2005 Dodge Caravan
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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These records cover every 2005 Dodge Caravan. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
9 recalls name the 2005 Dodge Caravan. Newest first.
Curt mfg IS recalling certain class 3 receiver hitches, p/n 13347, sold as aftermarket equipment for use on 1997-2007 chrysler town and country vans, 1996-2007 dodge caravans, and 1996-2004 plymouth voyager vans. when the hitch IS loaded to the maximum rating, the hitch may fracture or break at the bend location where the main body of the hitch meets the…
Risk and remedy
Risk
If the area in question fractures or breaks, this could cause an unstable driving condition, possibly resulting in a crash.
Remedy
Curt mfg will notify owners of record and will replace the hitch free of charge. the safety recall IS expected to begin during august 2010. owners may contact curt mfg at 1-715-831-8713.
Chrysler IS recalling certain model year 2005-2006 dodge caravan, grand caravan and chrysler town & country vehicles originally sold in or currently registered in the states of connecticut, delaware, iowa, illinois, indiana, kansas, kentucky, massachusetts, maine, maryland, michigan, minnesota, missouri, nebraska, new hampshire, new jersey, new york, north…
Risk and remedy
Risk
If the front crash sensors become inoperative, the driver IS immediately alerted by illumination of the airbag warning light and the vehicle should be promptly serviced. until the vehicle IS repaired, the airbags may not provide the enhanced protection in the event of a crash.
Remedy
Chrysler will replace the front airbag sensors with a new design. This service will be performed free of charge. the safety improvement campaign will begin during june 2010. owners may contact chrysler at 1-800-853-1403.
Eagle eyes IS recalling 11,534 headlamp assemblies, p/nos. Cs090-b001l and cs090-b001r, sold for use as replacement equipment for the above listed passenger vehicles. these headlamps fail to conform to the lower beam photometry requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment."
Risk and remedy
Risk
Decreased lighting visibility may result in a vehicle crash.
Remedy
Eagle eyes will notify owners and offer replacement headlamps free of charge. the recall began on september 30, 2008. owners may contact eagle eyes at 1-800-568-1098.
Maxzone IS recalling 2,520 headlight assemblies, depo brand, p/nos. 3341103L-as and 334-1103r-as sold for use as aftermarket equipment for 2001-2007 dodge caravan passenger vehicles. these headlamps fail to conform to the requirements of federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Risk and remedy
Risk
Decreased lighting visibility may result in a vehicle crash.
Remedy
Maxzone will notify owners and offer reimbursement for any noncompliant headlights. the recall began on june 16, 2008. owners may contact maxzone at the following locations: 1-888-286-1188 (wa, or, ca, ID, NV, az, mt, wy, ut, co, ks, nm, ok, tx, ar, la, ak, hi) 1-877-253-8930 (me, nh, vt, ma, ct, ri, ny, nj, pa, md, de, wv, va) 1-800-859-4755 (nc, sc, ga, fl, tn, al, ms) 1-866-783-6858 (nd, sd, ne, mn, ia, mo, wi, il, mi, in, oh, ky).
Certain curved tempered replacement glass manufactured by hangzhou safety glass ltd and supplied to safelite by auto temp inc., identified as dot-430, and sold for use on certain domestic and foreign vehicles may not break into small pieces as expected of tempered glass and fails to conform to federal motor vehicle safety standard no. 205, "glazing…
Risk and remedy
Risk
In the event of a vehicle crash, the occupant(s) may be seriously injured by shattered glass.
Remedy
Safelite will notify its retail customers and replace the glass free of charge. Retail customers can contact safelite toll free at 1-888-843-2906. Safelite will notify its wholesale customers and reimburse wholesale customers for current inventory and at a specified rate for replacing their customer's glass. Wholesale customers can contact safelite's wholesale division, service autoglass toll free at 1-888-246-6298. The recall began on january 15, 2008.
