2004 Dodge Viper

ODI opened PE13-010 on April 26, 2013, to investigate two complaints alleging loss of control crashes caused by rear suspension knuckle failure in model year (MY) 2005 and 2006 Dodge Viper vehicles.The incidents described in the complaints occurred in November and December 2012.Chrysler's response to ODI's Information Request (IR) letter for PE13-010 indicates that the left and right rear knuckles used in MY 2005 and 2006 Dodge Viper vehicles were used in MY 2003 through 2010 Dodge Viper SRT-10 vehicles and in all Dodge Viper Competition Coupe and ACRX race cars (see Figure 1 of attachment to this resume for a view of the rear suspension in the subject vehicles).Chrysler's response included information about 8 reports related to rear knuckle failures, including the 2 incidents identified by ODI in the opening resume for PE13-010.In addition, after PE13-010 was opened, ODI received 2 additional complaints resulting in a total of 10 incidents of rear knuckle failure in MY 2003 through 2010 Viper vehicles, including 8 alleging crashes.Based on its review of physical evidence from field inspections of 6 of the 8 incident vehicles identified in its response, including the two incidents that were the basis for ODI opening PE13-010 (VOQs 10492180 and 10492169/10491122), Chrysler concluded that collision forces were the causal factor of rear suspension control knuckle failure.Chrysler's assessment was primarily based on examination of knuckle fracture surfaces, as well as evidence of wheel rim damage that would indicate impact loading of the affected suspension components.Each of the fracture surfaces examined by Chrysler displayed clean, granular fracture surfaces indicative of single event, overload failure.None of the parts showed any indication of fatigue crack growth.In addition to the 6 vehicles inspected by Chrysler, ODI obtained a fractured knuckle from a recent incident involving a MY 2004 Viper (VOQ 10510248).NHTSA's Vehicle Research and Testing Center in Ohio submitted this part to a laboratory for fracture surface and metallurgical analysis.The analysis concluded that there was no evidence of fatigue in the part and that the fracture was due to a single overload event (see Figures 2-4 in attachment to this resume).Analysis of the fracture surfaces found evidence of a mix of load states, with some failures associated with rear toe links in tension (Figures 2-4) and some in compression (Figures 5-6).Seven of the 8 incidents in which the side of the knuckle failure was identified involved right knuckles, the side that is generally most common for impact failures involving wheel and suspension components.The single, left side failure was associated with an incident involving an impact with a concrete barrier dividing highway travel lanes.Analysis of the failure data indicated these are random events and do not show any clear patterns related to vehicle build range, vehicle age or mileage.Examination and testing of failed knuckles have not identified evidence of a manufacturing or design defect in the parts.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor complaints and other information relating to the alleged defect in the subject vehicles and take further action in the future if warranted.VOQs associated with this investigation: 10523321, 10510248, 10492180, 10492169 (duplicate to 10491122).

TL* THE CONTACT OWNS A 2004 DODGE VIPER. THE CONTACT STATED THAT THE AIR BAG SENSOR WARNING LIGHT WOULD SPORADICALLY ILLUMINATE, INDICATING THAT THE AIR BAG SYSTEM WAS DISABLED. THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN ID NUMBER:13V040000 (AIR BAGS) BUT THE CONTACT WAS ADVISED BY THE DEALER THAT THE PARTS NEEDED TO COMPLETE THE REPAIR WERE NOT AVAILABLE. THE CONTACT RECEIVED THE NOTICE MONTHS AGO. THE MANUFACTURER WAS ALSO CONTACTED AND PROVIDED AN UNREASONABLE DATE FOR WHEN THE VEHICLE WOULD RECEIVE THE RECALL REPAIRS. THE FAILURE WAS RECURRING. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 3000.

NHTSA ID

10573562

Incident

Jan 1, 2014

Mileage

3,000 mi

TL* THE CONTACT OWNS A 2004 DODGE VIPER. THE CONTACT STATED THAT NHTSA CAMPAIGN NUMBER 13V040000 (AIR BAGS) HAD A EXCEEDED A REASONABLE TIME FOR REPAIR, THE DEALER ADVISED THE CONTACT THAT THE PART WAS NOT AVAILABLE FOR REPAIR. THE CONTACT HAD NOT EXPERIENCED A FAILURE.

