NHTSA Complaint #10285060 — 2007 DODGE SPRINTER 2500

1. INITIALLY I HAD BEEN HAVING PROBLEMS WITH THE CHASSIS BATTERY FROM THE BEGINNING OF PURCHASE (8/25/08). DURING THE FIRST AUTO DEALER'S SERVICE (5/13/09)), THE CHASSIS BATTERY WAS CHECKED AND CLEARED AS SATISFACTORY. THEN CHASSIS BATTERY BOILED DRY AND HAD TO BE REPLACED (5/30/09) LATER THE DEALER ADMITTED THAT THE TERMINALS ON THE CHASSIS BATTERY HAD NOT BEEN INSPECTED. 2. NEXT WAS A FAILURE OF THE ELECTRIC WIRING SYSTEM CONNECTING THE ALTERNATOR TO THE STARTER SYSTEM. THE FAILURE WAS DUE TO THE BATTERY ISOLATING SWITCH MECHANISM (DISCONNECT SWITCH) WHICH IS LOCATED NEXT TO THE ACCELERATOR BEING JOSTLED BY THE OPERATOR'S FOOT. THIS CAUSES THE BATTERY TO CALL FOR EXCESSIVE VOLTAGE. CONSEQUENTLY THE EXCESSIVE CHARGING OVER A PERIOD OF TIME DESTROYED THE CHASSIS BATTERY, DESTROYED THE WIRING FROM THE ALTERNATOR TO THE STARTER SOLENOID WITH POSSIBLE DAMAGE TO THE ECM SYSTEMS. 3. I REPLACED THE CHASSIS BATTERY; THE DEALER PERFORMED TESTS AND REPLACED THE DESTROYED WIRING. WITH MY BACKGROUND IN MECHANICS, I DISCOVERED A DESIGN FLAW IN THE BATTERY ISOLATING SWITCH (DISCONNECT SWITCH). THE DEALER PERFORMING THE INSPECTION FOUND THE "DISCONNECT SWITCH" WAS WORKING AS DESIGNED AND THE AUTO MANUFACTURER DOES NOT RECOMMEND MODIFYING THIS DESIGN. AS A CUSTOMER I ASKED FOR THE DISCONNECT SWITCH TO BE STABILIZED WITH A DOUBLE NUT SYSTEM. THE REFUSAL OF THE AUTO MANUFACTURING TO MODIFY THIS DESIGN LEAVES THE BATTERY ISOLATING SWITCH (DISCONNECT SWITCH) SUBJECT TO MOVEMENT OF THE VEHICLE OR THE DRIVER'S FOOT WHICH CAUSES THE GROUND CONNECTION TO BE WEAK AND THUS CAUSING THE ALTERNATOR TO OVERCHARGE. THE CURRENT DISCONNECT DESIGN ALLOWS FOR THE FAILURE OF THE ELECTRICAL SYSTEMS AND A POTENTIAL FIRE HAZARD. QUOTING: DODGE SPRINTER 2008 MANUAL: "CAUTION! MAKE SURE THAT THE KEY IS IN POSITION 0 IN THE IGNITION LOCK AND WAIT AT LEAST 20 SECONDS BEFORE DISCONNECTING OR CONNECTING THE BATTERY ISOLATING SWITCH. YOU COULD OTHERWISE DAMAGE ELECTRICAL SYSTEM COMPONENTS." *TR