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2002 Dodge Durango

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2002 Dodge Durango do not stand out strongly from the model-year median of 231.

About this comparison →

When problems were reported

Mileage at the reported incident

287 reports with mileage · 136 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Suspension. Review the 144 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Power Train. Review the 71 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 48 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

35 crash reports13 fire reports23 injury reports

Engine And Engine Cooling complaints

46 reports
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59,000 miles · Apr 2, 2008
Engine And Engine Cooling

THE VALVES ON THIS ENGINE BURNED OUT AT 59,000 MILES. THE CAUSE WAS REVEALED TO BE A DEFECTIVE CAMSHAFT WHICH WAS ROUGH AND PITTED AND HAD BURNED THE VALVES. THIS WAS A MANUFACTURER'S DEFECT AND NOT POOR MAINTENANCE; I HAVE HAD THE OIL CHANGED WITH SYNTHETIC OIL EVERY 3,000 MILES AND OTHERWISE TAKEN EXCELLENT CARE OF THIS VEH…

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THE VALVES ON THIS ENGINE BURNED OUT AT 59,000 MILES. THE CAUSE WAS REVEALED TO BE A DEFECTIVE CAMSHAFT WHICH WAS ROUGH AND PITTED AND HAD BURNED THE VALVES. THIS WAS A MANUFACTURER'S DEFECT AND NOT POOR MAINTENANCE; I HAVE HAD THE OIL CHANGED WITH SYNTHETIC OIL EVERY 3,000 MILES AND OTHERWISE TAKEN EXCELLENT CARE OF THIS VEHICLE. THE SUV REQUIRED A NEW CAMSHAFT AND COMPLETE VALVE JOB, COSTING APPROXIMATELY $2200 INCLUDING PARTS AND LABOR. *TR

NHTSA ODI #10223167

82,000 miles · Mar 24, 2008
Engine And Engine Cooling

WHILE DROPPING MY CHILDREN OFF AT SCHOOL THE CHECK GAUGES LIGHT LIT UP. NOTHING ON MY GAUGES APPEARED TO BE WRONG EXCEPT FOR THE FUEL GAUGE BEING ON 1/4 TANK SO I CONTINUED ON MY 1 MILE TRIP TO THE SCHOOL. WHEN MY CHILDREN EXITED THE VEHICLE THE CHECK GAUGES LIGHT LIT AGAIN AND THE TRUCK STARTED TO SPUTTER. I THEN TURNED THE TRU…

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WHILE DROPPING MY CHILDREN OFF AT SCHOOL THE CHECK GAUGES LIGHT LIT UP. NOTHING ON MY GAUGES APPEARED TO BE WRONG EXCEPT FOR THE FUEL GAUGE BEING ON 1/4 TANK SO I CONTINUED ON MY 1 MILE TRIP TO THE SCHOOL. WHEN MY CHILDREN EXITED THE VEHICLE THE CHECK GAUGES LIGHT LIT AGAIN AND THE TRUCK STARTED TO SPUTTER. I THEN TURNED THE TRUCK OFF AND TURNED IT BACK ON. THE LIGHT CAME ON AGAIN AND THEN THE ENGINE STOPPED. I CALLED FOR A TOW. SEVERAL HOURS AND AT A COST THE MECHANIC TOLD ME THAT MY ENGINE HAD SEIZED AND THE PROBLEM WAS ENGINE SLUDGE. *TR

NHTSA ODI #10222198

68,000 miles · Feb 26, 2008
Engine And Engine Cooling

TL*THE CONTACT OWNS A 2002 DODGE DURANGO. WHILE DRIVING 55-60 MPH, THE CHECK ENGINE LIGHT ILLUMINATED THEN THE VEHICLE SHOOK THEN SHUT OFF. IN ADDITION, SHE NOTICED SMOKE COMING FROM THE ENGINE. THE MECHANIC STATED THAT THE POWER STEERING PRESSURE SWITCH CAUSED THE FAILURE AND THEY REPLACED THE SWITCH. APPROXIMATELY FIVE MON…

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TL*THE CONTACT OWNS A 2002 DODGE DURANGO. WHILE DRIVING 55-60 MPH, THE CHECK ENGINE LIGHT ILLUMINATED THEN THE VEHICLE SHOOK THEN SHUT OFF. IN ADDITION, SHE NOTICED SMOKE COMING FROM THE ENGINE. THE MECHANIC STATED THAT THE POWER STEERING PRESSURE SWITCH CAUSED THE FAILURE AND THEY REPLACED THE SWITCH. APPROXIMATELY FIVE MONTHS LATER THE FAILURE OCCURRED AGAIN. THE MECHANIC WAS UNABLE TO DIAGNOSE THE FAILURE. THE FAILURE MILEAGE WA 68,000 AND CURRENT MILEAGE WAS 89,800. UPDATED 03/10/08. *LJ

NHTSA ODI #10219242

91,053 miles · Jan 11, 2008
Engine And Engine CoolingPower Train

TL*THE CONTACT OWNS A 2002 DODGE DURANGO. WHILE DRIVING 35 MPH, THE OIL PUMP FAILED WITHOUT WARNING. THE OIL PRESSURE DROPPED AND THE MOTOR LOCKED. THE DEALER REBUILT THE TRANSMISSION, BUT THE FAILURE CONTINUED. THE VEHICLE WAS TAKEN TO THE DEALER NUMEROUS TIMES, BUT THEY COULD NOT DUPLICATE THE FAILURE. THE CONTACT STATED …

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TL*THE CONTACT OWNS A 2002 DODGE DURANGO. WHILE DRIVING 35 MPH, THE OIL PUMP FAILED WITHOUT WARNING. THE OIL PRESSURE DROPPED AND THE MOTOR LOCKED. THE DEALER REBUILT THE TRANSMISSION, BUT THE FAILURE CONTINUED. THE VEHICLE WAS TAKEN TO THE DEALER NUMEROUS TIMES, BUT THEY COULD NOT DUPLICATE THE FAILURE. THE CONTACT STATED THAT THERE WAS OIL LEAKAGE IN COLD WEATHER. WHEN THE ENGINE HEATED UP, THERE WAS SLUDGE BECAUSE THE LEAKER STOPPED THE STRAINER. THE PURCHASE DATE WAS UNKNOWN. THE CURRENT MILEAGE WAS APPROXIMATELY 112,300 AND FAILURE MILEAGE WAS 91,053.

