1996 Dodge GRAND CARAVAN: complaints, problems and recalls

ON DECEMBER 05/2002 MY 1996 DODGE GRAND CARAVAN CAUGHT ON FIRE. THE CAR WAS JUST WARMING UP PRIOR TO BEING USED TO TAKE MY KIDS TO SCHOOL. THE FIRE WAS EXTINGUISHED BY THE DEKALB COUNTY, GEORGIA FIRE DEPARTMENT. I LEARNED AFTER THE FIRE THAT CHRYSLER HAD A RECALL RELATED TO A FUEL RAIL/SYSTEM DEFECT. I HAVE ALL MAJOR MECHANIC WORK DONE AT THE AUTHORIZED CHRYSLER DEALERSHIP AND WAS NEVER TOLD OF THIS RECALL.

Owner-reported narrative. 190,000 miles reported. Look up ODI 10000064 at NHTSA ↗

INTERNAL MECHANICAL FAILURE OF INTEGRATED CHILD SAFETY SEAT, RIGHT HAND SIDE. THE CABLE ASSEMBLY IN THE SEAT MODULE HAS FAILED. THIS CABLE ASSEMBLY LOCKS THE RETRACTABLE SHOULDER BELTS. THE CABLE HOOKS DIRECTLY TO THE LATCH PLATE AND WHEN THE BELT BUCKLE IS CONNECTED TO THE LATCH PLATE THE PLATE'S FORWARD MOVEMENT PULLS THE CABLE CAUSING THE SHOULDER BELT'S RETRACTOR TO LOCK. THIS CABLE CONNECTION HAS SEPARATED FROM THE LATCH PLATE (CABLE END IS ALSO FRAYED WITH THREE STRANDS LEFT ON IT'S END), RENDERING THE SHOULDER BELTS, RETRACTOR ASSEMBLY …

Owner-reported narrative. Look up ODI 10000697 at NHTSA ↗

FRONT STRUTS ARE RUSTING THROUGH, RESULTING IN WINDSHIELD CRACKING. DEALER CONTACTED. PLEASE PROVIDE ADDITIONAL INFORMATION. TS...*AK

Owner-reported narrative. 60,000 miles reported. Look up ODI 10001724 at NHTSA ↗

CONSUMER STATES WHILE DRIVING THE VEHICLE THE VEHICLE CAUGHT ON FIRE. DEALER NOTIFIED. TS

Owner-reported narrative. Look up ODI 10001760 at NHTSA ↗

WHILE TRAVELING ON HIGHWAY THERE WAS A FUEL SMELL COMING FROM INSIDE OF THE VENTS, AND FUEL WAS LEAKING FROM UNDERNEATH THE VEHICLE. BUILT IN CHECK ON TOP OF FUEL TANK WAS CRACKED AND LEAKING. .*JB. *AK

Owner-reported narrative. Look up ODI 10002532 at NHTSA ↗

WHEN CONSUMER WAS FILLING UP THE GASOLINE TANK, THE DRIVER SIDE DOOR WOULD NOT OPEN. PLEASE FURNISH ADDITIONAL INFORMATION.*JB

Owner-reported narrative. Look up ODI 10003663 at NHTSA ↗

CONSUMER STATED VEHICLE'S HORN IS NOT WORKING DUE TO ELECTRICAL PROBLEMS. DEALER WON'T REPAIR. PLEASE PROVIDE ADDITIONAL INFORMATION. TS

Owner-reported narrative. Look up ODI 10003712 at NHTSA ↗

CONSUMER SMELLED FUEL WHILE DRIVING, VEHICLE WAS TOWED TO REPAIR SHOP. MECHANIC DETERMINED A FLEXIBLE FUEL LINE IS POROUS FROM FRAME TO FUEL RAIL, SPRAYING FUEL OVER ENGINE. TS

Owner-reported narrative. 93,662 miles reported. Look up ODI 10004123 at NHTSA ↗

Reported: 2000-09-13 (September 13, 2000)

VEHICLE DESCRIPTION: MINI VANS BUILT WITH 3.3L AND 3.8L ENGINES HAVE FUEL RAILS WITH NITROLE RUBBER O-RING SEALS THAT CAN DEGRADE OVER TIME. FUEL LEAKAGE FROM THE UNDERHOOD FUEL INJECTION FUEL RAIL COULD RESULT, INCREASING THE LIKELIHOOD OF A VEHICLE FIRE.

Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE.

Remedy: DEALERS WILL INSTALL A SEAL ON THE VEHICLE FUEL RAILS TO PREVENT EXTERNAL LEAKAGE OF FUEL FROM THE FUEL RAIL CROSSOVER TUBE, SHOULD THE EXISTING O-RINGS CONTINUE TO DEGRADE. OWNER NOTIFICATION BEGAN ON JANUARY 25, 2002. DUE TO THE LARGE QUANTITY OF VEHICLES INVOLVED IN THIS CAMPAIGN, THE OWNER NOTIFICATION WILL BE PHASED OVER THE NEXT SEVERAL MONTHS. HOWEVER, IF A VEHICLE IS LEAKING FUEL FROM THE O-RINGS, THE VEHICLE SHOULD BE TAKEN INTO A DEALER TO HAVE THIS REPAIRED AS SOON AS POSSIBLE. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.

Reported: 2002-11-07 (November 7, 2002)

ON CERTAIN MINI VANS, THE CLOCKSPRING ASSEMBLY MAY HAVE BEEN WOUND INCORRECTLY DURING THE VEHICLE ASSEMBLY PROCESS.

