Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
SUSPENSION
EA03023CHRYSLER GROUP LLC11/19/200302/11/2005UPPER BALL JOINT SEPARATION04V596000
 Daimlerchrysler corporation (dcc) is recalling the target population of approximately 600,000 my 2000 through 2003 durango and dakota vehicles with four-wheel drive to replace the front suspension upper ball joints with redesigned parts that do not have the joint integrity concerns and have substantially improved joint retention capacity (nhtsa recall no. 04v-596).though dcc does not admit to a safety-defect in the subject components, odi believes that the facts in this investigation show otherwise.because of the low rates of separation incidents in the remaining subject vehicles, a safety-related defect has not been identified in those populations and further use of agency resources does not appear to be warranted.the closing of this investigation does not constitute a finding by nhtsa that no safety-related defect exists in those vehicles.the agency reserves the right to take further action if warranted by the circumstances.for additional information, see the attached closing report.
SUSPENSION - FRONT
EA03023CHRYSLER GROUP LLC11/19/200302/11/2005UPPER BALL JOINT SEPARATION04V596000
 Daimlerchrysler corporation (dcc) is recalling the target population of approximately 600,000 my 2000 through 2003 durango and dakota vehicles with four-wheel drive to replace the front suspension upper ball joints with redesigned parts that do not have the joint integrity concerns and have substantially improved joint retention capacity (nhtsa recall no. 04v-596).though dcc does not admit to a safety-defect in the subject components, odi believes that the facts in this investigation show otherwise.because of the low rates of separation incidents in the remaining subject vehicles, a safety-related defect has not been identified in those populations and further use of agency resources does not appear to be warranted.the closing of this investigation does not constitute a finding by nhtsa that no safety-related defect exists in those vehicles.the agency reserves the right to take further action if warranted by the circumstances.for additional information, see the attached closing report.
SUSPENSION - FRONT - CONTROL ARM
EA03023CHRYSLER GROUP LLC11/19/200302/11/2005UPPER BALL JOINT SEPARATION04V596000
 Daimlerchrysler corporation (dcc) is recalling the target population of approximately 600,000 my 2000 through 2003 durango and dakota vehicles with four-wheel drive to replace the front suspension upper ball joints with redesigned parts that do not have the joint integrity concerns and have substantially improved joint retention capacity (nhtsa recall no. 04v-596).though dcc does not admit to a safety-defect in the subject components, odi believes that the facts in this investigation show otherwise.because of the low rates of separation incidents in the remaining subject vehicles, a safety-related defect has not been identified in those populations and further use of agency resources does not appear to be warranted.the closing of this investigation does not constitute a finding by nhtsa that no safety-related defect exists in those vehicles.the agency reserves the right to take further action if warranted by the circumstances.for additional information, see the attached closing report.
SUSPENSION - FRONT - CONTROL ARM - UPPER ARM
EA03023CHRYSLER GROUP LLC11/19/200302/11/2005UPPER BALL JOINT SEPARATION04V596000
 Daimlerchrysler corporation (dcc) is recalling the target population of approximately 600,000 my 2000 through 2003 durango and dakota vehicles with four-wheel drive to replace the front suspension upper ball joints with redesigned parts that do not have the joint integrity concerns and have substantially improved joint retention capacity (nhtsa recall no. 04v-596).though dcc does not admit to a safety-defect in the subject components, odi believes that the facts in this investigation show otherwise.because of the low rates of separation incidents in the remaining subject vehicles, a safety-related defect has not been identified in those populations and further use of agency resources does not appear to be warranted.the closing of this investigation does not constitute a finding by nhtsa that no safety-related defect exists in those vehicles.the agency reserves the right to take further action if warranted by the circumstances.for additional information, see the attached closing report.