Certain minivans are being recalled that were originally sold in or currently registered in the 27 states plus the district of columbia that use greater amounts of salt for winter road deicing. the up-front (uf) air bag sensors that contain brass bushings installed in these vehicles may corrode and crack allowing water to enter the sensor. these sensors…
Risk and remedy
Risk
In one of these crashes, with one or both of the vehicle's uf sensors inoperative, the occupants will not benefit from the enhanced air bag protection that these sensors would provide.
Remedy
For vehicles registered in the recall states, dealers will replace the original uf air bag sensors with ones with greater corrosion resistance. vehicles registered in other states will obtain a lifetime free replacement of any uf sensor that fails. the campaign began on july 2, 2007. owners may contact daimlerchrysler at 1-800-853-1403.
Certain aftermarket brake hydraulic master cylinders sold as replacement brake cylinders for certain ford, daimlerchrysler, and jeep passenger vehicles. these brake cylinders were sold under the brand names of napa, raybestos, aimco, ac delco, carquest, bendix, and wagner. only products that were manufactured from july 27, 2005 through january 17, 2006…
Risk and remedy
Risk
Loss of brake fluid can lead to a decrease in brake line pressure and an increase in stopping distance, which can result in a vehicle crash.
Remedy
Affinia (brake parts, inc.) will replace the subject brake hydraulic master cylinders free of charge. the recall began on march 20, 2006. owners can contact affina group customer service at 1-800-323-0354.
On certain vans and sport utility vehicles, the front windshield wiper motor armature shaft may break.
Risk and remedy
Risk
During certain operating conditions, loss of front windshield wiping capability could occur, and the driver's vision could be obscured which could result in a crash.
Remedy
Dealers will inspect and replace the windshield wiper motor free of charge. the recall began on june 19, 2006, to dodge durango owners. minivan owners will be notified during july 2006. owners may contact daimlerchrysler at 1-800-853-1403.
After performing the ncap test, it was discovered that on certain minivans equipped without the available "stow 'n go" seating option, the right front seat belt retractor assembly may have been improperly assembled.
Risk and remedy
Risk
As a result, the seat belt may not properly restrain the occupant during certain crash conditions, which can increase the risk of injury.
Remedy
Dealers will inspect the retractor assemblies and any seat belt assembly that does not have the stake will be replaced. owner notification began on february 23, 2004. owners should contact daimlerchrysler at 1-800-853-1403.
Owner complaints
537 complaints19 involved a crash19 injuries
What owners report most
Latest complaints
- Air bags
Air bag Light stays On, even with seat belt attached, so this means air bag is not working, not sure driver side, or passenger. went to Dodge dealer, they would NOT fix it!!
- Electrical system · Structure › Body
The door locks do not work for the sliding doors or the passenger side of the vehicle. We tried to fix this issue by checking the door lock fuse out to make sure it was okay, and it was. The driver's side is the only one that locks. The passenger door lock will not push down and lock when pressed…
The door locks do not work for the sliding doors or the passenger side of the vehicle. We tried to fix this issue by checking the door lock fuse out to make sure it was okay, and it was. The driver's side is the only one that locks. The passenger door lock will not push down and lock when pressed down manually. I feel this is a safety issue and I have seen that others online are having problems with their door locks not working or getting stuck and not unlocking. I don't understand why there is no recall on this issue with the 2005 Dodge Grand Caravan. This is a serious safe issue on any vehicle. My sliding doors have to be manually locked and as I said, the passenger side won't lock, so it's dangerous for me to have passengers. My local Dodge dealership offered to diagnose it, but it's $125.00 for them to just find out what's causing this if they could even do that. Clearly it is an issue of some kind since one door locks. Can you please look into this? Again, I know others have had door lock issues with the Dodge Caravan. Why hasn't this been fixed and recalled already? This is very frustrating. Also, I don't remember the exact date I purchased my vehicle in June, so I've given it my best guess. Thank you for your time in reviewing this. Resolution that fixes this for myself and everyone else who is dealing with this, would be much appreciated.
