NHTSA Complaint #10937669 — 2008 DODGE CARAVAN

THE INCIDENT HAPPENED ON A 2008 DODGE CARAVAN (3.3L / 4SPD) WITH 115,562 MILES (SPENT ITS ENTIRE LIFE IN MICHIGAN). DURING A RIGHT-HAND TURN FROM A STOP THERE WAS A LOUD CLUNKING NOISE THAT OCCURRED JUST AFTER THE THROTTLE WAS PRESSED AND THE VEHICLE WAS IMMEDIATELY DISABLED (NO MORE POWER/TORQUE TO THE WHEELS WITH THROTTLE) FOLLOWED BY A LARGE PLUME OF SMOKE (FROM UNDER THE HOOD AND CAME IN THROUGH THE VENTS). THE ROADS WERE DRY BUT THE WEATHER WAS COLD (~25F). UPON FURTHER INSPECTION, IT WAS A RIGHT HALFSHAFT BARSHAFT THAT HAD FRACTURED/FAILED AND IT DID SO WITHOUT WARNING. THERE WAS SIGNIFICANT CORROSION THAT OCCURRED UNDER THE DAMPER THAT WEAKENED THE SHAFT AND THAT'S WHERE THE FRACTURE TOOK PLACE UNDER LOAD. THE SMOKE WAS A RESULT OF BARSHAFT FRACTURE - THE BOOT TORE/INBOARD JOINT CAME APART (WITH VEHICLE MOVEMENT / THROTTLE) AND GREASE SPRAYED ALL OVER THE HOT ENGINE. THIS OCCURRED ON A VERY BUSY CITY STREET (4 LANES) AND BECAUSE THE HALFSHAFT BROKE THE VEHICLE NO LONGER HAD PARK (WHICH WAS ONLY DISCOVERED AFTER GETTING OUT OF THE VEHICLE WHEN THE VEHICLE STARTED TO ROLL BACKWARDS ' HAD TO JUMP IN VEHICLE AND SET THE PARKING BRAKE). THE VEHICLE HAD TO BE TOWED TO THE SHOP.