NHTSA Complaint #10402256 — 1999 PLYMOUTH VOYAGER

I HAVE SEEN ON CERTAIN CHRYSLER MODELS, ESPECIALLY MINIVANS, WITH THE 2-PIN FLOATING CALIPER DESIGN THAT THE SURFACE OF THE STEERING KNUCKLE WHERE THE BRAKE PADS RIDE WEARS AWAY AND CAN CAUSE THE AFFECTED WHEEL TO LOCK UP EITHER DURING A STOP OR AFTER THE BRAKE PEDAL IS RELEASED. THIS IS CAUSED BY THE BRAKE PADS WEDGING IN THE GROOVE. IF THIS WERE TO HAPPEN DURING A BRAKE APPLICATION, THE VEHICLE COULD VEER INTO ONCOMING TRAFFIC, CAUSING AN ACCIDENT. I HAVE ALSO NOTICED THAT THE MOUNTING DESIGN (IE: BOLTS AND SLIDE PINS,) IS FLAWED. THE BOLTS ARE TOO SHORT AND DO NOT MAKE ENOUGH CONTACT WITH THE THREADS, ESPECIALLY AFTER ROUTINE BRAKE MAINTENANCE THE HOLES CAN BECOME STRIPPED. CHRYSLER RECOMMENDS A TORQUE OF 119 IN/LBS OR 16 FT/LBS (SOURCE: ALLDATA 2011 LLC,) ALTHOUGH WHEN TORQUED TO SPECIFICATION, THE BOLT THREADS STRIP OUT. IF THE BOLTS WERE TO BE LOOSE OR ULTIMATELY FALL OFF THE VEHICLE, THE CALIPER WILL RIDE ON THE INSIDE OF THE WHEEL, MAKING NOISE OR LOCKING THE WHEEL DURING ANY DRIVING MANEUVER; WHICH CAN LEAD TO A CRASH. CORRECTION TO THE FAILING KNUCKLE IS SIMPLE IF FOUND EARLY ENOUGH. THE EDGES CAN BE GROUND DOWN TO ALLOW THE PADS TO MOVE SMOOTHLY, SHIMS CAN BE ADDED TO COMPENSATE FOR THE REMOVED MATERIAL AND A DECENT HIGH-TEMPERATURE BRAKE GREASE SHOULD BE USED ON THE SLIDING SURFACE. CORRECTION TO THE CALIPER MOUNTING HARDWARE IS THREAD REPAIR WITH A HELICOIL SET FOR 9MM BOLTS. IT WOULD BE NICE TO HAVE EXTENDED BOLTS AVAILABLE (METRIC GRADE 10.9,) FROM THE MANUFACTURER. TOO OFTEN THAN NOT I HAVE SEEN THESE PROBLEMS WHERE BRAKE MAINTENANCE IS ALMOST/OVER DUE. *TR