2004 Dodge Durango problems

What is wrong

Chrysler (FCA US LLC) is recalling various Dodge, Chrysler, and RAM vehicles equipped with Kidde Plastic-Handle or Push Button 'Pindicator' Fire Extinguishers. A list of the affected trailer models is available at: These extinguishers may become clogged, preventing the extinguisher from discharging as expected or requiring excessive force to activate the extinguisher. Additionally, in certain models, the nozzle may detach from the valve assembly with enough force that it could cause injury and also render the product inoperable. For a full list of the affected fire extinguisher models visit:

Risk

If the fire extinguisher does not function properly, it can increase the risk of injury in the event of a fire.

Remedy

Chrysler will notify owners instructing them to contact Kidde for a replacement fire extinguisher, free of charge. The recall began February 14, 2018. Owners may contact Chrysler customer service at 1‑800‑853‑1403 or Kidde customer service service toll-free at 1‑855‑262‑3540, or online at www.kidde.com and click on "Product Safety Recall" for more information. Chrysler's number for this recall is T82.

Recall number 17V824000 · Recall details

What is wrong

Chrysler (FCA US LLC) expanded the affected population to include 73,712 2005-2009 RAM 2500 trucks produced at the St. Louis North Assembly Plant. With this change, Chrysler is recalling certain model year 2004-2008 RAM 1500, 2005-2009 RAM 2500, 2006-2009 RAM 3500, 2007-2010 RAM 3500 Cab Chassis, 2008-2010 RAM 4500 and 5500 Cab Chassis, 2004-2009 Dodge Durango, 2007-2009 Chrysler Aspen, 2007-2012 Jeep Wrangler, 2008-2012 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2012 Chrysler 300, 2006-2012 Dodge Charger, 2005-2011 Dodge Dakota, and 2006-2009 Mitsubishi Raider vehicles originally sold, or ever registered, in AL, CA, FL, GA, HI, LA, MS, SC, TX, Puerto Rico, American Samoa, Guam, the Northern Mariana Islands (Saipan), and the U.S. Virgin Islands, or "Zone A." Additionally, unless included in "Zone A" above, Chrysler is also recalling 2004-2008 RAM 1500, 2005-2009 RAM 2500, 2006-2009 RAM 3500, 2007-2009 RAM 3500 Cab Chassis, 2008-2009 RAM 4500 and 5500 Cab Chassis, 2004-2009 Dodge Durango, 2007-2009 Chrysler Aspen, 2007-2009 Jeep Wrangler, 2008-2009 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2009 Chrysler 300, 2006-2009 Dodge Charger, 2005-2009 Dodge Dakota and 2006-2009 Mitsubishi Raider vehicles originally sold, or ever registered, in AZ, AR, DE, Washington D.C., IL, IN, KS, KY, MD, MO, NE, NV, NJ, NM, NC, OH, OK, PA, TN, VA, and WV, or "Zone B." Lastly, unless included in "Zone A" or "Zone B" above, Chrysler is recalling certain 2005-2008 RAM 2500, 2006-2008 RAM 3500, 2007-2008 RAM 3500 Cab Chassis, 2008 RAM 4500 and 5500 Cab Chassis, 2004-2008 Dodge Durango, 2007-2008 Chrysler Aspen, 2007-2008 Jeep Wrangler, 2008 Dodge Challenger, 2005-2008 Dodge Magnum, 2005-2008 Chrysler 300, 2006-2008 Dodge Charger, 2005-2008 Dodge Dakota, and 2006-2008 Mitsubishi Raider vehicles originally sold, or registered, in AK, CO, CT, ID, IA, ME, MA, MI, MN, MT, NH, NY, ND, OR, RI, SD, UT, VT, WA, WI, and WY.

Risk

These vehicles are equipped with certain air bag inflators assembled as part of the passenger frontal air bag modules, and used as original equipment or replacement equipment. These inflators may rupture due to propellant degradation occurring after long-term exposure to absolute humidity and temperature cycling. An inflator rupture may result in metal fragments striking the vehicle occupants resulting in serious injury or death.

