NHTSA Complaint #11079621 — 2009 DODGE GRAND CARAVAN

THIS VEHICLE HAS HAD SEVERAL ELECTRICAL COMPONENT FAILURES THAT WERE PREMATURE AND UNEXPLAINED. COMPUTER MODULE REPLACED TWICE, SENSORS REPLACED BEFORE THEY SHOULD HAVE GONE BAD. WE ALSO WERE EXPERIENCING SMALL ELECTRICAL ISSUES ALL OVER THE VEHICLE, PROBLEMS WITH WINDOWS, SLIDE DOORS, ACCESSORIES, RADIO ETC. AFTER INSPECTION OF THE ELECTRICAL SYSTEM A PROBLEM WAS OBSERVED WITH TWO OF THE MAIN WIRING HARNESSES FOR ENGINE COMPONENTS, ONE WAS ROUTED OVER THE TOP OF THE RADIATOR HOSE WHERE IT ATTACHES TO THE TOP OF THE MOTOR ALLOWING EXCESSIVE HEAT TO MELT THE WIRE PROTECTION SLEEVES AND WIRE COATING WHICH CAUSED CONTACT OF WIRES EXPOSED. ANOTHER SECTION OF WIRING ROUTED DOWN FROM THE MAIN FUSE BOX AND RESTED ON TOP OF THE TRANSMISSION COVER RESULTING IN OVERHEATING OF THE WIRES. THESE TWO ISSUES CAUSED EXCESSIVE HEATING OF THE WIRING TO EFFECT THE CURRENT FLOW TO AND FROM THE MAIN WIRE PORT FOR ALL ELECTRICAL COMPONENTS OF THE VEHICLE AND RESULTED IN SYSTEM MALFUNCTIONS EVERYWHERE. THIS IS A POOR DESIGN BY THE MANUFACTURER AND A SERIOUS SAFETY CONCERN. I WOULD WANT ANYONE WITH THE SAME VEHICLE TO KNOW THIS IS PROBABLY THE RESULT OF NUMEROUS ELECTRICAL COMPONENT FAILURES OR PROBLEMS THEY ARE EXPERIENCING THAT MAY LEAD TO EXCESSIVE REPAIRS THAT ARE NOT NECESSARY IF THE WIRING IS ROUTED IN A BETTER WAY TO AVOID OVERHEATING.