NHTSA Complaint #10541727 — 2005 DODGE DURANGO

2005 DODGE DURANGO 5.7 HEMI STALLS UPON ACCELERATION. DURING ACCELERATION IN THE FORWARD DIRECTION THE VEHICLE WILL LOSE ALL ELECTRICAL FUNCTION AND SHUT DOWN THE ENGINE CAUSING THE MOTORIST TO BE STRANDED IN THE MIDDLE OF AN INTERSECTION OR OTHER DANGEROUS SECTION OF ROADWAY. LOSS OF ELECTRICAL FUNCTION CAN BE ATTRIBUTED TO THE CLOSE PROXIMITY OF THE POSITIVE BATTERY CABLE TO THE EGR PIPE ON THE RIGHT SIDE OF THE ENGINE. DURING ACCELERATION THE ENGINE WILL TORQUE OVER CAUSING THE EGR PIPE TO MAKE CONTACT WITH THE BATTERY CABLE THUS CAUSING THE PLASTIC SHEATHING TO BECOME CHAFED. OVER TIME THIS CHAFING WILL WEAR THROUGH THE PLASTIC SHEATHING AND EXPOSE THE BARE COPPER WIRE ALLOWING IT TO COME IN CONTACT WITH THE METAL EGR PIPE. THE CONTACT OF THE COPPER WIRE FROM THE POSITIVE BATTERY CABLE TO THE METAL EGR PIPE CREATES A DIRECT SHORT WHICH IN TURN SHUTS DOWN THE ELECTRICAL SYSTEM AND ANY ENGINE CONTROL FUNCTIONS. IN SOME INSTANCES THIS SHORT CAN CAUSE THE BATTERY CABLE TO HEAT UP ENOUGH TO CATCH THE PLASTIC INSULATION ON FIRE AND POSSIBLY LEAD TO BATTERY EXPLOSION.