Remedy

Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler will notify the Chrysler, Dodge, Jeep and RAM owners. Mitsubishi owners will be notified by their company. Dealers will replace the passenger frontal air bag inflator, free of charge. The recall began on March 27, 2017. Owners may contact Chrysler customer service at 1‑800‑853‑1403. Chrysler's number for this recall is S43. Note: This recall supersedes recall 14V-7700.

Recall number 16V352000 · Recall details

What is wrong

Chrysler (FCA US LLC) is recalling certain model year 2005-2009 Dodge Ram 2500, 2004-2008 Dodge Ram 1500 and Durango, 2006-2009 Dodge Ram 3500, 2008-2010 Dodge Ram 4500 and 5500, 2007-2008 Chrysler Aspen, 2005-2010 Chrysler 300, 300C, 300S, and SRT8, 2006-2010 Dodge Charger, 2005-2008 Magnum, 2005-2011 Dodge Dakota, and 2006-2009 Mitsubishi Raider vehicles. The affected vehicles are equipped with a dual-stage driver frontal air bag that may be susceptible to moisture intrusion which, over time, could cause the inflator to rupture.

Risk

In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could rupture with metal fragments striking the driver or other occupants resulting in serious injury or death.

Remedy

Owners are advised not to drive their vehicle until the recall repair is complete. Chrysler will notify the affected Chrysler and Dodge owners and Mitsubishi will notify the affected Raider owners. Dealers will replace the driver's frontal air bag inflator, free of charge. The recall began for Chrylser on June 8, 2015. The recall for Mitsubishi started on June 24, 2015. Chrysler and Dodge owners may contact Chrysler customer service at 1‑800‑853‑1403. Mitsubishi owners may call 1‑888‑648‑7820. Chrysler's number for this recall is R25. Note: This recall supersedes recall 14V817 in its entirety. Vehicles that have had their driver side frontal air bag replaced previously need to have their air bag replaced under this recall as well.

Recall number 15V313000 · Recall details

What is wrong

Chrysler Group LLC (Chrysler) is recalling certain model year 2004-2005 Dodge Ram 1500, 2500, and 3500, 2004-2005 Dodge Durango, 2005 Dodge Dakota, 2005 Dodge Magnum and 2005 Chrysler 300, 300C and 300 SRT8 vehicles originally sold, or ever registered, in geographic locations associated with high absolute humidity. Specifically, vehicles sold, or ever registered, in Alabama, Florida, Georgia, Hawaii, Louisiana, Mississippi, Texas, Puerto Rico, U.S. Virgin Islands, Saipan, Guam, and American Samoa are addressed by this recall. Upon deployment of the passenger side frontal air bag, excessive internal pressure may cause the inflator to rupture.

Risk

In the event of a crash necessitating deployment of the passenger’s frontal air bag, the inflator could rupture with metal fragments striking the vehicle occupants potentially resulting in serious injury or death.

Remedy

Chrysler will notify owners, and dealers will replace the front passenger air bag inflator, free of charge. For vehicles that were sold, or are currently registered, in Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, owners were notified and the recall began on December 5, 2014. For all other vehicles, Chrysler notified owners and the recall began on February 3, 2015. Owners may contact Chrysler customer service at 1‑800‑853‑1403. Chrysler's number for this recall is P40 Expanded. Note: This recall has been superseded by recall 16V‑352. This recall superseded the passenger air bag portion of recall 14V‑354.

Recall number 14V770000 · Recall details

What is wrong

On some sport utility vehicles, under certain operating conditions, an integrated circuit in the instrument cluster that controls interior lighting may overheat.

Risk

This could potentially cause an instrument panel fire.

Remedy

Dealers will inspect the cluster for damage and replace it free of charge. The recall began on april 2, 2007. Owners may contact daimlerchrysler at 1-800-853-140.

Recall number 07V092000 · Recall details

What is wrong

On certain sport utility vehicles built with a 5.7l, 4.7l, or 3.7l engine, the positive battery cable may contact the front suspension upper control arm mounting bracket.

Risk

This contact could abrade the cable and cause a short circuit, which may result in an underhood fire.

