2006 Dodge Durango

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at www.nhtsa.gov/sites/nhtsa.gov/files/documents/expert_report-hrblomquist.pdf.Consequently, all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see nhtsa.gov/recalls?nhtsaId=EA21002 -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016 four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016 four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The investigation now includes all manufacturers and vehicles known to be affected at this time.ODI's investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The five ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

ON MARCH 9, 2006 ODI UPGRADED PRELIMINATRY EVALUATION PE05-056 TO ENGINEERNING ANALYSIS EA06-004 TO INVESTIGATE ALLEGATIONS OF LOOSE OR MISSING STEERING SHAFT COUPLING BOLTS AND STEERING COLUMN RETAINING BOLTS IN MODEL YEAR (MY) 2004 THROUGH 2006 DODGE DURANGO SPORT UTILITY VEHICLES AND MY 2005 THROUGH 2006 DODGE DAKOTA PICKUP TRUCKS.EITHER CONDITION COULD RESULT IN A LOSS OF STEERING CONTROL.ALTHOUGH ODI IDENTIFIED SOME QUALITY ISSUES IN THE MANUFACTURING PROCESSES FOR THE DAKOTA AND DURANGO VEHICLES, THE DATA DO NOT INDICATE THAT A SAFETY DEFECT TREND IS PRESENT IN EITHER POPULATION.THE FAILURE RATES ARE LOW FOR EACH CONDITION AND TREND ANALYSES INDICATE THAT PROBLEMS WITH THE SUBJECT BOLTS WERE ISOLATED TO A FEW UNITS AFFECTED BY ASSEMBLY ERROR THAT WERE DETECTED EITHER PRE-SALE OR OCCURRED EARLY IN VEHICLE SERVICE.FURTHER USE OF AGENCY RESOURCES IN THIS MATTER DOES NOT APPEAR TO BE WARRANTED.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUGJECT VEHICLES AND WILL TAKE FURHTER ACTION INTHE THE FUTURE IF WARRANTED.FOR MORE INFORMATION SEE THE ATTACHED CLOSING REPORT.

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with consistently high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly, ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016, four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016, four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The PE is now closed/upgraded to an Engineering Evaluation (EA15-001) to include all manufacturersand vehicles known to be affected at this time.ODI's EA investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The recalls related to this PE are: 14V343, 14V344, 14V348, 14V351, 14V353, 14V655, 14V700, 14V701, 14V752, 14V763, 14V770, 14V773, 14V787, 14V802 and 14V817.The number of vehicles affected are an estimate since some vehicles may have both the driver and passenger side inflators recalled. The five ODI reports cited above can be reviewed online at http://www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

Vehicle: 2006 Dodge Durango VIN: [XXX] Issue Type: Fuel System / Safety Hazard Description: During refueling, the vehicle repeatedly shuts the pump off and then sprays gasoline back out of the filler neck, creating a fire and injury hazard. This is a known defect covered under Dodge Customer Satisfaction Notification X39, which extends warranty coverage for the inlet check valve / ORVR failure on 2006–2008 Durango models. The symptoms match the documented defect exactly: pump shutoff, fuel expulsion, and fuel spray. This occurs at multiple stations and with different pumps. Stellantis customer service and local dealers have been unresponsive and will not acknowledge X39 unless forced. The defect poses a clear safety risk to me and others nearby during refueling. I am requesting NHTSA involvement to ensure Stellantis honors the X39 warranty extension and addresses this fuel system hazard. Safety Risk: Gasoline sprays out under pressure, contacting the vehicle, ground, and the person refueling. This is a fire hazard and exposes the user to fuel on skin and clothing. The condition is unpredictable and dangerous. Requested Action: Require Stellantis to inspect and repair the vehicle under CSN X39 and ensure compliance with the documented unlimited‑time warranty extension for this defect. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11747356

Incident

Jun 29, 2026

Fuel spills out when you fill it up. I read there were safety recalls due to this issue for 2006 Dodge Durango's but a recall isn't appearing for my vehicle. When filling it fills fine until almost a full tank. Once it reaches full tank the gas pump clicks off then a gush of fuel spills out of my car. I bought it last year and it does it every time we put a full tank in it if you don't catch it and manually shut pump off before full. Bought the car used

NHTSA ID

11709685

Incident

Apr 2, 2025

The contact owns a 2006 Dodge Durango. The contact stated that while driving at an undisclosed speed, another vehicle abruptly merged into his lane in front of him, prompting him to rapidly decrease speeds. However, the vehicle ahead was too close; as a result, the contact collided with the rear of the other vehicle, forcing his vehicle to careen to the shoulder of the roadway before coming to a complete stop. The air bags did not deploy. The air bag warning light was illuminated. A police report was filed, and no injuries were reported. The vehicle was not taken to the dealer or an independent mechanic. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 15V313000 (Air Bags); the VIN was included, and the vehicle was repaired. The manufacturer was not notified of the failure. The failure mileage was 231,000

NHTSA ID

11582337

Incident

Apr 11, 2024

Mileage

231,000 mi

Every time filling full of gas, once full it SPRAYS gas into the air for 2 to 3 seconds. It's evident this is a manufacturing defect as multiple self reported incidents can be found online throught the years. This is vreating a significant fire risk as other vehicles can be pulling up near by. Date provided isn't accurate as this is constant if we let it fill

