2006 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 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.

CHRYSLER WILL REPLACE THE FRAME RAIL-MOUNTED FRONT AIR BAG CRASH SENSORS IN APPROXIMATELY 312,442 MODEL YEAR (MY) 2005 AND 2006 CHRYSLER MINIVANS (RECALL 10V-008).THESE VEHICLES ARE EQUIPPED WITH FRONT CRASH SENSORS WITH ULTRADUR BRAND PLASTIC HOUSINGS AND STEEL BUSHINGS AND WERE BUILT BETWEEN JANUARY 19, 2005 AND APRIL 5, 2006.THIS ACTION COVERS VEHICLES ORIGINALLY SOLD, OR CURRENTLY REGISTERED, IN 27 STATES (ALASKA, CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, KANSAS, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEBRASKA, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, NORTH DAKOTA, OHIO, PENNSYLVANIA, RHODE ISLAND, SOUTH DAKOTA, UTAH, VERMONT, WEST VIRGINIA AND WISCONSIN) AND THE DISTRICT OF COLUMBIA.VEHICLES SOLD OR CURRENTLY REGISTERED OUTSIDE OF THESE STATES, APPROXIMATELY 185,000 MY 2005-2006 MINIVANS, ARE NOT INCLUDED IN THE RECALL.ALTHOUGH THESE VEHICLES USE THE SAME CRASH SENSORS AND WERE BUILT DURING THE SAME PERIOD AS THE ONES DESCRIBED ABOVE, THEY EXPERIENCE SIGNIFICANTLY LOWER FAILURE RATES BECAUSE OF REDUCED ROAD SALT EXPOSURE.ALSO, MY 2006-2007 MINIVANS BUILT AFTER APRIL 5, 2006, ARE NOT INCLUDED IN THE RECALL.THESE VEHICLES ARE EQUIPPED WITH FRONT CRASH SENSORS WITH CRASTIN BRAND PLASTIC HOUSINGS AND STEEL BUSHINGS AND EXPERIENCE SIGNIFICANTLY LOWER FAILURE RATES COMPARED TO THE RECALLED VEHICLES.NHTSA AND CHRYSLER DIFFER REGARDING THE SIGNIFICANCE AND IMPACT OF THE DEFECT, BUT IN THE INTEREST OF REMEDYING THE AFFECTED VEHICLES EXPEDITIOUSLY AND TO AVOID A PROTRACTED DISPUTE, CHRYSLER IS IMPLEMENTING STEPS TO REPLACE THE FRONT CRASH SENSORS.BASED ON THESE ACTIONS, THE AGENCY HAS DECIDED THAT FURTHER USE OF ITS RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS IN THE SUBJECT VEHICLES.THE AGENCY WILL MONITOR THE ISSUE AND RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SELECT DOCUMENT SEARCH FOR ADDITIONAL INFORMATION.

The contact owns a 2006 Dodge Grand Caravan. The contact stated that when the vehicle was purchased in 2010, the vehicle was missing the EGR (Exhaust Gas Recirculation) valve. The contact stated that while driving at an undisclosed speed, the vehicle failed to accelerate as intended while depressing the accelerator pedal. In addition, the vehicle idled roughly, jerked and stalled while driving. The check engine warning light was illuminated. The vehicle was taken to Auto Zone, where it was diagnosed with power train failure. The vehicle was taken to the dealer, where the contact was informed that the vehicle was missing the Exhaust Gas Recirculation (EGR) valve. The contact was provided DTCs: P0403 and P0404. The vehicle was not repaired. In 2019, the vehicle was taken to a tire business and the EGR valve was installed on the vehicle. The failure was progressively worsened, and the vehicle was no longer being driven. Upon further investigation, the contact found information on various auto websites indicating that the vehicle was manufactured in Canada and imported to the United States. The contact was the second owner. The contact found information on other auto websites that stated that the EGR valve was removed from the vehicle, and it was removed in stages. The manufacturer was notified of the failure. The contact was informed that the VIN was not under recall. The failure mileage was approximately 122,000.

NHTSA ID

11701888

Incident

Nov 5, 2013

Mileage

122,000 mi

The contact owns a 2006 Dodge Grand Caravan. The contact stated while driving 5-10 MPH and pulling out of the parking lot, the vehicle stalled. The contact was able to coast into a gas station. The contact stated that the engine was running, but the vehicle failed to respond while depressing the accelerator pedal. The vehicle was towed to the residence. The contact stated that the failure occurred while driving near the residence. The contact stated that upon turning off and restarting the vehicle, the vehicle responded as needed. Additionally, the contact stated that the sliding doors had failed to close and lock automatically and sometimes opened while driving. Additionally, the contact stated that one of the windows failed to roll down. The dealer was notified of the failure. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 130,000.