Remedy

Dealers will inspect the battery cable and, if necessary, reposition it away from the control arm mounting bracket. The recall began december 14, 2004. Owners should contact daimlerchrysler at 1‑800‑853‑1403.

Recall number 04V578000 · Recall details

What is wrong

On certain sport utility vehicles equipped with 3.7l and 4.7l engines, the throttle control cable may ingest water and freeze during extended cold temperature.

Risk

This could cause the throttle to stick in the open position and result in a crash.

Remedy

Dealers will replace the throttle control cable. Owner notification began on january 19, 2004. Owners should contact daimlerchrysler at 1‑800‑853‑1403.

Recall number 04V020000 · Recall details

What is wrong

On certain sport utility vehicles, an instrument cluster circuit board capacitor may overheat.

Risk

This could potentially result in an instrument panel fire.

Remedy

Dealers will remove the capacitor from the circuit board. Owner notification began on december 17, 2003. Owners should contact daimlerchrysler at 1‑800‑992‑1997.

Recall number 03V528000 · Recall details

From 2000 through 2017, Takata produced millions of air bag inflators using two types of phase-stabilized ammonium nitrate ("PSAN") propellant -- propellant 2004 and propellant 2004L. After prolonged exposure to high temperature cycles and humidity, inflators using propellant 2004 can degrade, causing the propellant to burn too quickly when ignited. The rapid burning can cause the inflator to rupture during deployment, potentially causing serious or even fatal injury to vehicle occupants. See 2016 Blomquist Report at all frontal inflators using propellant 2004 that do not contain a "desiccant" (a substance that traps and holds moisture) in US vehicles are under recall. These "non-desiccated" inflators either have been or are required to be replaced.In some cases, the remedy part for these recalled inflators was, or will be, an inflator using either propellant 2004 or 2004L that does contain a desiccant. None of these "desiccated" remedy parts (which were installed in older model year vehicles) are currently under recall for a degradation concern. Certain subsets of desiccated PSAN inflators using propellant 2004 for use as original equipment, however, have been recalled for a degradation concern. All Takata inflators produced with propellant 2004L contain desiccant, and none of these desiccated inflators using propellant 2004L are under recall for a degradation concern. There have been no reported field ruptures in any non-recalled desiccated PSAN inflators.It is understood that desiccants fully saturate at some threshold, at which point any additional moisture will not be captured. This means the degradation process observed in non-desiccated inflators using propellant 2004 may also occur in non-recalled desiccated inflators using propellant 2004, assuming additional moisture enters the inflator and high temperature cycling occurs. Based on available information, desiccant saturation can occur within the first five years in the worst environments, and the time required for full saturation is affected by multiple factors. While no present safety risk has been identified, further work is needed to evaluate the future risk of non-recalled desiccated inflators using propellant 2004.Three entities -- Takata (now known as TK Global), the Independent Testing Coalition, and Exponent -- have been studying the long-term behavior of Takata desiccated PSAN inflators using propellant 2004L (as well as 2004) in the presence of moisture and temperature cycling. The research efforts, which include development of predictive modeling techniques and field sample analysis, are ongoing. To date, none of the researchers have identified field evidence showing that propellant 2004L is undergoing a degradation process that leads to aggressive deployment and potential rupture. However, the time in service of such inflators remains short compared to that of the inflators using propellant 2004. Further study is needed to assess the long-term safety of desiccated inflators using propellant 2004L.The Office of Defects Investigation is opening this investigation to examine whether a safety defect related to propellant degradation exists in non-recalled desiccated PSAN frontal inflators manufactured by Takata. This investigation will require extensive information on Takata production processes and surveys of inflators in the field. Lists of recall actions that may have used desiccated PSAN inflators as remedy parts, as well as the makes and models originally manufactured with them, is available with the downloadable version of this document (see -- note this information is subject to change/revision as the investigation proceeds). This investigation does not supersede EA15-001, which remains open.