- Fuel/propulsion system · Vehicle speed control
TL* the contact owns a 2005 dodge grand caravan. The contact stated that after refueling the vehicle and attempting to accelerate, the vehicle hesitated. The vehicle's failure began to occur within approximately 2 minutes of starting the vehicle. The contact took the vehicle to the dealer (mountain…
TL* the contact owns a 2005 dodge grand caravan. The contact stated that after refueling the vehicle and attempting to accelerate, the vehicle hesitated. The vehicle's failure began to occur within approximately 2 minutes of starting the vehicle. The contact took the vehicle to the dealer (mountain valley motors, inc. 7535 appalachian hwy, blue ridge, ga 30513; (706) 516-1053) who informed them that the check valve failed and needed to be replaced, therefore, the entire tank needed to be replaced due to where the valve was located. The vehicle had not been repaired. The manufacturer was made aware of the failure and opened a case number. The manufacturer informed the contact that their vehicle was no longer covered under warranty. The approximate failure mileage was unknown.
- Fuel/propulsion system
TL* the contact owns a 2005 dodge caravan. The contact stated that a smog test detected a fuel leak from the fuel tank. There were no warning lights illuminated. The contact stated that there was a strong fuel odor outside of the vehicle prior to the smog test being performed. The vehicle was not…
TL* the contact owns a 2005 dodge caravan. The contact stated that a smog test detected a fuel leak from the fuel tank. There were no warning lights illuminated. The contact stated that there was a strong fuel odor outside of the vehicle prior to the smog test being performed. The vehicle was not taken to be diagnosed nor repaired. Neither the dealer nor the manufacturer was contacted or informed of the failure. The failure mileage was 148,936.
- Unknown or other
TL* the contact owns a 2005 dodge caravan. While driving 30 mph, the brake pedal was depressed, but the vehicle failed to stop. Also, the check engine indicator illuminated. The contact also mentioned that there was a strong odor of fuel inside the vehicle. As a result, the contact's vehicle…
TL* the contact owns a 2005 dodge caravan. While driving 30 mph, the brake pedal was depressed, but the vehicle failed to stop. Also, the check engine indicator illuminated. The contact also mentioned that there was a strong odor of fuel inside the vehicle. As a result, the contact's vehicle crashed into another vehicle. The air bags did not deploy. A police report was filed. The contact sustained bruising around her chest that required medical attention. The vehicle was taken to an independent mechanic where the contact was informed that there was a leak from the radiator and they replaced the hood. The contact also mentioned that her employer owned a fleet of vehicles that experienced the same failures. The manufacturer and dealer were not made aware of the failures. The vin was not available. The failure mileage was 22,000.
- Electrical system
Remote randomly will not lock/ unlock doors. Pull the battery cable and remote works. chrysler sent out tsb 08-040-04 on subject. they have a glitch in original software and seems unfair that consumer must pay to have it fixed. Sliding doors do not have keys to lock so one must crawl through the driver / passenger seat to lock manually. As an older adult this IS a safety hazard. It should be recalled.
- Steering
TL* the contact owned a 2005 dodge caravan. While driving 40 mph, the steering wheel seized and caused the contact to crash into a guardrail. There were no injuries. The airs bags did not deploy. A police report was filed. The vehicle was towed by an independent towing company to a salvage lot…
TL* the contact owned a 2005 dodge caravan. While driving 40 mph, the steering wheel seized and caused the contact to crash into a guardrail. There were no injuries. The airs bags did not deploy. A police report was filed. The vehicle was towed by an independent towing company to a salvage lot where it was deemed destroyed. Blevins seaway motors (98 center st, massena, ny 13662, (315) 764-0283) was contacted. The manufacturer was made aware of the failure and did not assist. The cause of the failure was not determined. The failure mileage was 136,000.