SUSPENSION - FRONT - CONTROL ARM - UPPER BALL JOINT
EA03023CHRYSLER GROUP LLC11/19/200302/11/2005UPPER BALL JOINT SEPARATION04V596000
 Daimlerchrysler corporation (dcc) is recalling the target population of approximately 600,000 my 2000 through 2003 durango and dakota vehicles with four-wheel drive to replace the front suspension upper ball joints with redesigned parts that do not have the joint integrity concerns and have substantially improved joint retention capacity (nhtsa recall no. 04v-596).though dcc does not admit to a safety-defect in the subject components, odi believes that the facts in this investigation show otherwise.because of the low rates of separation incidents in the remaining subject vehicles, a safety-related defect has not been identified in those populations and further use of agency resources does not appear to be warranted.the closing of this investigation does not constitute a finding by nhtsa that no safety-related defect exists in those vehicles.the agency reserves the right to take further action if warranted by the circumstances.for additional information, see the attached closing report.

Consumer Complaints


Fail datemilesoccurencesPurchase date
SUSPENSION
09/09/20051
 My 18 month old son and i were in a single car rollover, on september 9, 2005. i was driving a 2003 dodge dakota when my truck started to make a noise, then we were sent into a rollover. the right front tire was gone when we stopped. i was sent information from my uncle after i sent him pictures of the accident and he sent me information on the possible recall. i need to know what my options are and what do i do now. *nm
06/01/2004100710/25/2003
 Vehicle will either go into neutral when put in reverse or while reversing pop out of reverse into neutral. this mostly occurred when the vehicle was in 4-wheel drive. the dealership serviced the vehicle several times for this issue, but since they were unable to duplicate or resolve the problem. *ak the consumer had two transmission problems. the transmission module shorted out on four separate occasions. this problem caused the consumer to be nearly rear ended three times. the transmission shift indicator showed that the vehicle was in reverse but acted as if it were in neutral. the vehicle pulled to the left, the brakes would squeak and the vehicle had poor gas mileage. *sc the battery was replaced because the vehicle did not start at times. *jb
SUSPENSION - FRONT
09/28/201097000
 Upper ball joints were both loose and dealer recommended replacement. vin number was not included in previious recall by chrysler.
01/28/20091
 3 weeks after purchase had truck in shop with noise in front and rear tire/suspension areas...in for several service visits, seemed to get better than came back, they replaced bushings//had not heard noise...january 28, 2009 very loud noise and hard to turn drove to local tire company which said my suspension was bowed that tires were angled incorrectly and an immediate fix of the upper ball joints needed to be done for safety...$900.00 later they replaced. i found out that night through an on line search that there had been a recall of the same part that was consistent with my situation same model make year/ i have the removed defective parts. *tr
08/25/20081046011
 Upper ball joint failure passenger side of vehicle, i contacted chrysler and they say that my vehicle is not covered under the recall #04v216000, which covered 600,000 vehicles for this very type of failure. i was never offered or informed of a extended warranty given by chrysler to cover this very problem. if i was made aware of the possibility of this problem occurring with my vehicle, i would of made sure that my vehicle was inspected on a timely manner in this area. i did return my vehicle for a recall for my windshield washer assy in december of 2004 and also for my balljoints due the fact i was sent a recall notice. if the weather was worse or i did drive my vehicle off road i do believe my ball joint would have deteriorated as a accelerated rate. i also believe that if i experienced this failure in my vehicle,which was not recalled, there are many more dodge dakota pick up trucks that will experience this type of failure. chrysler says the numbers don't warrant a recall,but this failure in their vehicle compared to gm or ford products of the same type vehicle are about 300% to 1% comparing the numbers. i feel chrysler should be responsible for any and all expense that i have incurred to repair my vehicle and more vehicles should be put into a recall status for this problem. *tr
10/27/20033000106/30/2003