NHTSA ID

11509165

Incident

Feb 1, 2023

Several repairs for sensor Labor: Check and advise the check engine light is on and the vehicle wants to stall when accelerating. Vehicle loses engine power but has not stalled completely (low/reverse solenoid circuit. Test and replaced transmission solenoid assembly; cost: $819.65, prior to that $1200.00, $546.00. I'm unemployed and the truck costing more repairs. The plastic on radiator has cracked all the way cross and leaks coolant, stop radiator leak encourage by dealership and to seal leak or replace radiator (it's upsetting and its cost me thousands of dollars, my last two SUV was dodge Durango and I love them but this one has given the most problems and cost me financially. Plus, when I purchased the dealership replace windshield because of flaw in glass and it wasn't repaired correctly and Oakland County Sheriff said my truck was dangerous, but you said it was fine. Plus, the wrapped chrome grill has been replaced twice because it bubbles up. Information listed at your dealerships: Purchased at Milosch's Palace Chrysler Jeep Dodge (work performed) 3800 S. Lapeer Rd Lake Orion, MI 48359 Milosch Dodge Inc. 677 S. Lapeer Rd Lake Orion, MI 48326 Golling Chrysler Jeep Dodge Inc 2405 S. Telegraph Rd. Bloomfield Hills, MI 48302 2483343600 Firestone Complete Auto Care Pontiac/Waterford 2385 Elizabeth Lake Rd Waterford, MI 48328-3309 Tow company from sensor: Buckhorn Service 1258 S. Lapeer Road Po box 251 lake Orion MI 48360 (248)693-9375 Goodyear Auto Service Center 50300 Woodward Avenue Pontiac, MI 48342 (248)3356167 Monro Auto dba Speedy Auto 3484 Highland Rd. Waterford Mi 48328 (248)6816500 Other Tow companies had to tow under insurance policy for sensor. It's my truck[XXX] now current address [XXX] and the service work was completed under the following names in the system [XXX] Father),[XXX] (self) and son [XXX]. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ID

11447772

Incident

Oct 21, 2021

Fuel erupts from fuel filler neck EVERY TIME the fuel tank is filled, even when filling very slowly. A half-gallon or more of fuel ends up violently spitting out of the filler neck onto people in the vicinity, onto the side of the car, and onto the ground—every time the vehicle is refueled. Many owners apparently have the exact same issue, judging by the large number of complaints on Durango and Dodge forums. Apparently, there was a recall covering model-year 2005 Durangos for this issue, but the issue is present on our 2006 Durango. This is a clear safety defect that could easily create an extremely dangerous situation.

NHTSA ID

11440291

Incident

Nov 12, 2021

design issue on rack and pinion assembly. Basically metal transfer pipes on side of assembly rust out. This is my second Durango 2006 model to have this problem. Complete loss of steering assist occurs because of loss of power fluid out of fore mentioned pipes. The pipes cannot be repaired, entire rack and assembly must be replaced. Exposure to road salt is cause of rusting as assembly is totally exposed under vehicle. Stainless steel pipes are a better way except to bean counters.

NHTSA ID

11437762

Incident

Oct 16, 2021

In the winter of 2020 i had to use my 4wd lock in my durango. It never come out of 4wd lock. As a former ase technician and auto center manager I have to say dodge has a mess on their hands. 1st off its ridiculous to stop the flow of technical information to the owners of chrysler vehicles due to globalization!? I have been working on this vehicle for months as my patience allows. All testing and troubleshooting place the issue back into electrical issues within these durangos. This is a dangerous problem so many people own older dodge & chrysler products affected by this transfer case problem, recall it and get it done! Now it has to go to a chrysler dealer to have the codes cleared by a dodge scanner. Issue with that is the local dodge dealer in the village i live is not known for honesty. I took my durango there when i had issues with security system. I was told it would need a $1000. computer to start, then maybe another $1000. I took it home put a security module in it, been driving it since. Hold Chrysler accountable, do something for these thousands of people who own nice looking nice running dodge products they can't drive due to transfer case issues, and its not just one issue, there are several issues & components in that system that are troublesome!!

NHTSA ID

11429082

Incident

Jan 8, 2021

Verify Reman part number availability. Order the "R" part number for all orders: Warranty, Mopar, customer pay and service contract. Order "68" part number for New unsold units only.

Plate - Planetary

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.

GEAR MOTOR, Transfer Case The gear motor assembly is shipped in AWD/2WD position. The transfer case needs to be positioned in AWD/2WD position to properly assemble gear motor to T-Case. Please reference Star Online publication S2121000003 for further details. Do not have the transfer case in in another position other than AWD/2WD and rotate the motor to align the bolt holes as this could result in damage to the gear motor.

GEAR MOTOR, Transfer Case The gear motor assembly is shipped in AWD/2WD position. The transfer case needs to be positioned in AWD/2WD position to properly assemble gear motor to T-Case. Please reference Star Online publication S2121000003 for further details. Do not have the transfer case in in another position other than AWD/2WD and rotate the motor to align the bolt holes as this could result in damage to the gear motor.

Transfer Case Gear Motor/Actuator Installation Guidelines.