Consequence: THIS CONDITION WILL MANIFEST ITSELF THROUGH ILLUMINATION OF THE AIR BAG WARNING LAMP, AND COULD EVENTUALLY RESULT IN A DRIVER'S AIR BAG OPEN CIRCUIT, IF THE PART IS NOT REPLACED IN A REASONABLE AMOUNT OF TIME.

Remedy: DEALERS WILL REPLACE THE CLOCKSPRING ASSEMBLY ON ALL VEHICLES WITH 70,000 MILES OR LESS. AN EXTENDED LIFETIME WARRANTY WILL ALSO BE PLACED ON THIS COMPONENT FOR ALL AFFECTED VEHICLES, REGARDLESS OF MILEAGE. DAIMLERCHRYSLER WILL ALSO REIMBURSE OWNERS WHO HAVE PAID TO HAVE THE CLOCKSPRING REPLACED ON THEIR VEHICLES. OWNER NOTIFICATION BEGAN NOVEMBER 18, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.

Reported: 1995-11-28 (November 28, 1995)

THE BOLTS WHICH SECURE THE REAR BENCH SEATS TO THE SEAT RISERS MAY BE EMBRITTLED AND FRACTURE.

Consequence: IN CASE OF AN ACCIDENT, THE BOLT MAY FAIL AND CAN CAUSE THE SEAT TO BREAK AWAY FROM THE SEAT RISERS, WHICH INCREASES THE POTENTIALOF INJURY TO ITS OCCUPANTS.

Remedy: DEALERS WILL REPLACE THE REAR BENCH SEAT TO RISER BOLTS.

Reported: 1995-12-08 (December 8, 1995)

THE FUEL TANK ROLLOVER VALVE CAN ALLOW FUEL TO PASS INTO THE VAPOR CANISTER RESULTING IN THE POTENTIAL FOR FUEL LEAKAGE.

Consequence: FUEL LEAKAGE INCREASES THE POTENTIAL FOR A VEHICLE FIRE.

Remedy: DEALERS WILL REPLACE THE FUEL TANK FILLER TUBE WITH A FILLER TUBE THAT HAS AN ADDITIONAL ROLLOVER VALVE. THE ASSOCIATED ROLLOVER VALVE VAPOR HOSES WILL BE REROUTED.

Reported: 1996-01-16 (January 16, 1996)

A STATIC ELECTRIC CHARGE CAN BUILD UP ON THE UNGROUNDED METAL SECTION OF THE FUEL FILLER TUBE.

Consequence: THIS CONDITION COULD CAUSE A SPARK TO OCCUR WHEN FUELING THE VEHICLE AND POSSIBLY IGNITE THE FUEL VAPORS.

Remedy: DEALERS WILL INSTALL A GROUND STRAP FOR THE FUEL FILLER TUBE.

Reported: 1996-01-11 (January 11, 1996)

IN CERTAIN VEHICLES, THE ENGINE CYLINDER HEAD OIL GALLEY PLUG DOES NOT SEAL PROPERLY AND ENGINE CYLINDER HEAD OIL IS NOT ADEQUATELY RETAINED.

Consequence: INADEQUATE SEALING AND RETENTION OF THE PLUG CAN RESULT IN OIL LEAKAGE WHICH COULD CAUSE A FIRE IN THE ENGINE COMPARTMENT.

Remedy: DEALERS WILL INSTALL AN EXPANSION PLUG AND RETAINING BRACKET OVER THE CYLINDER HEAD OIL GALLEY PLUG.

Reported: 1996-07-18 (July 18, 1996)

THE BOLTS WHICH SECURE THE INTEGRATED CHILD SEAT MODULES TO THE SEAT FRAME CAN BREAK.

Consequence: IN THE EVENT OF A VEHICLE ACCIDENT, THE CHILD SEAT MAY NOT PROVIDE ADEQUATE PROTECTION TO THE OCCUPANT.

Remedy: DEALERS WILL REPLACE THE INTEGRATED CHILD SEAT MODULE BOLTS.

Reported: 1998-08-06 (August 6, 1998)

VEHICLE DESCRIPTION: MINI VANS EQUIPPED WITH INTEGRATED CHILD SEATS. THE SHOULDER HARNESS RESTRAINT ON THE INTEGRATED CHILD SEAT CAN BECOME DIFFICULT TO EXTRACT WHEN THE SAFETY BELT LATCH PLATE BECOMES CONTAMINATED.

Consequence: THIS CAN CAUSE DIFFICULTY IN RELEASING A CHILD FROM THE RESTRAINT.

Remedy: DEALERS WILL CLEAN THE LATCH MECHANISM. AN EXTENDER WILL BE ADDED TO THE EMERGENCY RELEASE ANCHOR FOR THE CHILD SEAT SAFETY BELTS SO THAT THE RELEASE CLIPS ARE MORE VISIBLE AND ACCESSIBLE TO THE OPERATOR IN THE EVENT THAT THE RETRACTOR MECHANISM CAN NOT BE UNLOCKED. IN ADDITION, AN INSTRUCTIONAL OWNER'S MANUAL SUPPLEMENT CARD WILL BE PROVIDED.

Reported: 1999-08-09 (August 9, 1999)

VEHICLE DESCRIPTION: MINIVANS. FUEL CAN LEAK FROM THE FUEL TANK AT THE INTERFACE OF THE FUEL PUMP MODULE ATTACHMENT.

Consequence: IF A FUEL LEAK OCCURS IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.

Remedy: DEALERS WILL REPLACE THE FUEL PUMP MODULE ATTACHING NUT WITH A NUT THAT INCLUDES TIGHTER DESIGN TOLERANCES. THE SEALING O-RING WILL ALSO BE REPLACED.