NHTSA ID

10549782

Incident

Feb 1, 2013

TL* THE CONTACT OWNS A 2004 DODGE VIPER. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 5 MPH, HE HEARD AN ABNORMAL THUMPING SOUND. THE VEHICLE WAS INSPECTED BY AN INDEPENDENT MECHANIC, WHO ADVISED THE CONTACT THAT THE REAR SUSPENSION KNUCKLE WAS CAUSING THE FAILURE. ADDITIONALLY, THE CONTACT NOTICED A WHINING SOUND COMING FROM THE STEERING WHEEL AND THE STEERING WHEEL BECAME DIFFICULT TO MANEUVER. THE MECHANIC ADVISED THAT THE POWER STEERING CONNECTER HAD EXPANDED, CAUSING POWER STEERING FLUID TO LEAK. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 32,000. *TR DUPLICATE TO 10511754*SMCH

NHTSA ID

10512426

Incident

Jan 15, 2013

Mileage

32,000 mi

TL* THE CONTACT OWNS A 2004 DODGE VIPER. THE CONTACT STATED THAT THE REAR SUSPENSION STARTED TO SEPARATE FROM THE VEHICLE. THE CONTACT LOST CONTROL OF THE VEHICLE WHILE TRAVELING 10 MPH AND VEERED OFF THE ROADWAY. THE AIR BAGS IMMEDIATELY DEPLOYED, ALTHOUGH THE CONTACT'S VEHICLE HAD NOT IMPACTED ANYTHING. THE CONTACT SUSTAINED NECK INJURIES FROM THE AIR BAG DEPLOYMENT. THE VEHICLE WAS TAKEN TO THE DEALER AND THE CONTACT WAS TOLD THAT THE REAR SUSPENSION KNUCKLE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE AND CURRENT MILEAGE WAS 23,240. *TR DUPLICATE TO 10512426 *SMCH

NHTSA ID

10511754

Incident

Apr 20, 2013

Mileage

23,240 mi

TL*THE CONTACT OWNS A 2004 DODGE VIPER. WHILE DRIVING 70 MPH THE VEHICLE BECAME DISABLED AND THE WARNING LIGHTS ILLUMINATED INDICATING THAT ALL OF THE ELECTRICAL COMPONENT ON THE VEHICLE HAD FAILED. OCCASIONALLY, AFTER TURNING THE VEHICLE OFF AND ON IT WOULD RESET ITSELF AND AT OTHER TIMES IT WOULD BE AN HOUR BEFORE HE WAS ABLE TO RESTART IT. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE BODY CONTROL MODULE COMPONENTS FAILED AND HAD TO BE REPLACED. THIS FAILURE OCCURRED AT LEAST FOUR TIMES. THE DEALER REPLACED THE COMPONENTS EACH TIME PER THE WARRANTY. THE MANUFACTURER WAS NOT NOTIFIED. A CLAIM WAS FILED FOR THE FAILURE WITH THE WARRANTY DEPARTMENT. THE FAILURE MILEAGE WAS 24,300.

NHTSA ID

10367235

Incident

Sep 17, 2010

Mileage

24,300 mi

2004 VIPER BLOWS EXCESSIVE HEAT IN THE CABIN AREA. *TS IN ADDITION, THE HEATING ISSUE ALSO CAUSED THE SIDE EXIT PANELS TO BECOME EXTREMELY HOT WHICH RESULTED IN THE CONSUMERS WIFE BURNING THE BACK OF HER RIGHT CALF WHEN SHE EXITED THE VEHICLE. THE DEALER INFORMED THE CONSUMER THE HEAT WAS COMING FROM THE ENGINE. THE DEALER SUGGESTED DRIVING WITH THE AIR CONDITION ON AT ALL TIMES. *JB

NHTSA ID

10159440

Incident

Jul 21, 2005

2004 DODGE VIPER PUTS OUT EXCESSIVE HEAT IN THE CABIN AREA, CAUSED CONSUMERS WIFE TO BURN HER CALF WHEN EXITING. *TS ***NAR*** THE SIDE PANELS BECAME VERY HOT WHEN THE CONSUMERS WIFE WAS INJURED. *JB

NHTSA ID

10156236

Incident

Apr 3, 2006

THE BRAKE PEDAL AND CLUTCH PEDAL ON THIS VEHICLE IS RUSTED AND PRESENTS A SAFETY HAZARD SINCE YOUR FOOT EITHER SLIPS OFF OR STICKS TO THE PEDAL DEPENDING ON THE TYPE OF SHOE BEING WORN. THE REGIONAL SERVICE MANAGER FOR DODGE AND THE DEALERSHIP ADMITS AN INFERIOR METAL WAS USED TO MFG. THE PEDAL BUT WILL NOT MAKE ANY REPAIRS OR REPLACEMENTS. *AK

NHTSA ID

10102967

Incident

Nov 1, 2004

Mileage

2,000 mi

MODULE KIT - OCCUPANT RESTRAINT

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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