NHTSA Complaint #10121827 — 2003 DODGE SPRINTER

WE OPERATE 2 2003 DODGE SPRINTER PASSENGER VANS IN OUR AIRPORT SHUTTLE BUSINESS. ON THURSDAY, MAY 19TH WE HAD A VEHICLE JUST QUIT AFTER START-UP WHEN THE DRIVER STEPPED ON THE GAS. SHE RE-STARTED, DROVE A BLOCK, IT QUITS AGAIN. WE HAD 6 PASSENGERS ONBAORD TO GO TO THE AIRPORT. SHE COULD NOT MAKE THE VEHICLE RUN MORE THAN A FEW BLOCKS AND IF SHE STEPPED ON THE GAS TO ACCELERATE IT WOULD QUIT. WE TOWED IT TO THE DEALER AND THE NEXT DAY IT WAS DETERMINED THAT A WIRE BUNDLE THAT RUNS FROM THE ECU TO THE ENGINE, WHICH IS TIED WRAPPED TO 2 OTHER WIRE BUNDLES HAD CHAFFED RIGHT THRU THE PROTECTIVE NYLON COVER AND WORN THRU 2 OR 3 WIRES IN THE BUNDLE AND COMPLETELY THUR THE INTERNAL WIRE. THESE WIRES WERE THOSE THAT PROVIDED VOLTAGE TO THE FUEL INJECTORS AND HENCE THE FAILURE OF POWER. THE DEALER WAS ABLE TO SPLICE THE WIRES AND PUT ON A HEAVY DUTY PLASTIC WIRE BUNDLE WRAP, SIMILAR TOTHOSE USED ELSEWHERE IN THE VEHICLE. THE PROBLEM IS THAT THIS BUNDLE IS TIED WRAPPED TO THE LOWER FRAME OF THE ENGINE COMPARTMENT AND IS PROBABLY THAT WAY IN EVERY SPRINTER. SINCE OUR SPRINTERS HAVE ABOUT 190,000 MILES IN ONLY A YEAR AND A HALF, WE'VE OBVIOUSLY HAVE MORE TIME AND VIBRATION AND CHAFFING THAN NEARLY ANY IN THE COUNTRY SO WE ARE SEEING HIGH MILEAGE ISSUES THAT A NORMAL CONSUMER WILL PROBABLY NEVER SEE. HOWEVER, THIS INSTANT FAILURE COLD HAVE BEEN A DISASTER WE IF HAD BEEN ON THE FREEWAY GOING 70 MPH INSTEAD OF IN A RESIDENTIAL AREA. WE INSPECTED OUR OTHER SPRINTER AND IT HAS THE SAME WIRING CONCEPT BUT FOR SOME REASON THIS MAIN WIRE BUNDLE WAS NOT TIE WRAPPED TO THE FRAME AND DOES NOT APPEAR TO BE CHAFFED. WE ARE HAVING OUR MAINTENANCE PERSON CHECK IT ON MONDAY THE 23RD. THIS IS A TRUE SAFETY ISSUE THAT SHOULD RESULT IN AT LEAST A RECALL FOR INSPECTION OF THE WIRE BUNDLE FOR CHAFFING. IT WAS ABOUT A 3-4 HOUR REPAIR.