EA21002

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016 four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016 four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The investigation now includes all manufacturers and vehicles known to be affected at this time.ODI's investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The five ODI reports cited above can be reviewed online at http://www-odi.the federal safety agency.dot.gov/owners/Searchreference under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

EA15001

The Office of Defects Investigation (ODI) opened PE14-016 in June 2014 based on six inflator rupture incidents involving consumer owned vehicles produced by five vehicle manufacturers.All six vehicles were operated in Florida or Puerto Rico at the time of the rupture and for the majority of their service life, and were equipped with inflators produced by Takata, a tier-one supplier of automotive air bag systems.During the course of PE14-016, ODI determined that five additional vehicle manufacturers used inflators of a similar design and vintage also supplied by Takata. No evidence of field failures was found in vehicles produced by these five additional manufacturers.Nonetheless, at ODI's insistence, all 10 vehicle manufacturers initiated a regional recall within approximately two weeks of the opening of the investigation.The regions recalled initially included Florida, Puerto Rico, Hawaii, and the U.S. Virgin Islands, areas with consistently high absolute humidity and climatic conditions believed to be a significant factor in the inflator ruptures.As part of the recall actions, inflators removed from remedied vehicles are to be returned to Takata for testing.Takata's initial test results on passenger inflators from remedied vehicles indicated a much higher than anticipated rupture frequency for inflators returned from Florida.Accordingly, ODI requested all 10 manufacturers expand the regional recalls for passenger inflators to include other geographic areas where high absolute humidity conditions exist, including the Gulf States and other coastal areas.Takata's testing of the passenger inflators to date continues to indicate this geographic area as having the highest risk, with no ruptures occurring from inflators returned from outside the expanded recall regions.During PE14-016, four additional passenger inflator field events occurred, all in vehicles from the same expanded geographic region.Also during PE14-016, four additional driver inflator field events occurred including two in vehicles from regions not known for high absolute humidity, specifically California and North Carolina.Accordingly, ODI requested all five of the affected vehicle manufacturers currently using the subject Takata driver inflators expand to nationwide recalls.Significantly, neither of the affected vehicle manufacturers or Takata provided any explanation to account for these two driver air bag inflator ruptures outside the area of high absolute humidity.Takata testing of returned driver inflators indicates a lower rupture frequency as compared to passenger inflator testing.All test ruptures reported by Takata to date have occurred on inflators returned from high absolute humidity areas.The PE is now closed/upgraded to an Engineering Evaluation (EA15-001) to include all manufacturersand vehicles known to be affected at this time.ODI's EA investigation will focus on, among other things, root cause analysis, other potential defect consequences, identification of affected vehicles scope, and adequacy of the remedy.The recalls related to this PE are: 14V343, 14V344, 14V348, 14V351, 14V353, 14V655, 14V700, 14V701, 14V752, 14V763, 14V770, 14V773, 14V787, 14V802 and 14V817.The number of vehicles affected are an estimate since some vehicles may have both the driver and passenger side inflators recalled. The five ODI reports cited above can be reviewed online at http://www-odi.the federal safety agency.dot.gov/owners/Searchreference under the following identification numbers: 10537899, 10568848, 10585224, 10605877, 10651492

PE14016

This investigation originated from complaints received by the agency reporting instrument panel (ip) fires on vehicles that were covered under a prior recall (recall 03v528) by daimler chrysler (dcc) to correct a cracked capacitor in the ip.dcc has now identified another condition that can cause overheating of an integrated circuit that controls interior lighting.this condition affects certain model year 2004-2006 dodge durango vehicles.dcc's march 6, 2007 letter to the agency states, under certain operating conditions, an integrated circuit located in the instrument cluster may overheat and result in an instrument panel fire.dcc will conduct a safety recall to inspect the cluster for damage and replace it if necessary.if the cluster shows no evidence of damage, it will be re-flashed [re-program the cluster] to prevent the potential for this condition.in addition, all vehicles will receive a wiring modification that directs the interior lighting to a portion of the integrated circuit with additional current carrying capacity.this recall covers 328,424 vehicles manufactured from 4/03/03 through 6/30/06.see the federal safety agency recall number 07v092 for details.