NHTSA ID

11661014

Incident

Apr 30, 2025

Mileage

130,000 mi

My complaint involves more than one incident...it is the braking system on this vehicle. One incident was in Panama City Beach, Florida. My entire braking system locked up and I had numerous items replaced. Another more recent incident happened in Alabama. My left front brake heated up to the point it smelled like the vehicle was on fire. I have had several calipers and rotors replaced, numerous brake pads and not all of these repairs has been done by the same garage. I read complaints from others about the manufacturers brake system is too small for this style vehicle. They have experienced the same problems I have had. I bought this vehicle in 2015 and I have 155,000 miles on it. I have had to replace a water pump and spark plugs and wires, regular oil changes, etc. The only real problem I have had has been the brakes. I have spent almost $3,500 on brakes alone. I would think the braking system could be a very hazardous situation in the traffic of today. Please help me and others who are experiencing this problem with the braking systems on the 2006 Dodge Grand Caravans. Thank you.

NHTSA ID

11603521

Incident

Mar 27, 2024

The contact owns a 2006 Dodge Grand Caravan. The contact stated that on several occasions, the air bag warning light illuminated for two minutes and then disappeared. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was 146,032.

NHTSA ID

11545805

Incident

May 16, 2023

Mileage

146,032 mi

The headlights and taillights come on randomly throughout the day and night while the car is parked and off. The warning dings for accidentally leaving your lights on happens every time you open the doors even though the lights are off. This has been going on since we got the vehicle.

NHTSA ID

11421495

Incident

Jun 19, 2021

LIGHTS GO OUT WHEN THE RAIN GETS UP UNDER THE CAR FROM SPLASHING ON THE ROAD. YOU HAVE TO PULL OVER TO THE SIDE OF THE ROAD, TURN IT OFF AND TURN IT BACK ON SEVERAL TIMES AND IT STAYS ON FOR A SHORT TIME. PROCEDURE IS REPEATED AGAIN. ONLY IN RAINY WEATHER AND OREGON GETS A LOT OF SPORADIC RAIN. ALSO, THE IGNITION TENDS TO TURN THE AIRBAG LIGHTS ON AND OFF WHENEVER I TURN A CORNER LEFT OR RIGHT OF HIT A BUMP.

NHTSA ID

11299939

Incident

Jan 15, 2020

Mileage

168,101 mi

TL* THE CONTACT OWNS A 2006 DODGE GRAND CARAVAN. WHILE DRIVING 45 MPH, THE OIL PRESSURE AND AN UNKNOWN WARNING INDICATOR ILLUMINATED WHEN THE BRAKE PEDAL WAS DEPRESSED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, BUT THE FAILURE COULD NOT BE DUPLICATED. ON NOVEMBER 9, 2019, WHILE DRIVING 55 MPH, WHEN THE ACCELERATOR PEDAL WAS DEPRESSED, THE VEHICLE FAILED TO ACCELERATE. THE VEHICLE WAS LOSING SPEED, BUT WAS ABLE TO BE PULLED OVER TO THE SIDE OF THE ROAD. IN ADDITION, THE STEERING WHEEL BECAME DIFFICULT TO TURN. THE VEHICLE WAS UNABLE TO BE DRIVEN. THE CONTACT CALLED THE POLICE DUE TO HER DISABLED HUSBAND BEING IN THE COLD FOR OVER TWO HOURS. A POLICE REPORT WAS FILED. HE WAS TRANSPORTED TO THE HOSPITAL, BUT THERE WERE NO INJURIES OR MEDICAL ATTENTION NEEDED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE AND THEN TOWED TO AN INDEPENDENT MECHANIC. THE CONTACT WAS INFORMED THAT THERE WAS AN OIL LEAK IN THE ENGINE AND THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. A DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

11280214

Incident

Dec 1, 2018

SLIDING DOOR LOCK ACTUATOR FROZE UP.THIS RENDERSTHE SLIDING DOOR COMPLETELY INOPERABLE.IF THAT DOOR WAS NEEDED FOREGRESS,IT WOULDNT BE AVAILABLE!!

NHTSA ID

11280071

Incident

Nov 10, 2019

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.

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 Salvage/Recycled Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of recycled or salvage parts.