2003 Dodge Grand 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

THIS INVESTIGATION WAS OPENED AS PE04-054 REGARDING REPORTS OF ALLEGED POWER LIFTGATE (PLG) OPENING WHILE DRIVING.THE INVESTIGATION WAS UPGRADED ON NOVEMBER 22, 2004 BASED ON INFORMATION PROVIDED BY DAIMLERCHRYSLER CORPORATION (DCC) IN ITS SEPTEMBER 17, 2004 RESPONSE TO PE04-054. BY LETTER OF APRIL 5, 2005, DCC HAS NOTIFIED THE AGENCY THAT IT WILL CONDUCT A SAFETY RECALL OF 70,235 MODEL YEAR (MY) 2003 CHRYSLER TOWN & COUNTRY AND DODGE GRAND CARAVAN VEHICLES EQUIPPED WITH THE PLG OPTION.DCC HAS IDENTIFIED A PROBLEM IN EARLY PRODUCTION MY 2003 PLG CONTROL MODULES THAT CAN PREVENT THE PLG DOOR FROM LATCHING CLOSED IN A POWER OPEN/CLOSE CYCLE.IN THIS CONDITION THE PLG CAN RISE (NOT POWER OPEN) DURING VEHICLE OPERATION.DEALERS WILL INSTALL A REVISED PLG CONTROL MODULE TO REMEDY THE AFFECTED VEHICLES.SEE SAFETY RECALL 05V134 FOR DETAILS.

THIS INVESTIGATION WAS OPENED ON JULY 30, 2004, BASED ON ODI CONSUMER COMPLAINTS ALLEGING UNWANTED OPENING OF THE VEHICLE'S POWER LIFTGATE (PLG) WHILE DRIVING.IN DAIMLERCHRYSLER CORPORATION (DCC)'S SEPTEMBER 17, 2004 RESPONSE TO ODI' S INFORMATION REQUEST LETTER, IT PROVIDED ADDITIONAL CONSUMER COMPLAINTS AND LAWSUITS.DCC STATES IN PART, ...THE PLG LATCH BECOMES STUCK IN A SEMI-CLOSED STATE NOT ALLOWING THE PLG LATCH TO ENGAGE THE STRIKER, THUS NOT CLOSING THE LIFTGATE COMPLETELY.IN THIS CONDITION THE PLG AJAR WARNING LIGHT WILL NOT BE ILLUMINATED AND THE PLG CAN RISE (NOT A POWERED OPEN) WHILE DRIVING. THIS INVESTIGATION HAS BEEN UPGRADED TO EA04-031 FOR FURTHER ANALYSIS.

The contact owns a 2003 Dodge Grand Caravan. The contact stated that while driving at an undisclosed speed and turning, the vehicle made an abnormal growling sound. The vehicle was taken to an independent mechanic, where it was diagnosed that the power steering fluid was leaking. The vehicle was not repaired. The dealer was not notified of the failure. The manufacturer was notified of the failure and informed the vehicle had been repaired under NHTSA Campaign Number: 04V386000 (Steering) in 2004. The failure mileage was approximately 329,281.

NHTSA ID

11564617

Incident

Jan 3, 2024

Mileage

329,281 mi

TL* THE CONTACT OWNS A 2003 DODGE GRAND CARAVAN. WHILE DRIVING, THE STEERING WHEEL BECAME DIFFICULT TO TURN TO THE RIGHT. THE VEHICLE WAS EXAMINED BY AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE CLOCKSPRING PIN WAS FRACTURED AND CAUSED THE FAILURE. THE LOCAL DEALER AND MANUFACTURER WERE NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 367,000.

NHTSA ID

11222228

Incident

Jun 22, 2019

Mileage

367,000 mi

TL* THE CONTACT OWNS A 2003 DODGE GRAND CARAVAN. WHILE ACCELERATING FROM A STOP, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO COAST THE VEHICLE TO THE SIDE OF THE ROAD AND POWERED OFF THE ENGINE. THE VEHICLE FAILED TO RESTART AND WAS TOWED TO THE CONTACT'S RESIDENCE. THE VEHICLE WAS NOT TAKEN TO A DEALER OR AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING OR REPAIRS. THE MANUFACTURER WAS NOT CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 238,000.