NHTSA ODI #10214508

Mileage unknown · Apr 19, 2007
Engine And Engine Cooling

2002 DODGE DURANGO...WHEN VEHICLE GETS HOT...MAINLY IN SUMMER DRIVING CONDITIONS...IT WILL GO TO A VERY LOW IDLE..ALMOST TO THE POINT OF STALLING...HAVE FOUND OUT THROUGH VEHICLE REPAIRMAN THAT THE MANIFOLD HEAT SENSOR IS TOO CLOSE TO THE ACTUAL MANIFOLD AND THUS IT DOES ITS JOB...SLOWS THE ENGINE IDLE DOWN...IN OTHER WORDS THIN…

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2002 DODGE DURANGO...WHEN VEHICLE GETS HOT...MAINLY IN SUMMER DRIVING CONDITIONS...IT WILL GO TO A VERY LOW IDLE..ALMOST TO THE POINT OF STALLING...HAVE FOUND OUT THROUGH VEHICLE REPAIRMAN THAT THE MANIFOLD HEAT SENSOR IS TOO CLOSE TO THE ACTUAL MANIFOLD AND THUS IT DOES ITS JOB...SLOWS THE ENGINE IDLE DOWN...IN OTHER WORDS THINKS THE ENGINE IS HOTTER THAN IT REALLY IS...THERE IS A AFTERMARKET KIT..COST 300 DOLLARS OR SO TO CORRECT THIS...CHRYSLER CORP WILL NOT REPAIR THIS...IT IS A DESIGN DEFECT AND SHOULD BE TAKEN CARE OF BY CHRYSLER...NOT BY THE VEHICLE OWNER...

NHTSA ODI #10188389

70,000 miles · Mar 21, 2007
Engine And Engine Cooling

TL* - THE CONTACT OWNS A 2002 DODGE DURANGO. THE VEHICLE OVERHEATS AND THE HEATER BLOWS OUT COLD AIR. THE DEALER HAD REPLACED THE THERMOSTAT TWICE AND THE RADIATOR CAP. THE CHECK ENGINE, ABS LIGHT AND CHECK GAUGES LIGHT HAVE TURNED ON. THE FAILURE MILEAGE WAS 70,000. THE CONTACT HAS REPAIR INVOICES.

NHTSA ODI #10185760

25,000 miles · Dec 8, 2006
Electrical SystemEngine And Engine CoolingInjury

DODGE DURANGO JUST STOPS RUNNING AT RANDOM TIMES. THIS OCCURS AT SPEEDS OF 10-60 MPH OR EVEN WHEN THE CAR IS BEING STARTED. THE ODOMETER BLINKS AND READS NO BUS. THERE ARE NUMEROUS REPORTS OF THIS ON DODGE INTERNET FORUMS. THE POWERTRAIN CONTROL MODULE AND/OR CRANKSHAFT SENSORS END UP BEING REPLACED, BUT THE PROBLEM IS HARD …

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DODGE DURANGO JUST STOPS RUNNING AT RANDOM TIMES. THIS OCCURS AT SPEEDS OF 10-60 MPH OR EVEN WHEN THE CAR IS BEING STARTED. THE ODOMETER BLINKS AND READS NO BUS. THERE ARE NUMEROUS REPORTS OF THIS ON DODGE INTERNET FORUMS. THE POWERTRAIN CONTROL MODULE AND/OR CRANKSHAFT SENSORS END UP BEING REPLACED, BUT THE PROBLEM IS HARD TO DIAGNOSE AND DANGEROUS BECAUSE IT OCCURS WITHOUT WARNING AND WHILE DRIVING. WITH SO MANY REPORTS ON 1999-2002 DODGE DURANGOS HAVING THIS PROBLEM (SEARCH DURANGO PCM "NO BUS") SOMETHING MUST BE DEFECTIVE. MY DURANGO BEGAN DOING THIS ABOUT A MONTH AGO AND THE DEALER DOESN'T SEE ANYTHING WRONG. I WAS MILDLY INJURED DURING ONE OF THE FAILURES, WHEN MY DURANGO 'SHUT OFF' WHILE I WAS COMING DOWN A HIGHWAY RAMP AND I BUMPED MY HEAD AGAINST THE DRIVER SIDE WINDOW WHILE TRYING TO STABILIZE THE CAR, WHICH SUDDENLY AND WITHOUT WARNING HAD NO POWERTRAIN CONTROL. *JB

NHTSA ODI #10175548

2,000 miles · Dec 5, 2006
Electrical SystemEngine And Engine CoolingPower Train

2002 DODGE DURANGO. CAR ENGINE "SURGES" WHEN STARTING TO DRIVE, THEN RETURNS TO NORMAL AFTER A FEW HUNDRED YARDS. OCCURS AT SPEEDS OF 10-20 MPH. REPORTED TO DEALER. DEALER UNABLE TO REPRODUCE PROBLEM. OCCURS RANDOMLY, BUT ABOUT 1-2 A MONTH. CAR ALSO STOPS AND WILL NOT RESTART. RECURS RANDOMLY AND WITHOUT WARNING. LOCAL MECH…

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2002 DODGE DURANGO. CAR ENGINE "SURGES" WHEN STARTING TO DRIVE, THEN RETURNS TO NORMAL AFTER A FEW HUNDRED YARDS. OCCURS AT SPEEDS OF 10-20 MPH. REPORTED TO DEALER. DEALER UNABLE TO REPRODUCE PROBLEM. OCCURS RANDOMLY, BUT ABOUT 1-2 A MONTH. CAR ALSO STOPS AND WILL NOT RESTART. RECURS RANDOMLY AND WITHOUT WARNING. LOCAL MECHANIC FEELS PROBLEM COULD BE POWERTRAIN CONTROL MODULE RELATED. OCCURS AT SPEEDS OF 0-60 MPH. *JB

