge Caravan. Why hasn't this been fixed and recalled already? This is very frustrating. Also, I don't remember the exact date I purchased my vehicle in June, so I've given it my best guess. Thank you for your time in reviewing this. Resolution that fixes this for myself and everyone else who is dealing with this, would be much appreciated.

NHTSA ID

11446727

Incident

Jun 7, 2021

TL* THE CONTACT OWNS A 2005 DODGE GRAND CARAVAN. THE CONTACT STATED THAT AFTER REFUELING THE VEHICLE AND ATTEMPTING TO ACCELERATE, THE VEHICLE HESITATED. THE VEHICLE'S FAILURE BEGAN TO OCCUR WITHIN APPROXIMATELY 2 MINUTES OF STARTING THE VEHICLE. THE CONTACT TOOK THE VEHICLE TO THE DEALER (MOUNTAIN VALLEY MOTORS, INC. 7535 APPALACHIAN HWY, BLUE RIDGE, GA 30513; (706) 516-1053) WHO INFORMED THEM THAT THE CHECK VALVE FAILED AND NEEDED TO BE REPLACED, THEREFORE, THE ENTIRE TANK NEEDED TO BE REPLACED DUE TO WHERE THE VALVE WAS LOCATED. THE VEHICLE HAD NOT BEEN REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OPENED A CASE NUMBER. THE MANUFACTURER INFORMED THE CONTACT THAT THEIR VEHICLE WAS NO LONGER COVERED UNDER WARRANTY. THE APPROXIMATE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

11373501

Incident

Dec 10, 2017

TL* THE CONTACT OWNS A 2005 DODGE CARAVAN. THE CONTACT STATED THAT A SMOG TEST DETECTED A FUEL LEAK FROM THE FUEL TANK. THERE WERE NO WARNING LIGHTS ILLUMINATED. THE CONTACT STATED THAT THERE WAS A STRONG FUEL ODOR OUTSIDE OF THE VEHICLE PRIOR TO THE SMOG TEST BEING PERFORMED. THE VEHICLE WAS NOT TAKEN TO BE DIAGNOSED NOR REPAIRED. NEITHER THE DEALER NOR THE MANUFACTURER WAS CONTACTED OR INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS 148,936.

NHTSA ID

11309976

Incident

Feb 18, 2020

Mileage

148,936 mi

TL* THE CONTACT OWNS A 2005 DODGE CARAVAN. WHILE DRIVING 30 MPH, THE BRAKE PEDAL WAS DEPRESSED, BUT THE VEHICLE FAILED TO STOP. ALSO, THE CHECK ENGINE INDICATOR ILLUMINATED. THE CONTACT ALSO MENTIONED THAT THERE WAS A STRONG ODOR OF FUEL INSIDE THE VEHICLE. AS A RESULT, THE CONTACT'S VEHICLE CRASHED INTO ANOTHER VEHICLE. THE AIR BAGS DID NOT DEPLOY. A POLICE REPORT WAS FILED. THE CONTACT SUSTAINED BRUISING AROUND HER CHEST THAT REQUIRED MEDICAL ATTENTION. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE CONTACT WAS INFORMED THAT THERE WAS A LEAK FROM THE RADIATOR AND THEY REPLACED THE HOOD. THE CONTACT ALSO MENTIONED THAT HER EMPLOYER OWNED A FLEET OF VEHICLES THAT EXPERIENCED THE SAME FAILURES. THE MANUFACTURER AND DEALER WERE NOT MADE AWARE OF THE FAILURES. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 22,000.

NHTSA ID

11286891

Incident

Nov 22, 2019

Mileage

22,000 mi

REMOTE RANDOMLY WILL NOT LOCK/ UNLOCK DOORS. PULL THE BATTERY CABLE AND REMOTE WORKS. CHRYSLER SENT OUT TSB 08-040-04 ON SUBJECT. THEY HAVE A GLITCH IN ORIGINAL SOFTWARE AND SEEMS UNFAIR THAT CONSUMER MUST PAY TO HAVE IT FIXED. SLIDING DOORS DO NOT HAVE KEYS TO LOCK SO ONE MUST CRAWL THROUGH THE DRIVER / PASSENGER SEAT TO LOCK MANUALLY. AS AN OLDER ADULT THIS IS A SAFETY HAZARD. IT SHOULD BE RECALLED.