- Fuel/propulsion system
When pumping gasoline into the tank, within a few seconds the gasoline backlows and turns off the pump. In order to get 5 gallons into the tank it may take 20 stops, wait & starts which may take 5 minutes. The charcoal vapor trap IS working fine since the hose to it from the gasoline tank was…
When pumping gasoline into the tank, within a few seconds the gasoline backlows and turns off the pump. In order to get 5 gallons into the tank it may take 20 stops, wait & starts which may take 5 minutes. The charcoal vapor trap IS working fine since the hose to it from the gasoline tank was disconnected to test the vapor canister. Mechanic does not have a clue how to resolve this problem. This IS an ongoing problem for over a month and a half.
- Air bags
Had a recall on the airbag sensor and had it fixed 3 or 4 years ago. On 12-2-2018 the warning light came on, doing the same problem. I have not as yet found if the sensor was fixed with another bad one. This needs looked into. To see if others have this reacurring safty problem. Comes on 10 minutes into drive,goes off after sitting 2 minutes with switch off
- Tires
Tire cracking and tread separation on tourmax gft sold by eldorado. Its not in your list. Poor wear characteristics. I took my car in to an alignment shop because it was pulling toward the center of the road. I was informed that a near new tire had stress cracks and tread separation and the…
Tire cracking and tread separation on tourmax gft sold by eldorado. Its not in your list. Poor wear characteristics. I took my car in to an alignment shop because it was pulling toward the center of the road. I was informed that a near new tire had stress cracks and tread separation and the alignment and inflation pressure was ok.two more of the same tires on the same car were wearing unusually fast with no alignment issues. I feel these tires have the potential to be unsafe. The tourmax gft from eldorado has not instilled safety confidence.
- Electrical system · Fuel system, gasoline · Service brakes · Steering
2005 dodge caravan MINI van. Consumer writes in regards to multiple issues with vehicle. *Ld *js
- Electrical system
TL* the contact owns a 2005 dodge caravan. The contact stated that the key failed to turn over in the ignition and the vehicle was unable to start. The vehicle was not diagnosed by a dealer or independent mechanic. The manufacturer was notified of the failure. The vin was not available. The approximate failure mileage was 101,000.
- Exterior lighting · Fuel/propulsion system · Seat belts
When filling with gas the engine turns off while driving, this happened on a left turn with vehicles approaching, cars had to stop and help push van out of street. luckily it did not cause an accident, had two young children in vehicle , very fortunate for the quick response of other drivers.…
When filling with gas the engine turns off while driving, this happened on a left turn with vehicles approaching, cars had to stop and help push van out of street. luckily it did not cause an accident, had two young children in vehicle , very fortunate for the quick response of other drivers. fuel reading wrong first time car shut off while driving showing 1/ 4 tank of gas. now shuts off showing more than 3/4 tank of gas this happen on the highway, lost all power steering as well. Again I had two young children in car. seat belt not working properly. headlight very dim at night not good few for night time driving. this vehicle IS becoming more unsafe to drive.
- Fuel/propulsion system
My van stalls everytime I fill up the tank. I do not tap off the tank I fill it till the handle clicks once and thats it. I have done a ton of research and found that its the fuel vapor separator. Then only way to fix said problem which IS totally common on all chysler vans the way I am reading it IS that I have to replace the entire fuel tank. It stalls after filling up and when I start to drive.
- Power train
While driving, vehicle completely loses power. Before coming to a stop, power returns. This has happened during city driving, at a variety of speeds.
- Air bags · Electronic stability control (esc) · Service brakes
Myself and two others just recently got into a car accident and my airbags didnt go off . Thank god that we had our seatbelts on. A car cut a bus off on hwy44 wwst in inverness fl, we all had to hit our brakes and ending up hitting another car at 30-40 mph. When made inpack with the other car the airbags did not go off leading to injuries and had to go to the hospital.
- Electrical system · Unknown or other
Turn signal switch problem of the 2005 dodge grand caravan turn signals are not working correctly - vin # [xxx] when you signal to turn right, the left turn signals comes on. information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(B)(6). *Jb *tr
- Air bags
TL* the contact owns a 2005 dodge caravan. While driving 20 mph, the air bag indicator illuminated without warning. The vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was 72,000.