NHTSA ID

11191715

Incident

May 20, 2018

Mileage

238,000 mi

THERE ARE TWO PROBLEMS THAT ARE VERY SERIOUS. FIRST, IN 2017 AS I WAS EXITING THE INTERSTATE, I DROVE THROUGH A PUDDLE. AS I ATTEMPTED TO TURN LEFT ONTO THE ROAD, MY STEERING WHEEL LOCKED AND IT WAS ONLY WITH EXTREME FORCE AND SLAMMING ON THE BRAKES THAT I KEPT FROM RUNNING THROUGH THE GUARDRAIL, AND DROPPING DOWN TO THE INTERSTATE BELOW. I WAS UNABLE TO MAKE THE TURN AND STOPPED ON THE OVERPASS UNTIL MY STEERING WHEEL UNLOCKED. YES, MY ENGINEER HUSBAND KEEPS UP WITH ALL OF OUR REGULAR MAINTENANCE, INCLUDING THE BELTS. NEXT, WITH AN UNUSUALLY HEAVY RAIN THIS PAST WEEK, MY BATTERY LIGHT CAME ON. AFTER PARKING FOR AN HOUR, MY STEERING WHEEL WOULD NOT TURN WHEN I ATTEMPTED GO AGAIN. I RESTARTED THE CAR FIVE TIMES BEFORE THE STEERING UNLOCKED. ALL WEEK, DURING THAT HEAVY RAIN, THE STEERING LOCKED REGULARLY. THESE PROBLEMS ARE ALL OVER THE WEB. WOMEN AND CHILDREN EVERYWHERE ARE IN DANGER OF DYING FROM SOMETHING THAT SHOULD HAVE BEEN RECALLED YEARS AGO. WHY IS THERE NO RECALL FOR THIS PROBLEM? IF YOU ARE REFUSING TO DO ANYTHING ABOUT THIS, THEN YOU ARE ELIGIBLE FOR BEING SUED ALONG WITH CHRYSLER, FOR ALLOWING THIS TO CONTINUE UNCORRECTED.

NHTSA ID

11152335

Incident

Nov 12, 2018

Mileage

238,958 mi

THE PASSENGER SIDE SEAT BELT WARNING LIGHT TURNS ON EVEN WHEN THERE IS NO ONE IN THAT SEAT AND THE PASSENGER SIDE SEAT BELT RELEASES WHEN THERE IS SOMEONE IN THE SEAT! ADULTS AND OLDER CHILDREN HAVE PUT THE SEAT BELT IN PLACE BUT THE WARNING LIGHT STAYS ON. WHILE DRIVING OR SITTING STILL, THE SEAT BELT WILL RELEASE AT RANDOM, CAUSING THE PASSENGER TO HAVE TO CLICK IT INTO PLACE AGAIN. WHEN THE PASSENGER CLICKS THE SEAT BELT IN PLACE AND PULLS ON IT, IT EITHER STAYS IN POSITION OR RELEASES. IF IT STAYS IN POSITION, THEN WHILE DRIVING AND OR PARKED, THE SEAT BELT WILL SUDDENLY RELEASE. WHEN THE DRIVER HAD TO STEP HARDER ON THE BRAKE TO AVOID A DRIVER WHO STOPPED SUDDENLY, THE SEAT BELT RELEASED YET AT OTHER TIMES, THE SEAT BELT REMAINS IN PLACE. IT DOESN'T MATTER WHETHER OR NOT THE VAN IS IN GEAR OR PARKED, OR IF WE'RE STOPPED, MOVING, HIGHWAY DRIVING OR CITY DRIVING, THE SEAT BELT WILL RELEASE AT RANDOM TIMES. THIS HAD HAPPENED MULTIPLE TIMES SINCE WE BOUGHT THE VEHICLE, SOMETIMES MULTIPLE TIMES IN ONE TRIP. OTHER TIMES IT DOESN'T HAPPEN AT ALL. THE DATE GIVEN IS THE MOST RECENT TIME THAT IT RELEASED ON ITS OWN. I HAD BEEN PARKED AND THEN WAS BACKING OUT OF A PARKING SPACE WHEN MY DAUGHTER'S SEAT BELT (PASSENGER SIDE) RELEASED ON ITS OWN. I STOPPED AND PUT THE VAN IN PARK THEN HAD HER CLICK IN PLACE AGAIN. WE BOTH PULLED ON IT AND SINCE IT DIDN'T RELEASE, WE CONTINUED OUR TRIP, PRAYING THAT IT WOULDN'T DISCONNECT AGAIN WHILE WE WERE DRIVING.