NHTSA ID

11192740

Incident

Mar 30, 2019

TL* THE CONTACT OWNED A 2005 DODGE CARAVAN. WHILE DRIVING 40 MPH, THE STEERING WHEEL SEIZED AND CAUSED THE CONTACT TO CRASH INTO A GUARDRAIL. THERE WERE NO INJURIES. THE AIRS BAGS DID NOT DEPLOY. A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED BY AN INDEPENDENT TOWING COMPANY TO A SALVAGE LOT WHERE IT WAS DEEMED DESTROYED. BLEVINS SEAWAY MOTORS (98 CENTER ST, MASSENA, NY 13662, (315) 764-0283) WAS CONTACTED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND DID NOT ASSIST. THE CAUSE OF THE FAILURE WAS NOT DETERMINED. THE FAILURE MILEAGE WAS 136,000.

NHTSA ID

11183164

Incident

Jan 8, 2019

Mileage

136,000 mi

WHEN PUMPING GASOLINE INTO THE TANK, WITHIN A FEW SECONDS THE GASOLINE BACKLOWS AND TURNS OFF THE PUMP. IN ORDER TO GET 5 GALLONS INTO THE TANK IT MAY TAKE 20 STOPS, WAIT & STARTS WHICH MAY TAKE 5 MINUTES. THE CHARCOAL VAPOR TRAP IS WORKING FINE SINCE THE HOSE TO IT FROM THE GASOLINE TANK WAS DISCONNECTED TO TEST THE VAPOR CANISTER. MECHANIC DOES NOT HAVE A CLUE HOW TO RESOLVE THIS PROBLEM. THIS IS AN ONGOING PROBLEM FOR OVER A MONTH AND A HALF.

NHTSA ID

11173726

Incident

Dec 15, 2018

Mileage

89,929 mi

Transmission Kit with Torque Converter 1. All Promaster (VF) 3.6L/62TE equipped vehicles. If the transmission bracket to the transmission case fasteners are removed during servicing, the fasteners (Part Number 06511385A$) are one-time usage. Vehicles built prior to 10/23/2015 requires Service Kit PN 68461214AA; includes Transmission Isolator PN 68264483AA, and Adaptation Bracket 68264479AA and Fastener Service Kit PN 68329056AA Vehicles built after on or after 10/23/2015 will require only the Fastener Service Kit PN 68329056AA. 2. All 3.6L/62TE equipped vehicles. If the vehicle you are repairing has a crack in the flex plate or failed pump bushing inspect and confirm that both (2) dowel pins are present in the engine block, which align the transmission center line to the crank shaft centerline and visually inspect the dowel alignment holes in the transmission case. If the holes are damaged or elongated the transmission should be replaced to prevent further damage to the transmission/flexplate or pump bushing due to the inability to properly align the engine to the transmission during the repair. 3. All 62TE equipped vehicles. If pump bushing is scored or damaged and the dowel pin alignment holes are ok, replace the pump assembly as opposed to complete transmission. 4. All 62TE equipped vehicles. If vehicle is jerking/slipping with MIL code(s) P0740 or P2764, check TCC Solenoid operation. If TCC Solenoid is ok, the codes are indicative of a torque converter failure. Replace the torque converter.

Transmission Kit with Torque Converter 1. All Promaster (VF) 3.6L/62TE equipped vehicles. If the transmission bracket to the transmission case fasteners are removed during servicing, the fasteners (Part Number 06511385A$) are one-time usage. Vehicles built prior to 10/23/2015 requires Service Kit PN 68461214AA; includes Transmission Isolator PN 68264483AA, and Adaptation Bracket 68264479AA and Fastener Service Kit PN 68329056AA Vehicles built after on or after 10/23/2015 will require only the Fastener Service Kit PN 68329056AA. 2. All 3.6L/62TE equipped vehicles. If the vehicle you are repairing has a crack in the flex plate or failed pump bushing inspect and confirm that both (2) dowel pins are present in the engine block, which align the transmission center line to the crank shaft centerline and visually inspect the dowel alignment holes in the transmission case. If the holes are damaged or elongated the transmission should be replaced to prevent further damage to the transmission/flexplate or pump bushing due to the inability to properly align the engine to the transmission during the repair. 3. All 62TE equipped vehicles. If pump bushing is scored or damaged and the dowel pin alignment holes are ok, replace the pump assembly as opposed to complete transmission. 4. All 62TE equipped vehicles. If vehicle is jerking/slipping with MIL code(s) P0740 or P2764, check TCC Solenoid operation. If TCC Solenoid is ok, the codes are indicative of a torque converter failure. Replace the torque converter.

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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Charging System, Battery Diagnostic Tools and Warranty This information only bulletin discusses using the correct test equipment for testing batteries and charging systems, and also warranty reimbursement when battery replacements are necessary.