- Fuel/propulsion system
Top of the fuel pump IS made of plastic and was found cracked in two places. internet search yielded many other examples with photos showing cracks in exactly the same place. result of these cracks IS a fuel leak as well as strong gas fumes in and around the vehicle resulting in an obvious fire hazard. leaks at all time that the vehicle IS running as well as for some time after the vehicle IS stopped and parked.
- Exterior lighting · Fuel/propulsion system
Strong gas smell while driving and at stop. lights turn on and off at will.
- Fuel/propulsion system
Fuel leak caused by cracks in fuel pump fittings
- Seat belts
During a left side impact collision with a semi truck the left seatbelt of the middle row seat failed to lock. It caused my backseat passenger to be thrown from side to side in the van because of the seatbelt releasing too much slack upon collision. She sustained multiple injuries and was unable to walk for 6 weeks.
- Fuel/propulsion system
Purchased used 2005 dodge caravan with 100000 miles and it was leaking fuel around the fuel pump, took it to merlins to have it checked out resulting in replacement of fuel pump modeule due to the fact it was cracked and had to be replaced.
- Structure
TL* the contact owns a 2005 dodge caravan. The contact stated that the rear passenger side sliding door could not open or close correctly. There was also rust on the side panel that prevented the door from closing. The vehicle was taken to an independent mechanic, but was not repaired. The manufacturer was notified of the failure. The failure mileage was 67,453. updated 08/02/16*lj
- Air bags · Electrical system
Airbag warning light lit. Looked up on nhtsa website, chrysler issued a"safety improvement campaign" copy enclosed. I took my van to the dealer to have it fixed plus a new key and a recall notice for a fuel/stalling problem. I was informed that the airbag problem was not covered because of the vin…
Airbag warning light lit. Looked up on nhtsa website, chrysler issued a"safety improvement campaign" copy enclosed. I took my van to the dealer to have it fixed plus a new key and a recall notice for a fuel/stalling problem. I was informed that the airbag problem was not covered because of the vin number. The van was purchased in mass. And I purchased it in rhode island. I donot think I should have to pay 216.61 dollars to have this fixed. Thank you *tr
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Engine Stall After Refueling
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…
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
- Loss of headlight illumination
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 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.
- Fleet Vehicle Recall Completion Audit
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…
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.
- Loss of Headlight Illumination
To date, ODI has interviewed several complainants who confirmed that the headlights fully extinguish, and remain extinguished, on an intermittent basis.In most cases this occurred while the vehicle was in motion.The occurrences do not show a repeatable pattern, and the problem occurs at a low frequency, typically one…
To date, ODI has interviewed several complainants who confirmed that the headlights fully extinguish, and remain extinguished, on an intermittent basis.In most cases this occurred while the vehicle was in motion.The occurrences do not show a repeatable pattern, and the problem occurs at a low frequency, typically one or more weeks between failures.For this reason most complainants have not attempted diagnosis or repair of the problem, so the cause is unknown, and the problem continues to occur.In the cases where repairs have been attempted, which consisted mainly of headlight switch and body control module replacements, mixed success is reported.In interviews complainants advised ODI that they can usually toggle the headlight switch, or turn on the high beams by actuating the column stalk (pulling it upward), when the headlights unexpectedly turn off.Complainants report that toggling the switch is usually effective, and the high beams have always been available when the column is used.During the course of the interviews ODI was able to obtain a few suspect headlamp switches for further evaluation.No verifiable crashes or injuries have been identified in the vehicle owner complaints (VOQs).Chrysler notes that its complaints also include allegations of dimming or flickering of the headlights in addition to loss of headlamps, and that their analysis of available data indicates a declining trend occurring in the field.Chrysler data reports two alleged crash incidents; one where a consumers vehicle lost forward lighting and struck a deer, and one where a consumer alleged their lighting stopped working, causing them to depart the roadway and drive into a ditch.A minor injury is alleged in this second incident.Both incidents occurred several years ago, and neither allegation has been confirmed by ODI.ODI is upgrading this investigation to an Engineering Analysis (EA11-010) to continue its analysis of the alleged defect and its consequences, which will include additional analysis of consumer reports, their frequency and trend, and Chrysler's technical information for the headlight system and its components.Additionally testing will be conducted to evaluate possible root cause(s) of the alleged defect, and will include analysis of suspect components collected from the field, and/or assessment of subject vehicles that have reportedly experienced the condition.