EA06015

This investigation originated from complaints received by the agency reporting instrument panel (ip) fires on vehicles that were recalled(recall 03v528) by daimlerchrysler (dcc) to correct a defect that caused ip fires.the recall corrected a defect caused by a certain capacitor on the ip printed circuit board (pcb) that could crack and overheat.the fire could occur without warning while the vehicle is parked or in use.the recall remedy was to remove the capacitor from the ip.ips used for vehicles produced after the recall (december 2003) did not contain the capacitor.odi has also received reports of fires in vehicles produced after the recall, which do not have the defective capacitor.dcc and its supplier for the ip have identified a different location on the pcb that may overheat.this investigation has been upgraded to an engineering analysis (ea06-015) to further study this issue.

RQ06006

On march 9, 2006 odi upgraded preliminatry evaluation pe05-056 to engineerning analysis ea06-004 to investigate allegations of loose or missing steering shaft coupling bolts and steering column retaining bolts in model year (my) 2004 through 2006 dodge durango sport utility vehicles and my 2005 through 2006 dodge dakota pickup trucks.either condition could result in a loss of steering control.although odi identified some quality issues in the manufacturing processes for the dakota and durango vehicles, the data do not indicate that a safety defect trend is present in either population.the failure rates are low for each condition and trend analyses indicate that problems with the subject bolts were isolated to a few units affected by assembly error that were detected either pre-sale or occurred early in vehicle service.further use of agency resources in this matter does not appear to be warranted.the agency will continue to monitor complaints and other information relating to the alleged defect in the sugject vehicles and will take furhter action inthe the future if warranted.for more information see the attached closing report.

EA06004

Analysis of the complaint, field report and warranty data shows that the majority of stalling incidents in the subject vehicles appear to be related to the engine calibration concerns that daimlerchrysler addressed with service bulletins releasing revised PCM software.analysis of the complaints and odi's survey of owners of vehicles that received engine management software updates under tsb #18-013-05 show that these stalling incidents have the following characteristics: - they occur at low speeds, often during parking lot ordriveway maneuvers; - they occur during decelerations, such as braking for a stop sign or traffic signal; and - the operator is almost always able to immediately restart the vehicle.when compared with other safety defect investigations and recalls of conditions that result in stalling during low-speed deceleration with immediate engine restart possible, the failure rate in the subject vehicles is low.analyses of complaint and warranty data also show a declining trend.accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by the federal safety agency 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.see document file for additional information regarding this resume.

EA05018

On october 26, 2005 odi opened pe05-056 to investigate allegations of loose or missing steering wheel or steering shaft coupling bolts in model year (my) 2004 and 2005 dodge durango sport utility vehicles and my 2005 dodge dakota pickup trucks manufactured by daimlerchrysler corporation (dcc).during pe05-056 odi identified 3 owner complaints to odi or dcc, 21 field reports to dcc and 142 warranty claims related to the alleged defect conditions.the reports and claims included 8 incidents of either steering wheel separation or steering shaft decoupling while driving due to loose or missing bolts.one of the failures resulted in a crash. Pe05-056 has been upgraded to an engineering analysis (ea06-004) to continue to investigate the scope, frequency and safety consequences of the alleged defect.

PE05056

On may 16, 2005,odi opened preliminary evaluation pe05-027 to investigate complaints of engine stalling in model year 2004-05 dodge durango suvs and ram 1500 series pickups equipped with the 5.7l v8 engine.information provided by daimlerchrysler during pe05-027 indicated that a large percentage of the complaints are related to an idle undershoot condition that may cause the engine to stall during turning maneuvers.in february 2005, daimlerchrysler revised the powertrain control module software in production vehicles and issued a technical service bulletin (tsb 18-013-05) releasing the new software as a service remedy for the idle undershoot condition.the bulletin was superceded by tsb 18-013-05a in april 2005.daimlerchrysler believes that the failure rate for stalling while driving due to the idle undershoot condition is low and that the bulletin has adequately addressed the problem. Since pe05-027 was opened, odi has continued to receive complaints from owners of the subject vehicles who allege experiencing engine stall incidents under all types of driving conditions.in some instances the stalling has continued after the vehicle received the service bulletin repairs.this investigation has been upgraded to an engineering analysis (ea05-018) to further assess the scope, frequency, and safety consequences of the alleged defect in dodge durango and ram 1500/2500/3500 series pickup trucks.

PE05027