NHTSA ODI #10175244

Mileage unknown · Jul 24, 2006
Engine And Engine CoolingEquipment

I HAVE HAD TO HAVE THE VACUUM HOSES REPLACED IN MY 2002 DODGE DURANGO 4 TIMES SINCE BUYING IT IN JULY OF 2003. THE CHECK ENGINE LIGHT COMES ON EVERY TIME. I HAVE COMPLAINED TO THE DEALERSHIP THAT HAS WORKED ON IT, BUT THEY DON'T SEEM TO CARE. I HAD ONE OF THE MECHANICS SAY THEY HAVE SEEN THE PROBLEM BEFORE WHEN I HAD HIM SHOW…

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I HAVE HAD TO HAVE THE VACUUM HOSES REPLACED IN MY 2002 DODGE DURANGO 4 TIMES SINCE BUYING IT IN JULY OF 2003. THE CHECK ENGINE LIGHT COMES ON EVERY TIME. I HAVE COMPLAINED TO THE DEALERSHIP THAT HAS WORKED ON IT, BUT THEY DON'T SEEM TO CARE. I HAD ONE OF THE MECHANICS SAY THEY HAVE SEEN THE PROBLEM BEFORE WHEN I HAD HIM SHOW ME WHERE THE HOSES WERE LOCATED. THE HOSES WERE CRACKED AND LOOKED LIKE THEY HAD BEEN ON THE CAR FOR 10 YEARS OR MORE, BUT IN ACTUALLITY IT HAD ONLY BEEN MONTHS. EVERYTIME, I HAVE HAD TO PAY $75 TO HAVE THE HOSE REPLACED EVEN THOUGH I HAD THE EXTENDED WARRANTY. MY DURANGO IS NOW OUT OF WARRANTY AND THE CHECK ENGINE LIGHT CAME ON AGAIN. I WENT TO A PARTS STORE TO HAVE THEM HOOK UP TO THE COMPUTER TO GET THE ERROR CODE--VACUUM LEAK AGAIN. WHEN THE PARTS STORE GUY LOOKED UNDER THE HOOD TO GET THE RIGHT LENGTH OF HOSE TO GIVE ME(GOING TO CHANGE IT MYSELF AND NOT PAY TO HAVE IT FIXED), HE SAID IT HAD NOT EVEN BEEN REPLACED WITH VACUUM HOSE. INSTEAD, ONE WAS REPLACED WITH FUEL LINE HOSE AND THE OTHER REPLACED WITH TRANMISSION HOSE. THIS IS AN ONGOING PROBLEM THAT I HAVE HAD AND IT DOESN'T SEEM TO MATTER TO THEM. IT ISN'T A SERIOUS PROBLEM, BUT IS STILL A PROBLEM. IF THE HOSE IS DEGRADING THAT QUICKLY, IT MUST BE SUBMITTED TO HIGH TEMPERATURES WHICH COULD LEAD TO A BIG PROBLEM. *NM

NHTSA ODI #10163262

62,084 miles · Feb 16, 2006
Engine And Engine Cooling

I PURCHASED A 2002 DODGE DURANGO USED WITH 60K I HAVE ACCUMULATED LESS THAN 3K FROM SEPTEMBER UNTIL JANUARY AND I'VE HAD TO REPLACE MY ENTIRE ENGINE. REASON MECHANIC STATES THERE IS SLUDGE THROUGHOUT THE ENGINE. *JB

NHTSA ODI #10150458

Official recalls

4

07V555000 · Power Train:automatic Transmission:lever And Linkage:column Shift

Dec 4, 2007

ON CERTAIN VAN AND PICKUP TRUCKS EQUIPPED WITH AUTOMATIC TRANSMISSIONS, THE IGNITION/PARK SHIFT INTERLOCK SYSTEM MAY BECOME INOPERATIVE. THIS CAN ALLOW THE SHIFTER TO BE MOVED OUT OF THE "PARK" POSITION WITH THE IGNITION KEY REMOVED (OR IN THE "LOCK" POSITION). THIS CAN ALSO ALLOW THE IGNITION KEY TO BE REMOVED WHEN THE SHIFTER HAS NOT BEEN PLACED IN THE "PARK" POSITION.

Consequence & remedy

Consequence: EITHER OF THESE CONDITIONS COULD ALLOW THE VEHICLE TO ROLL AWAY CAUSING A CRASH WITHOUT WARNING.

Remedy: DEALERS WILL REPLACE THE GEARSHIFT BLOCKER AND BRACKET ASSEMBLY FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JANUARY 2008. OWNERS MAY CONTACT CHRYSLER AT 1-800-853-1403.

06V339000 · Electrical System

Sep 7, 2006

ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH FRONT BENCH SEATS ONLY, IF FLUID IS SPILLED FROM THE FLOOR MOUNTED CUP HOLDER, AN UNUSED CONSOLE POWER OUTLET CONNECTOR LOCATED UNDER THE SEAT MAY BECOME CONTAMINATED.

Consequence & remedy

Consequence: THIS MAY ALLOW DEVELOPMENT OF A HIGH RESISTIVE SHORT CIRCUIT IN THE CONNECTOR, WHICH COULD EVENTUALLY LEAD TO A FIRE.

Remedy: DEALERS WILL INSPECT THE CONSOLE WIRING CONNECTOR FOR CORROSION, CLEAN AS REQUIRED, AND INSTALL A CAP TO PREVENT ADDITIONAL FLUID FROM CONTAMINATING THE CONNECTOR FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 30, 2006. OWNERS MAY CONTACT DAIMLER CHRYSLER AT 1-800-853-1403.