- Front air bag crash sensor failure
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…
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.
- Front air bag crash sensor failure
Daimlerchrysler (dcc) will replace the frame rail-mounted front air bag crash sensors in approximately 270,958 my 2005 daimlerchrysler minivans (nhtsa recall no. 07V-192).these vehicles are equipped with front crash sensors with brass bushings and were built between april 24, 2003 and february 2, 2005.this action…
Daimlerchrysler (dcc) will replace the frame rail-mounted front air bag crash sensors in approximately 270,958 my 2005 daimlerchrysler minivans (nhtsa recall no. 07V-192).these vehicles are equipped with front crash sensors with brass bushings and were built between april 24, 2003 and february 2, 2005.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 133,128 my 2005 minivans, will receive a lifetime warranty on the front crash sensors.although these vehicles use the same brass bushing 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.dcc will also provide written notification to all affected vehicle owners.nhtsa and dcc 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, dcc IS implementing steps to replace the subject components.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.
- Front air bag crash sensor failure
The model year (my) 2005 daimlerchrysler (dc) minivans have the new advanced frontal air bag systems with two front crash sensors mounted on the frame rails behind the front bumper and a main crash sensor inside the air bag control module mounted in the passenger compartment.according to dc, the front crash sensors…
The model year (my) 2005 daimlerchrysler (dc) minivans have the new advanced frontal air bag systems with two front crash sensors mounted on the frame rails behind the front bumper and a main crash sensor inside the air bag control module mounted in the passenger compartment.according to dc, the front crash sensors are designed to optimize detection of frontal offset and angular crashes.the advanced air bag system offers different levels of air bag inflation based on input from the crash sensors.this investigation revealed that the front crash sensors can corrode from water entering the sensor assembly.dc IS still investigating all potential root causes of sensor failures.a corroded sensor can set a fault code, illuminate the air bag warning lamp, and become disabled.it appears that failure of one or both front crash sensors can potentially result in no/late deployment of frontal air bags and non-deployment of driver's higher inflation levels in certain frontal crashes.it should be noted that occupants of vehicles involved in a crash may not be aware of late or improperly reduced level of air bag inflation and thus field reporting of such events may be suppressed.this preliminary evaluation has been upgraded to an engineering analysis (ea06-003) for further investigation of my 2005 (and 2006) dc minivans.note: total number of odi and manufacturer complaints includes some duplicate reports.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10229256KEY, 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.
- 10229181Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications. An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine.
- 10223854Service - Four Piece Oil Pan Gasket All Cummins Equipped Vehicles ONLY - The replacement oil pan gasket can be a four piece gasket rather than a single piece gasket. This applies to Cummins 5.9L and 6.7L engines only. Installation: 1. Clean the oil pan T-joints.~ 2. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar Silicone Rubber Adhesive Sealant or equivalent. 3. Apply a 2-mm [0.063-in] bead of Mopar Engine Sealant RTV Silicone Rubber Adhesive, to the oil pan flange.~ 4. The four piece gasket will need to be assembled to make a complete oil pan gasket. 5. Lay the oil pan gasket(s) onto the oil pan flange.~ 6. Ensure the oil pan gasket segment joints are properly aligned. 7. Apply a 2-mm [0.063-in] bead of Mopar Engine Sealant RTV Silicone Rubber Adhesive, to the top of the oil pan gasket.~ 8. Install the oil pan. Starting from the center and working outward, tighten the oil pan bolts to 28 Nm [21 ft. lbs.].