 I keep hearing a loud bang and louding creaking noises in the front end of my 2003 dodge dakota when i turn the wheel. i have taken it to the dodge dealer several times, but they haven't found anything. i keep telling them it sounds like a cracked coil spring or body mount. they said if i bring it in again as warranty work, then they'll charge me for the time. also, the turn signals keep shorting out and when you turn the left one on, the emergency flashers come on. finally, the left power window slows down excessively when i attempt to put the window up. it goes down fine, but it won't go up at normal speed.*ak
SUSPENSION - FRONT - CONTROL ARM
03/04/20071
 To whom it may concern, i own a 2003 dodge dakota quad cab slt. and i have run into a lot of problems with this truck that people i know say they had very similar problems with the same make of vehicle. to start with my truck only has about 62,184 miles on it, for a 2003 model truck, that is considered low mileage. the problems i have run into is as follows: both front wheel hub bearing sets have prematurely failed, in particular, the right front hub tried to lock up on me and almost caused me to loose control of the truck, i have since replaced that hub but still need to replace the left front before it locks up:second is that the steering and suspension system has no provisions for preventative maintenance, i.e. no grease zircs for the ball joints, tie rods,upper and lower control arm bushings, wheel bearings, etc...causing rapid wear and failure:third big issue, i have already replaced all four brake rotors due to warpage. the brake calipers were built with some type of composite plastic pistons that distort due to excessive heat build up in the brakes. which in turn causes uneven pad contact, that then causes excessive heat, accelerated pad wear, brake fade, rotor warpage, and an awful squeal when the brakes are applied. i have noticed that my brand new brake pads are actually cracked now because of a combination of the calipers and the hubs going bad: fourth issue is that the transmission causes the engine to over rev in the highway passing gear especially with the over drive and cruise control on. when you're driving down the highway and you give it a little more gas to get around somebody, the engine rpm's shouldn't go up to sometimes around 7000, that in turn could cause premature engine or transmission failure. i have been in contact with daimler-chrysler about these concerns but they just keep giving me the run around and not answering my questions. i still have the old parts also.
SUSPENSION - FRONT - CONTROL ARM - LOWER BALL JOINT
12/04/200723000201/22/2003
 I own a 2003 dodge dakota (pickup) purchased new (i am the original owner). the lower ball joints were replaced by the dealer at 23,000 miles (under warranty). they are now bad again at 78,000 miles (no warranty now, this bill was on me)! the upper ball joints were also replaced twice (those are under an official nhtsa recall). my complaint is about the lower ball joints. these parts should not wear out this often, and i feel this is a bad design! this is a safety issue (in my opinion) and also a big expense for the owners of these vehicles. i feel the lower ball joints should also be an official nhtsa recall!!! *tr
03/04/20071
 To whom it may concern, i own a 2003 dodge dakota quad cab slt. and i have run into a lot of problems with this truck that people i know say they had very similar problems with the same make of vehicle. to start with my truck only has about 62,184 miles on it, for a 2003 model truck, that is considered low mileage. the problems i have run into is as follows: both front wheel hub bearing sets have prematurely failed, in particular, the right front hub tried to lock up on me and almost caused me to loose control of the truck, i have since replaced that hub but still need to replace the left front before it locks up:second is that the steering and suspension system has no provisions for preventative maintenance, i.e. no grease zircs for the ball joints, tie rods,upper and lower control arm bushings, wheel bearings, etc...causing rapid wear and failure:third big issue, i have already replaced all four brake rotors due to warpage. the brake calipers were built with some type of composite plastic pistons that distort due to excessive heat build up in the brakes. which in turn causes uneven pad contact, that then causes excessive heat, accelerated pad wear, brake fade, rotor warpage, and an awful squeal when the brakes are applied. i have noticed that my brand new brake pads are actually cracked now because of a combination of the calipers and the hubs going bad: fourth issue is that the transmission causes the engine to over rev in the highway passing gear especially with the over drive and cruise control on. when you're driving down the highway and you give it a little more gas to get around somebody, the engine rpm's shouldn't go up to sometimes around 7000, that in turn could cause premature engine or transmission failure. i have been in contact with daimler-chrysler about these concerns but they just keep giving me the run around and not answering my questions. i still have the old parts also.