04V596000 · Suspension:front:control Arm:upper Ball Joint

Dec 21, 2004

ON CERTAIN SPORT UTILITY VEHICLES AND PICKUP TRUCKS EQUIPPED WITH FOUR-WHEEL DRIVE (4X4), IF MOISTURE LEAKS INTO THE FRONT SUSPENSION UPPER BALL JOINT, EVACUATION OF THE LUBRICANT AND CORROSION OF THE JOINT MAY CAUSE THE JOINT TO WEAR OVER AN EXTENDED PERIOD OF TIME. THIS COULD CAUSE A CLUNKING NOISE IN THE FRONT SUSPENSION, WHICH MAY NOT ALWAYS BE HEARD BY THE VEHICLE OCCUPANTS.

Consequence & remedy

Consequence: EXCESSIVE WEAR IN THE UPPER BALL JOINT MAY ALLOW IT TO SEPARATE, WHICH COULD RESULT IN LOSS OF CONTROL OF THE VEHICLE.

Remedy: DEALERS WILL REPLACE THE FRONT SUSPENSION UPPER BALL JOINTS. THIS SAFETY IMPROVEMENT CAMPAIGN BEGAN ON DECEMBER 21, 2004. OWNERS CAN CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.

04V216000 · Visibility:windshield Wiper/washer

May 5, 2004

ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES, THE WINDSHIELD WIPER MODULE MOTOR MAY BE SUSCEPTIBLE TO WATER INTRUSION THAT COULD CAUSE INTERNAL CORROSION AND RESULT IN PARTIAL OR COMPLETE LOSS OF FRONT WINDSHIELD WIPING CAPABILITY.

Consequence & remedy

Consequence: DRIVER VISIBILITY COULD BE REDUCED, WHICH COULD RESULT IN A CRASH.

Remedy: DEALERS WILL REPLACE THE FRONT WINDSHIELD WIPER MODULE. OWNER NOTIFICATION BEGAN ON JULY 12, 2004. OWNERS SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

5

EA06011 · Vehicle UNDER-SEAT Fire

Opened Jun 19, 2006 · Closed Sep 22, 2006

Status: closed (inferred from source dates) · Electrical System; Electrical System:wiring

DAIMLERCHRYLSER CORPORATION (DCC) WILL RECALL 35,103 MY 2001-2003 DODGE DURANGO VEHICLES EQUIPPED WITH FRONT BENCH SEATS (RECALL # 06V339, SEE DEFECT REPORT FOR DETAILS).THE SUBJECT VEHICLES ARE EQUIPPED WITH EITHER FRONT BUCKET SEATS OR A 40-20-40 SPLIT FRONT BENCH SEAT.VEHICLES EQUIPPED WITH FRONT BENCH SEAT CONTAIN AN UNCAPPED, UNUSED CONNECTOR LOCATED UNDER THE FRONT EDGE OF THE SEAT.THE CONNECTOR PROVIDES POWER TO THE CENTER CONSOLE POWER OUTLET FOR VEHICLES WITH BUCKET SEATS, BUT IT IS UNUSED IN VEHICLES EQUIPPED WITH BENCH SEATS.THE CONNECTOR IS LOCATED REARWARD OF THE CUP HOLDER ON THE TUNNEL FOR VEHICLES EQUIPPED WITH THE BENCH SEAT.THIS CONNECTOR CONTAINS A FUSED B+ CIRCUIT WIRE (THAT IS CONTINUOUSLY POWERED WITH THE KEY OFF) AND A GROUND WIRE. DCC DETERMINED THAT IF LIQUID IS SPILLED FROM THE CUP HOLDER ONTO THE TUNNEL, THE UNCAPPED CONNECTOR MAY BECOME CONTAMINATED.THIS CONTAMINATION MAY ALLOW DEVELOPMENT OF A HIGH RESISTANCE SHORT CIRCUIT IN THE CONNECTOR, CAUSING LOCALIZED HEATING, WHICH COULD EVENTUALLY LEAD TO A FIRE.DCC WILL INSPECT THE UNCAPPED CONNECTOR FOR CORROSION, CLEAN AS REQUIRED, AND INSTALL A CAP TO PREVENT LIQUID CONTAMINATION.ALL OF THE REPORTED UNDER-SEAT FIRES WERE ON SUBJECT VEHICLES WITH A 40-20-40 BENCH SEAT.THIS INVESTIGATION IS CLOSED.

Additional source detail variants (2)

Electrical System

DAIMLERCHRYLSER CORPORATION (DCC) WILL RECALL 35,103 MY 2001-2003 DODGE DURANGO VEHICLES EQUIPPED WITH FRONT BENCH SEATS (RECALL # 06V339, SEE DEFECT REPORT FOR DETAILS).THE SUBJECT VEHICLES ARE EQUIPPED WITH EITHER FRONT BUCKET SEATS OR A 40-20-40 SPLIT FRONT BENCH SEAT.VEHICLES EQUIPPED WITH FRONT BENCH SEAT CONTAIN AN UNCAPPED, UNUSED CONNECTOR LOCATED UNDER THE FRONT EDGE OF THE SEAT.THE CONNECTOR PROVIDES POWER TO THE CENTER CONSOLE POWER OUTLET FOR VEHICLES WITH BUCKET SEATS, BUT IT IS UNUSED IN VEHICLES EQUIPPED WITH BENCH SEATS.THE CONNECTOR IS LOCATED REARWARD OF THE CUP HOLDER ON THE TUNNEL FOR VEHICLES EQUIPPED WITH THE BENCH SEAT.THIS CONNECTOR CONTAINS A FUSED B+ CIRCUIT WIRE (THAT IS CONTINUOUSLY POWERED WITH THE KEY OFF) AND A GROUND WIRE. DCC DETERMINED THAT IF LIQUID IS SPILLED FROM THE CUP HOLDER ONTO THE TUNNEL, THE UNCAPPED CONNECTOR MAY BECOME CONTAMINATED.THIS CONTAMINATION MAY ALLOW DEVELOPMENT OF A HIGH RESISTANCE SHORT CIRCUIT IN THE CONNECTOR, CAUSING LOCALIZED HEATING, WHICH COULD EVENTUALLY LEAD TO A FIRE.DCC WILL INSPECT THE UNCAPPED CONNECTOR FOR CORROSION, CLEAN AS REQUIRED, AND INSTALL A CAP TO PREVENT LIQUID CONTAMINATION.ALL OF THE REPORTED UNDER-SEAT FIRES WERE ON SUBJECT VEHICLES WITH A 40-20-40 BENCH SEAT.THIS INVESTIGATION IS CLOSED.