NHTSA ID

11051525

Incident

Nov 29, 2017

Mileage

191,600 mi

TL* THE CONTACT OWNS A 2003 DODGE GRAND CARAVAN. WHILE DRIVING 65 MPH, THE SUN ROOF EXPLODED WITHOUT WARNING WHILE THE COVER WAS CLOSED. THERE WERE NO INJURIES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE LOCAL DEALER (CENTURY DODGE CHRYSLER JEEP RAM, 13500 VETERANS MEMORIAL PKWY, WENTZVILLE, MO 63385) WAS CALLED AND STATED THAT THERE WERE NO OPEN RECALLS ON THE VEHICLE. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

11044437

Incident

Oct 31, 2017

TL* THE CONTACT OWNS A 2003 DODGE GRAND CARAVAN. WHILE DRIVING FROM THE GAS STATION AT 5 MPH, THE BRAKES FAILED TO WORK WITHOUT WARNING. THE CONTACT ALSO NOTICED SMOKE COMING FROM THE FRONT OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC ON HIGHWAY 52 IN FLORIDA WHERE IT WAS DIAGNOSED THAT THE FRAME THAT HELD THE MOTOR NEEDED TO BE REPLACED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT CONTACTED AND WAS NOT AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 98,000.

NHTSA ID

11013950

Incident

Aug 4, 2017

Mileage

98,000 mi

DURING A MARCH 2016 ROAD TRIP TO ATLANTA, GA, FROM MICHIGAN, WHILE TRAVELING ABOUT 65 MPH ON I-75, TEMPERATURE GAUGE NEEDLE BEGAN TO CLIMB TOWARD THE RED ZONE ON THE INSTRUMENT DIAL. WITHIN MINUTES I PULLED OFF ONTO A HIGHWAY CONSTRUCTION SITE WHERE I STOPPED THE VEHICLE AND TURNED OFF THE IGNITION SWITCH. OPENING THE HOOD, I BEGAN TO INVESTIGATE THE PROBLEM(S). COOL UPPER RADIATOR HOSE. COOL RADIATOR CAP. TURNED CAP OFF AND DISCOVERED NO COOLANT IN RADIATOR. NO APPARENT SOURCE OF LEAKING. ADDED ICE WATER FROM ICE CHEST TO RADIATOR HOPING TO LOCATE SOURCE OF LEAK. TURNED ENGINE ON AND LOCATED LEAK BENEATH PASSENGER SIDE OF VEHICLE: TWO SMALL HOLES IN CORRODED EXPOSED STEEL TUBING ROUTING COOLANT TO REAR HEATER ASSEMBLY IN REAR OF VAN. THE NEXT DAY DISCOVERED THAT CHRYSLER HAD CHANGED THE PART FROM STEEL TO ALUMINUM IN LATE 2000'S TO HELP PREVENT THE CORROSIVE ACTION OF ROAD SALT IN THE NORTHERN CLIMATES THAT HAD AFFECTED MANY SIMILAR VEHICLES DURING THE MID-2000'S. HOWEVER, DAIMLER CHRYSLER CHOSE NOT TO INSTITUTE A RECALL OF THE FAULTY DESIGNED PART FULLY EXPOSED BENEATH THE VEHICLE. THE COST OF REPLACING THE PART AT THE DEALERSHIP IN STONE MOUNTAIN, GA, WAS AROUND $650.00 USD, NOT A HUGE SUM, BUT OBVIOUSLY NOT COST-EFFICIENT FOR THE AUTOMAKER AND ITS SHAREHOLDERS. THIS PROBLEM COULD BE LIFE-THREATENING IF THE DRIVER AND PASSENGERS WERE STRANDED DURING THE WINTER MONTHS IN NORTHERN U.S. OR CANADA, WHEN LOSS OF ALL COOLANT OCCURRED. OPERATING VEHICLE WITH NO COOLANT COULD RESULT IN THE ENGINE SEIZING UP WHILE TRAVELING AT HIGHWAY SPEEDS, CAUSING INJURY TO DRIVER AND PASSENGERS AND POSSIBLY OTHER MOTORISTS. A DANGEROUS SITUATION THAT CHRYSLER HAS CORRECTED ON ITS LATER MODEL VEHICLES SINCE 2010 OR 2011.

NHTSA ID

10884827

Incident

Mar 17, 2016

Mileage

195,000 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.

Disinfectant Solution Recommended for COVID-19

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.

Use of Aftermarket Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of aftermarket parts.

Repair Parts Used For Structural Repairs This bulletin involves discussing FCA US LLC position with regard to structural repair parts usage.