- 10223602Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications. An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine.
- 10223599Part Description: Valve Body Assembly Issue Description: Valve body design was changed between 2010MY and 2011MY applications. To prevent mix matching valve bodies and solenoid packs the connectors are color coded.~ Valve bodies with a white connector can be used on 2010, 2009, 2008..., model years. Valve bodies with a gray connector can only be used on 2011, 2012, 2013..., model years.~ Solenoid packs with a white connector are used with 2010, 2009, 2008..., model years. Solenoid packs with a gray connector are used with 2011, 2012, 2013..., model years.
- 10221686KEY, 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.
- 10221097Transmission 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.
- 10220840Transmission 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.
- 10220101Use of Aftermarket Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of aftermarket parts.
- 10220099Use 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.
- 10220097Repair Parts Used For Structural Repairs This bulletin involves discussing FCA US LLC position with regard to structural repair parts usage.
- 10219763Extended Warranty on the Fuel Tank/Vapor Cannister
- 10218069This bulletin involves replacing the fuel tank and vapor canister.
- 10217728Generic Powertrain Control Module (PCM) Procedure This bulletin involves programming a generic PCM with software.
- 10209634Extended Warranty on the Fuel Tank/Vapor Cannister
- 10191460Valve Body. These may cause over drive cycling.
- 10175743Disinfectant Solution Recommended for COVID-19
- 10175735Charging 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.
- 10169249Use of Aftermarket Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of aftermarket parts.
- 10169247Use 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.
- 10169245Repair Parts Used For Structural Repairs This bulletin involves discussing FCA US LLC position with regard to structural repair parts usage.
- 10141243Generic Powertrain Control Module (PCM) Procedure This bulletin involves programming a generic PCM with software.
- 10139595Part Description: Insulator in Lever Assembly - Valve Body - Trans Issue Description: The manual valve insulator, attaching rivet and an instruction sheet are now available as a kit. If the insulator requires replacement lease order 68253099AA. Note: Insulator color is not relevant for service
- 10136932Part Description: Seat Belt - Retaining Button Kits. Issue Description: Do not replace the entire seat belt if the seat belt web stop button is missing or damaged.~Belt Web Button:~ 1D1 - Light Graystone - 05093280AB Belt Web Button~1D5 - Medium Slate Gray - 05093280AB Belt Web Button~1DA - Pastel Slate Gray - 05093280AB Belt Web Button~1J3 - Medium Khaki - 05093283AB Belt Web Button~ZJ3 - Medium Khaki - 05093283AB Belt Web Button~1L2 - Light Natural Beige - 05114207AA Belt Web Button~BD1 - Light Graystone - 05093280AB Belt Web Button~ BD5 - Medium Slate Grey - 05093280AB Belt Web Button~ BDA - Pastel Slate Gray - 05093280AB Belt Web Button~ ZP7 - Deep Seamist Green - 05093280AB Belt Web Button~ 5JB571D1A$, 5JB571D5A$, 5JB571J3A$, 5JX141D1A$, 5JX141D5A$, 5JX141DVA$, 5JX141J3A$, 5JX14ZJ3A$, 1EY841D1A$, 1EY841D5A$, 1EY841J3A$, 1EY851D1A$, EY851D5A$, 1EY851J3A$ use the following mini Belt Web Buttons:~1D1 - Light Graystone - 05093285AB Mini Belt Web Button~1D5 - Medium Slate Gray - 05093285AB Mini Belt Web Button~1DV - Slate Gray - 05093285AB Mini Belt Web Button~1J3 - Medium Khaki - 05093286AB Mini Belt Web Button~ZJ3 - Medium Khaki - 05093286AB Mini Belt Web Button~ Position the button as originally installed, or use the opposite side as reference.