Electrical System:wiring

DAIMLERCHRYLSER CORPORATION (DCC) WILL RECALL 35,103 MY 2001-2003 DODGE DURANGO VEHICLES EQUIPPED WITH FRONT BENCH SEATS (RECALL # 06V339, SEE DEFECT REPORT FOR DETAILS).THE SUBJECT VEHICLES ARE EQUIPPED WITH EITHER FRONT BUCKET SEATS OR A 40-20-40 SPLIT FRONT BENCH SEAT.VEHICLES EQUIPPED WITH FRONT BENCH SEAT CONTAIN AN UNCAPPED, UNUSED CONNECTOR LOCATED UNDER THE FRONT EDGE OF THE SEAT.THE CONNECTOR PROVIDES POWER TO THE CENTER CONSOLE POWER OUTLET FOR VEHICLES WITH BUCKET SEATS, BUT IT IS UNUSED IN VEHICLES EQUIPPED WITH BENCH SEATS.THE CONNECTOR IS LOCATED REARWARD OF THE CUP HOLDER ON THE TUNNEL FOR VEHICLES EQUIPPED WITH THE BENCH SEAT.THIS CONNECTOR CONTAINS A FUSED B+ CIRCUIT WIRE (THAT IS CONTINUOUSLY POWERED WITH THE KEY OFF) AND A GROUND WIRE. DCC DETERMINED THAT IF LIQUID IS SPILLED FROM THE CUP HOLDER ONTO THE TUNNEL, THE UNCAPPED CONNECTOR MAY BECOME CONTAMINATED.THIS CONTAMINATION MAY ALLOW DEVELOPMENT OF A HIGH RESISTANCE SHORT CIRCUIT IN THE CONNECTOR, CAUSING LOCALIZED HEATING, WHICH COULD EVENTUALLY LEAD TO A FIRE.DCC WILL INSPECT THE UNCAPPED CONNECTOR FOR CORROSION, CLEAN AS REQUIRED, AND INSTALL A CAP TO PREVENT LIQUID CONTAMINATION.ALL OF THE REPORTED UNDER-SEAT FIRES WERE ON SUBJECT VEHICLES WITH A 40-20-40 BENCH SEAT.THIS INVESTIGATION IS CLOSED.

PE06008 · Fire Under The Driver's Seat

Opened Feb 2, 2006 · Closed Jun 19, 2006

Status: closed (inferred from source dates) · Electrical System:wiring:interior/under Dash; Seats

ODI IS AWARE OF 10 REPORTS ALLEGING THAT A FIRE ORIGINATES UNDERNEATH THE DRIVER'S SEAT.SIX OF THEFIRES OCCURRED WHILE THE VEHICLE WAS PARKED WITH THE IGNITION SWITCH TURNED OFF (KEY NOT IN THE IGNITION).THE SUBJECT VEHICLES ARE EQUIPPED WITH MANUAL SEATS. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS, (EA06-011), TO ALLOW FURTHER INVESTIGATION OF THE ISSUE.

Additional source detail variants (2)

Electrical System:wiring:interior/under Dash

ODI IS AWARE OF 10 REPORTS ALLEGING THAT A FIRE ORIGINATES UNDERNEATH THE DRIVER'S SEAT.SIX OF THEFIRES OCCURRED WHILE THE VEHICLE WAS PARKED WITH THE IGNITION SWITCH TURNED OFF (KEY NOT IN THE IGNITION).THE SUBJECT VEHICLES ARE EQUIPPED WITH MANUAL SEATS. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS, (EA06-011), TO ALLOW FURTHER INVESTIGATION OF THE ISSUE.

Seats

ODI IS AWARE OF 10 REPORTS ALLEGING THAT A FIRE ORIGINATES UNDERNEATH THE DRIVER'S SEAT.SIX OF THEFIRES OCCURRED WHILE THE VEHICLE WAS PARKED WITH THE IGNITION SWITCH TURNED OFF (KEY NOT IN THE IGNITION).THE SUBJECT VEHICLES ARE EQUIPPED WITH MANUAL SEATS. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS, (EA06-011), TO ALLOW FURTHER INVESTIGATION OF THE ISSUE.

EA03023 · Upper Ball Joint Separation

Opened Nov 19, 2003 · Closed Feb 11, 2005

Status: closed (inferred from source dates) · Suspension; Suspension:front; Suspension:front:control Arm; Suspension:front:control Arm:upper Arm; Suspension:front:control Arm:upper Ball Joint

DAIMLERCHRYSLER CORPORATION (DCC) IS RECALLING THE TARGET POPULATION OF APPROXIMATELY 600,000 MY 2000 THROUGH 2003 DURANGO AND DAKOTA VEHICLES WITH FOUR-WHEEL DRIVE TO REPLACE THE FRONT SUSPENSION UPPER BALL JOINTS WITH REDESIGNED PARTS THAT DO NOT HAVE THE JOINT INTEGRITY CONCERNS AND HAVE SUBSTANTIALLY IMPROVED JOINT RETENTION CAPACITY (NHTSA RECALL NO. 04V-596).THOUGH DCC DOES NOT ADMIT TO A SAFETY-DEFECT IN THE SUBJECT COMPONENTS, ODI BELIEVES THAT THE FACTS IN THIS INVESTIGATION SHOW OTHERWISE.BECAUSE OF THE LOW RATES OF SEPARATION INCIDENTS IN THE REMAINING SUBJECT VEHICLES, A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED IN THOSE POPULATIONS AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS IN THOSE VEHICLES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.

