2004 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

The contact owns a 2004 Dodge Grand Caravan. The contact stated that while driving at an undisclosed speed, another vehicle crashed into the rear passenger side of the vehicle. The air bags failed to deploy. The air bags warning light illuminated. The contact stated that her face hit the steering wheel. A police report was filed. The contact drove to the nearest hospital, however, she was unconscious upon arrival and was transported inside the hospital. The vehicle was towed to the contact's residence. The contact had been seeking medical assistance. The dealer was notified of the failure and informed the contact that her VIN was not included in a recall related to the failure. The manufacturer was not notified of the failure. The vehicle was not diagnosed or repaired. The approximate failure mileage was unknown.

NHTSA ID

11441320

Incident

May 15, 2021

SLIDING DOOR LOCKING ACTIVATOR FAILURE PREVENTS TO DOOR FROM BEING UNLOCKED MANUALLY WHICH IS A BIG SAFETY ISSUE BECAUSE REAR PASSENGERS CANNOT EXIT THEM DOORS AND THEREFORE HAVE TO CLIMB OVER THE CONSOLE AND FRONT SEATS TO EXIT .. THIS IS A BIG PROBLEM AFFECTING ALL GRAND CARAVAN AND CARAVANS WITH POWER LOCK AND SLIDING DOORS. I WILL REPEAT THIS YOU CANNOT UNLOCK THE DOOR MANUALLY IF THE ACTUATOR FAILS WHICH PREVENTS PASSENGERS FROM EXITING THE VEHICLE IN THE CASE OF AN EMERGENCY AND CHRYSLER NEEDS TO RECALL THESE VEHICLES AND REPAIR THEM SO THE LOCKS CAN BE UNLOCK UNDER ALL CIRCUMSTANCES FROM THE INSIDE

NHTSA ID

11403971

Incident

Mar 19, 2021

Mileage

200,000 mi

TL* THE CONTACT OWNS A 2004 DODGE GRAND CARAVAN. THE CONTACT STATED WHILE DRIVING, THE VEHICLE OVERHEATED WITHOUT WARNING. THE FAILURE OCCURRED SEVERAL TIMES. THE CONTACT STATED AS PRECAUTION THE VEHICLE WAS STOPPED TO ALLOW THE ENGINE TO COOL DOWN. THE VEHICLE WAS NOT TAKEN TO A DEALER NOR WAS THE MANUFACTURED NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 213,000.*DT CONSUMER STATED AFTER CHANGING THE THERMOSTAT PIECES OF PLASTIC CAME OUT OF THE MOTOR. PROBLEM WITH OVERHEATING HAS OCCURED FOR 4 YEARS. *JB*DT*JB

NHTSA ID

11319349

Incident

Mar 20, 2017

Mileage

213,000 mi

HAIRLINE CRACKS IN FUEL PUMP OUTLET JUST BEFORE CONNECTING TO FUEL LINE LEADS TO STRONG FUEL SMELL AND FUEL VAPORS ALL AROUND VEHICLE. FUEL PUMP NEEDS REPLACEMENT TO REPAIR THIS DANGEROUS CONDITION. HIGHLY SUGGEST DIFFERENT FUEL PUMP DESIGN THAT IS NOT PRONE TO HAIRLINE CRACKS AND POTENTIAL FIRE HAZARD AS FUEL LEAK IS ABOUT ONE FOOT AWAY FROM A HOT MUFFLER AND A TOSSED CIGARETTE OR OTHER SPARK COULD CAUSE A FIRE OR EXPLOSION.

NHTSA ID

11253106

Incident

Aug 30, 2019

Mileage

260,000 mi

AFTER FILLING THE GAS TANK, WITHIN A FEW MILES THE VEHICLE WILL STALL. DODGE ALREADY HAS EXTENDED THE WARRANTY ON THE FUEL TANK OF VEHICLE BUILT AFTER SEPTEMBER 2003 BUT MINE WAS BUILT AUGUST 5 2003 SO IT IS OUTSIDE THEIR WINDOW. THIS IS A VERY DANGEROUS ISSUE BECAUSE IT HAS HAPPENED TO ME ON THE HIGHWAY AT 55 MILES AN HOUR AND I THEN HAVE NO POWER AND NEED TO GET OUT OF THE WAY OF TRAFFIC THAT IS GOING TO RUN ME OVER.

NHTSA ID

10924275

Incident

Nov 3, 2016

Mileage

115,000 mi

EVERY TIME WE FILL THE FUEL TANK THE CARAVAN CUTS OFF AND RIDES VERY ROUGH. THE RECALL ON THE DODGE CARAVAN WAS ON VANS BUILD STARTING ON 09/01/2003 MY CARAVAN WAS BUILT ON 09/29/2013.

NHTSA ID

10824863

Incident

Nov 1, 2014

Mileage

150,000 mi

TL* THE CONTACT OWNS A 2004 DODGE GRAND CARAVAN. THE CONTACT STATED THAT AFTER REFUELING THE VEHICLE, IT STALLED WITHOUT WARNING. AFTER SEVERAL ATTEMPTS THE VEHICLE WAS ABLE TO RESTART BUT THE FAILURE RECURRED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 70,000.

NHTSA ID

10823476

Incident

Apr 20, 2012

Mileage

70,000 mi

ENGINE STALLS OUT 10 OR 15 SECONDS AFTER FILLING THE GAS TANK. USUALLY ON THE HIGHWAY YOU ARE TURNING ON TO. ITS BEEN DOING THIS FOR A COUPLE OF YEARS.

NHTSA ID

10819667

Incident

Jan 11, 2016

Mileage

160,000 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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