~ Web Button Location CS:~Front Driver O/B: 690 +/- 10 mm~Front Passenger O/B: 435 +/- 10 mm~Rear O/B: 435 +/- 10 mm~Rear Center: 290 +/- 10 mm~Rear Center Mini: 854 +/- 10 mm~ Web Button Location RG/RS SWB:~Front O/B: 550 +/- 6 mm~2nd Row O/B: 558 +/- 6 mm~ 3rd Row O/B: 584 +/- 6 mm~Web Button Location RG/RS LWB:~Front O/B: 550 +/- 6 mm~ 2nd Row O/B: 518 +/- 6 mm (Exception 52029368A$, 04680197A$: 690 +/- 6 mm)~ 3rd Row O/B: 585 +/- 6 mm (Exception 1CK35BD1A$, 1CK35BD5A$, 1CK35ZJ3A$, 52029369A$, 52029370A$: 434 +/-6 mm)~ Apply a small dot of Bond-All Gel, p/n 04467709, around the backside hole of the female button. Press the female button over the post of the male that is sticking through the rearwar
- 1012900882212076, 82203694 - Fabric Cleaner This "fabric cleaner" is not intended for sale in California, the otc states (Connecticut, Delaware, Massachusetts, Maine, New Hampshire, New Jersey, New York, Pennsylvania, Virginia, and Washington dc), and some ladco states (Illinois, Michigan, and Ohio). Mopar offers an alternative product (82213192) which is a water based product approved for sale in the aforementioned states.~ ~ Please inform the customer & your prep dept that spraying excessive amounts of the fabric protector on load floors will result in the breaking down of the adhesive (glue) that is used to create the bond between the fabric (carpet) and the load floor. This will apply to any vehicles equipped with rear load floors such as WK, WD, PM, MK, KA, KK. The carpet will appear to be loose, wrinkly, or bunch up~
- 10121927NAG1 (5A580) Valve Body As per Warranty Bulletin D-13-22, please use R2108213A$ valve body for all Warranty (W), Mopar (M) and Mopar Vehicle Protection (F) claims.~ Assembly also includes Filter (52108325AA) and Gasket (52108332AA).~
- 10119629Engine Stall Immediately Following Fuel Tank Fill-Up (X60 Warranty Extension) This bulletin involves replacing the fuel tank and vapor canister. Some customers may experience an engine stumble or stall condition which occurs immediately after filling the fuel tank. The integral multi-functional control valve may stick allowing liquid fuel to enter the evaporative emissions system causing a rich fuel condition when the purge system is initiated.
- 10076430(X60) fuel tank/vapor canister - 2004-2005-town and country (RS) and caravan/grand caravan (RS)
- 10074652Summary to be provided on a future date.
- 10051987Chrysler: the park lamps remain illuminated when both headlamps are on and then off, or both headlights fail to illuminate while park lamps remain illumnated after switching on. Models 2005-2006 town & country, voyager, grand caravan, caravan, grand voyager.
- 10046001Dodge/chrysler: behavior of headlamp switch function may impact lighting systems such as overload spike of electrical systems, turning off or unanticipated illumination, flickering or dimming of exterior and/or interior light with engine IS at idle speed, or single lamp in either interior or exterior lighting system. Models 2005-2006 town & country, voyager, caravan and grand caravan.
- 10033108Dodge/chrysler: supplemental front airbag sensors on about 310,000 certain vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Right and left supplemental front airbag sensors must be replaced and the sensor wiring harness connectors must be inspected and replaced, if necessary. Csc letter was rec'd.
- 100234201-2 and/or 2-3 shift harness. Erasing and reprogramming the powertrain control module with new software IS necessary.
- 10022182Power sliding door adjustment and diagnosis aid. Updated 10/26/07.
- 10021684Generic powertrain control module (pcm) procedure.
- 10021668Cleaning procedure for the mechanical throttle body.
- 10021599Passenger air bag deactivation.
- 10021247Tire pressure monitor system information.
- 10021239Powertrain control module initialization.
- 10020494Snow/water ingestion into rear brake drum.
Every Dodge Caravan model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.