Additional source detail variants (5)

Suspension

DAIMLERCHRYSLER CORPORATION (DCC) IS RECALLING THE TARGET POPULATION OF APPROXIMATELY 600,000 MY 2000 THROUGH 2003 DURANGO AND DAKOTA VEHICLES WITH FOUR-WHEEL DRIVE TO REPLACE THE FRONT SUSPENSION UPPER BALL JOINTS WITH REDESIGNED PARTS THAT DO NOT HAVE THE JOINT INTEGRITY CONCERNS AND HAVE SUBSTANTIALLY IMPROVED JOINT RETENTION CAPACITY (NHTSA RECALL NO. 04V-596).THOUGH DCC DOES NOT ADMIT TO A SAFETY-DEFECT IN THE SUBJECT COMPONENTS, ODI BELIEVES THAT THE FACTS IN THIS INVESTIGATION SHOW OTHERWISE.BECAUSE OF THE LOW RATES OF SEPARATION INCIDENTS IN THE REMAINING SUBJECT VEHICLES, A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED IN THOSE POPULATIONS AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS IN THOSE VEHICLES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.

Suspension:front

DAIMLERCHRYSLER CORPORATION (DCC) IS RECALLING THE TARGET POPULATION OF APPROXIMATELY 600,000 MY 2000 THROUGH 2003 DURANGO AND DAKOTA VEHICLES WITH FOUR-WHEEL DRIVE TO REPLACE THE FRONT SUSPENSION UPPER BALL JOINTS WITH REDESIGNED PARTS THAT DO NOT HAVE THE JOINT INTEGRITY CONCERNS AND HAVE SUBSTANTIALLY IMPROVED JOINT RETENTION CAPACITY (NHTSA RECALL NO. 04V-596).THOUGH DCC DOES NOT ADMIT TO A SAFETY-DEFECT IN THE SUBJECT COMPONENTS, ODI BELIEVES THAT THE FACTS IN THIS INVESTIGATION SHOW OTHERWISE.BECAUSE OF THE LOW RATES OF SEPARATION INCIDENTS IN THE REMAINING SUBJECT VEHICLES, A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED IN THOSE POPULATIONS AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS IN THOSE VEHICLES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.

Suspension:front:control Arm

DAIMLERCHRYSLER CORPORATION (DCC) IS RECALLING THE TARGET POPULATION OF APPROXIMATELY 600,000 MY 2000 THROUGH 2003 DURANGO AND DAKOTA VEHICLES WITH FOUR-WHEEL DRIVE TO REPLACE THE FRONT SUSPENSION UPPER BALL JOINTS WITH REDESIGNED PARTS THAT DO NOT HAVE THE JOINT INTEGRITY CONCERNS AND HAVE SUBSTANTIALLY IMPROVED JOINT RETENTION CAPACITY (NHTSA RECALL NO. 04V-596).THOUGH DCC DOES NOT ADMIT TO A SAFETY-DEFECT IN THE SUBJECT COMPONENTS, ODI BELIEVES THAT THE FACTS IN THIS INVESTIGATION SHOW OTHERWISE.BECAUSE OF THE LOW RATES OF SEPARATION INCIDENTS IN THE REMAINING SUBJECT VEHICLES, A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED IN THOSE POPULATIONS AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS IN THOSE VEHICLES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.

Suspension:front:control Arm:upper Arm

DAIMLERCHRYSLER CORPORATION (DCC) IS RECALLING THE TARGET POPULATION OF APPROXIMATELY 600,000 MY 2000 THROUGH 2003 DURANGO AND DAKOTA VEHICLES WITH FOUR-WHEEL DRIVE TO REPLACE THE FRONT SUSPENSION UPPER BALL JOINTS WITH REDESIGNED PARTS THAT DO NOT HAVE THE JOINT INTEGRITY CONCERNS AND HAVE SUBSTANTIALLY IMPROVED JOINT RETENTION CAPACITY (NHTSA RECALL NO. 04V-596).THOUGH DCC DOES NOT ADMIT TO A SAFETY-DEFECT IN THE SUBJECT COMPONENTS, ODI BELIEVES THAT THE FACTS IN THIS INVESTIGATION SHOW OTHERWISE.BECAUSE OF THE LOW RATES OF SEPARATION INCIDENTS IN THE REMAINING SUBJECT VEHICLES, A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED IN THOSE POPULATIONS AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS IN THOSE VEHICLES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.

Suspension:front:control Arm:upper Ball Joint

DAIMLERCHRYSLER CORPORATION (DCC) IS RECALLING THE TARGET POPULATION OF APPROXIMATELY 600,000 MY 2000 THROUGH 2003 DURANGO AND DAKOTA VEHICLES WITH FOUR-WHEEL DRIVE TO REPLACE THE FRONT SUSPENSION UPPER BALL JOINTS WITH REDESIGNED PARTS THAT DO NOT HAVE THE JOINT INTEGRITY CONCERNS AND HAVE SUBSTANTIALLY IMPROVED JOINT RETENTION CAPACITY (NHTSA RECALL NO. 04V-596).THOUGH DCC DOES NOT ADMIT TO A SAFETY-DEFECT IN THE SUBJECT COMPONENTS, ODI BELIEVES THAT THE FACTS IN THIS INVESTIGATION SHOW OTHERWISE.BECAUSE OF THE LOW RATES OF SEPARATION INCIDENTS IN THE REMAINING SUBJECT VEHICLES, A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED IN THOSE POPULATIONS AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS IN THOSE VEHICLES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.FOR ADDITIONAL INFORMATION, SEE THE ATTACHED CLOSING REPORT.

PE03032 · Front Susp. Upper Ball Joint Failure

Opened Jul 16, 2003 · Closed Nov 19, 2003

Status: closed (inferred from source dates) · Suspension:front; Suspension:front:control Arm; Suspension:front:control Arm:upper Arm; Suspension:front:control Arm:upper Ball Joint

IN JULY 2003, ODI OPENED PE03-032 BASED ON 4 CONSUMER COMPLAINTS ALLEGING SEPARATION OF AN UPPER BALL JOINT.COMPLAINTS ALLEGED AN UNEXPECTED COLLAPSE IN THE FRONT END AND IN SOME OCCASIONS THE BALL JOINT SEPARATION IS ALLEGED TO HAVE RESULTED IN THE WHEEL, BRAKE ROTOR, AND STEERING KNUCKLE SEPARATING FROM THE VEHICLE.SINCE OPENING THE PE, ODI HAS RECEIVED 23 ADDITIONAL COMPLAINTS RELATED TO BALL JOINT SEPARATION. DAIMLERCHRYSLER HAS IDENTIFIED A WEAROUT CONCERN IN THE SUBJECT BALL JOINTS THAT IS BELIEVED TO OCCUR AFTER WATER INTRUSION EVACUATES THE JOINT LUBRICANT.DAIMLERCHRYSLER DOES NOT BELIEVE THE CONDITION POSES AN UNREASONABLE RISK TO SAFETY BECAUSE THE SUSPENSION DESIGN IN THE SUBJECT VEHICLES SIGNIFICANTLY REDUCES THE LIKELIHOOD OF JOINT SEPARATION.OVER 99 PERCENT OF THE FAILURES ARE RELATED TO WORN BALL JOINTS (E.G., NOISE COMPLAINTS).DAIMLERCHRYSLER REVISED THE REPAIR PROCEDURE IN AUGUST 2003 TO ALLOW THE UPPER BALL JOINTS TO BE SERVICED SEPARATELY FROM THE UPPER CONTROL ARM AND REDUCE REPAIR COSTS. DAIMLERCHRYSLER CHANGED THE SUPPLIER OF THE SUBJECT BALL JOINTS FROM TRW TO NEW CASTLE MACHINING & FORGE FOR MY 2000 VEHICLES.MY 2000 DURANGO VEHICLES ACCOUNT FOR 25 OF THE 37 SEPARATION COMPLAINTS.THE UPPER BALL JOINT WAS REDESIGNED IN MY 2003.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER ASSESS THE ALLEGED DEFECT IN MY 2000-02 DURANGO VEHICLES.

Additional source detail variants (4)

Suspension:front

IN JULY 2003, ODI OPENED PE03-032 BASED ON 4 CONSUMER COMPLAINTS ALLEGING SEPARATION OF AN UPPER BALL JOINT.COMPLAINTS ALLEGED AN UNEXPECTED COLLAPSE IN THE FRONT END AND IN SOME OCCASIONS THE BALL JOINT SEPARATION IS ALLEGED TO HAVE RESULTED IN THE WHEEL, BRAKE ROTOR, AND STEERING KNUCKLE SEPARATING FROM THE VEHICLE.SINCE OPENING THE PE, ODI HAS RECEIVED 23 ADDITIONAL COMPLAINTS RELATED TO BALL JOINT SEPARATION. DAIMLERCHRYSLER HAS IDENTIFIED A WEAROUT CONCERN IN THE SUBJECT BALL JOINTS THAT IS BELIEVED TO OCCUR AFTER WATER INTRUSION EVACUATES THE JOINT LUBRICANT.DAIMLERCHRYSLER DOES NOT BELIEVE THE CONDITION POSES AN UNREASONABLE RISK TO SAFETY BECAUSE THE SUSPENSION DESIGN IN THE SUBJECT VEHICLES SIGNIFICANTLY REDUCES THE LIKELIHOOD OF JOINT SEPARATION.OVER 99 PERCENT OF THE FAILURES ARE RELATED TO WORN BALL JOINTS (E.G., NOISE COMPLAINTS).DAIMLERCHRYSLER REVISED THE REPAIR PROCEDURE IN AUGUST 2003 TO ALLOW THE UPPER BALL JOINTS TO BE SERVICED SEPARATELY FROM THE UPPER CONTROL ARM AND REDUCE REPAIR COSTS. DAIMLERCHRYSLER CHANGED THE SUPPLIER OF THE SUBJECT BALL JOINTS FROM TRW TO NEW CASTLE MACHINING & FORGE FOR MY 2000 VEHICLES.MY 2000 DURANGO VEHICLES ACCOUNT FOR 25 OF THE 37 SEPARATION COMPLAINTS.THE UPPER BALL JOINT WAS REDESIGNED IN MY 2003.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER ASSESS THE ALLEGED DEFECT IN MY 2000-02 DURANGO VEHICLES.

Suspension:front:control Arm

IN JULY 2003, ODI OPENED PE03-032 BASED ON 4 CONSUMER COMPLAINTS ALLEGING SEPARATION OF AN UPPER BALL JOINT.COMPLAINTS ALLEGED AN UNEXPECTED COLLAPSE IN THE FRONT END AND IN SOME OCCASIONS THE BALL JOINT SEPARATION IS ALLEGED TO HAVE RESULTED IN THE WHEEL, BRAKE ROTOR, AND STEERING KNUCKLE SEPARATING FROM THE VEHICLE.SINCE OPENING THE PE, ODI HAS RECEIVED 23 ADDITIONAL COMPLAINTS RELATED TO BALL JOINT SEPARATION. DAIMLERCHRYSLER HAS IDENTIFIED A WEAROUT CONCERN IN THE SUBJECT BALL JOINTS THAT IS BELIEVED TO OCCUR AFTER WATER INTRUSION EVACUATES THE JOINT LUBRICANT.DAIMLERCHRYSLER DOES NOT BELIEVE THE CONDITION POSES AN UNREASONABLE RISK TO SAFETY BECAUSE THE SUSPENSION DESIGN IN THE SUBJECT VEHICLES SIGNIFICANTLY REDUCES THE LIKELIHOOD OF JOINT SEPARATION.OVER 99 PERCENT OF THE FAILURES ARE RELATED TO WORN BALL JOINTS (E.G., NOISE COMPLAINTS).DAIMLERCHRYSLER REVISED THE REPAIR PROCEDURE IN AUGUST 2003 TO ALLOW THE UPPER BALL JOINTS TO BE SERVICED SEPARATELY FROM THE UPPER CONTROL ARM AND REDUCE REPAIR COSTS. DAIMLERCHRYSLER CHANGED THE SUPPLIER OF THE SUBJECT BALL JOINTS FROM TRW TO NEW CASTLE MACHINING & FORGE FOR MY 2000 VEHICLES.MY 2000 DURANGO VEHICLES ACCOUNT FOR 25 OF THE 37 SEPARATION COMPLAINTS.THE UPPER BALL JOINT WAS REDESIGNED IN MY 2003.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER ASSESS THE ALLEGED DEFECT IN MY 2000-02 DURANGO VEHICLES.

Suspension:front:control Arm:upper Arm

IN JULY 2003, ODI OPENED PE03-032 BASED ON 4 CONSUMER COMPLAINTS ALLEGING SEPARATION OF AN UPPER BALL JOINT.COMPLAINTS ALLEGED AN UNEXPECTED COLLAPSE IN THE FRONT END AND IN SOME OCCASIONS THE BALL JOINT SEPARATION IS ALLEGED TO HAVE RESULTED IN THE WHEEL, BRAKE ROTOR, AND STEERING KNUCKLE SEPARATING FROM THE VEHICLE.SINCE OPENING THE PE, ODI HAS RECEIVED 23 ADDITIONAL COMPLAINTS RELATED TO BALL JOINT SEPARATION. DAIMLERCHRYSLER HAS IDENTIFIED A WEAROUT CONCERN IN THE SUBJECT BALL JOINTS THAT IS BELIEVED TO OCCUR AFTER WATER INTRUSION EVACUATES THE JOINT LUBRICANT.DAIMLERCHRYSLER DOES NOT BELIEVE THE CONDITION POSES AN UNREASONABLE RISK TO SAFETY BECAUSE THE SUSPENSION DESIGN IN THE SUBJECT VEHICLES SIGNIFICANTLY REDUCES THE LIKELIHOOD OF JOINT SEPARATION.OVER 99 PERCENT OF THE FAILURES ARE RELATED TO WORN BALL JOINTS (E.G., NOISE COMPLAINTS).DAIMLERCHRYSLER REVISED THE REPAIR PROCEDURE IN AUGUST 2003 TO ALLOW THE UPPER BALL JOINTS TO BE SERVICED SEPARATELY FROM THE UPPER CONTROL ARM AND REDUCE REPAIR COSTS. DAIMLERCHRYSLER CHANGED THE SUPPLIER OF THE SUBJECT BALL JOINTS FROM TRW TO NEW CASTLE MACHINING & FORGE FOR MY 2000 VEHICLES.MY 2000 DURANGO VEHICLES ACCOUNT FOR 25 OF THE 37 SEPARATION COMPLAINTS.THE UPPER BALL JOINT WAS REDESIGNED IN MY 2003.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER ASSESS THE ALLEGED DEFECT IN MY 2000-02 DURANGO VEHICLES.

Suspension:front:control Arm:upper Ball Joint

IN JULY 2003, ODI OPENED PE03-032 BASED ON 4 CONSUMER COMPLAINTS ALLEGING SEPARATION OF AN UPPER BALL JOINT.COMPLAINTS ALLEGED AN UNEXPECTED COLLAPSE IN THE FRONT END AND IN SOME OCCASIONS THE BALL JOINT SEPARATION IS ALLEGED TO HAVE RESULTED IN THE WHEEL, BRAKE ROTOR, AND STEERING KNUCKLE SEPARATING FROM THE VEHICLE.SINCE OPENING THE PE, ODI HAS RECEIVED 23 ADDITIONAL COMPLAINTS RELATED TO BALL JOINT SEPARATION. DAIMLERCHRYSLER HAS IDENTIFIED A WEAROUT CONCERN IN THE SUBJECT BALL JOINTS THAT IS BELIEVED TO OCCUR AFTER WATER INTRUSION EVACUATES THE JOINT LUBRICANT.DAIMLERCHRYSLER DOES NOT BELIEVE THE CONDITION POSES AN UNREASONABLE RISK TO SAFETY BECAUSE THE SUSPENSION DESIGN IN THE SUBJECT VEHICLES SIGNIFICANTLY REDUCES THE LIKELIHOOD OF JOINT SEPARATION.OVER 99 PERCENT OF THE FAILURES ARE RELATED TO WORN BALL JOINTS (E.G., NOISE COMPLAINTS).DAIMLERCHRYSLER REVISED THE REPAIR PROCEDURE IN AUGUST 2003 TO ALLOW THE UPPER BALL JOINTS TO BE SERVICED SEPARATELY FROM THE UPPER CONTROL ARM AND REDUCE REPAIR COSTS. DAIMLERCHRYSLER CHANGED THE SUPPLIER OF THE SUBJECT BALL JOINTS FROM TRW TO NEW CASTLE MACHINING & FORGE FOR MY 2000 VEHICLES.MY 2000 DURANGO VEHICLES ACCOUNT FOR 25 OF THE 37 SEPARATION COMPLAINTS.THE UPPER BALL JOINT WAS REDESIGNED IN MY 2003.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER ASSESS THE ALLEGED DEFECT IN MY 2000-02 DURANGO VEHICLES.

PE02082 · Safety Belt Cinching Latch Plate

Opened Nov 6, 2002 · Closed Apr 23, 2003

Status: closed (inferred from source dates) · Seat Belts

THERE ARE NO INJURIES OR FATALITIES ASSOCIATED WITH THIS ALLEGED DEFECT.WHILE CONDUCTING THIS INVESTIGATION, ODI FOUND THAT THE SUBJECT CINCHES MEET THE LOAD BEARING REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD 208, AND THAT MANY OF THE REPORTED FAILURES WERE DUE TO INCORRECT CHILD SAFETY SEAT INSTALLATIONS. ADDITIONALLY, THE REPORT RATE IS LOW (1.60/100K).THE INFORMATION AVAILABLE FAILS TO ESTABLISH THE EXISTENCE OF A DEFECT TREND AT THIS TIME.FURTHER ALLOCATION OF AGENCY RESOURCES TO THIS ISSUE IS UNWARRANTED AND THE PRELIMINARY EVALUATION IS BEING CLOSED.