03/29/200541000110/13/2004
 1) at about 40,000 miles my front drivers side lower ball joint started making an extremely loud crunching noise as if metal were grinding with metal. 2) i subsequently took my truck to a local dealer who notified me that the lower ball joint was loose and that it was not covered by the previous recall which covered the upper ball joint only. 3) the parts and labor to replace this part cost in excess of $270.00 not including the $40 inspection fee
08/01/2004109/01/2003
 Uneven tire wear led me to have truck serviced at midas tire co. they reported excessive loose play in both top and bottom frontend ball joints. vehicle is under warranty w/daimlerchrysler so took to sales/service dealer soutars in barstow, ca two different times w/same concern. they reported nothing wrong w/ball joints both times. san bernardino sun telegram 12/11/04 news reports serious problems w/ball joints in dodge dakota 2003 models causing wheels to fall off.*ak
11/30/20042398501/10/2004
 Recent inspection by authorized mechanic reveals heavily worn ball joints on 2003 dodge dakota with 24,000 miles
12/21/2003200001
 Dodge dakota 2003 sport: first few months of ownership, i went to have tires rotated (20,000mi) and i was told that the ball joints were out of spec. by the mechanic and that i should take the vehicle to the dealer. after inspection, the dealer said nothing was wrong.i know something is wrong with the vehicle because since that time, everytime i turn left while applying brakes in a downhill situation, a terrible grinding sound is heard. the vehicle now has 54000mi and i hear about wheels breaking off. i am scared for my families and personal safety.*ak
11/10/2003500001
 My ball joints have worn out at about 55,000 miles. it is not covered in my 7 year 70,000 mile bumper to bumper warranty. *la
07/01/20046000104/01/2003
 When making sharp right turns a popping noise can be heard coming from the front of the vehicle. the owner suspects there may be a problem with the ball joints, but the vehicle has not been diagnosed by a dealer. *ak *nm
SUSPENSION - FRONT - CONTROL ARM - UPPER BALL JOINT
03/07/200871000108/07/2005
 Tl*the contact owns a 2003 dodge dakota quad cab. the contact stated that there is excessive wear on the ball joints. the dealer stated that his vin was not included in nhtsa campaign id number 04v596000 (suspension:front:control arm:upper ball joint). the current and failure mileages were 71,000. updated 03-25-08 *bf updated 03/25/08 *tr
01/18/200768800110/28/2004
 I have upper ball joints going out on my 2003 dodge dakota..and the dodge dealer in fargo nd says my vin number is not recalled. but on your site there is a recall for them? i want clarification, of why mine has not not recalled too? please contact me through my internet addresses. thank you. *jb
03/04/20071
 To whom it may concern, i own a 2003 dodge dakota quad cab slt. and i have run into a lot of problems with this truck that people i know say they had very similar problems with the same make of vehicle. to start with my truck only has about 62,184 miles on it, for a 2003 model truck, that is considered low mileage. the problems i have run into is as follows: both front wheel hub bearing sets have prematurely failed, in particular, the right front hub tried to lock up on me and almost caused me to loose control of the truck, i have since replaced that hub but still need to replace the left front before it locks up:second is that the steering and suspension system has no provisions for preventative maintenance, i.e. no grease zircs for the ball joints, tie rods,upper and lower control arm bushings, wheel bearings, etc...causing rapid wear and failure:third big issue, i have already replaced all four brake rotors due to warpage. the brake calipers were built with some type of composite plastic pistons that distort due to excessive heat build up in the brakes. which in turn causes uneven pad contact, that then causes excessive heat, accelerated pad wear, brake fade, rotor warpage, and an awful squeal when the brakes are applied. i have noticed that my brand new brake pads are actually cracked now because of a combination of the calipers and the hubs going bad: fourth issue is that the transmission causes the engine to over rev in the highway passing gear especially with the over drive and cruise control on. when you're driving down the highway and you give it a little more gas to get around somebody, the engine rpm's shouldn't go up to sometimes around 7000, that in turn could cause premature engine or transmission failure. i have been in contact with daimler-chrysler about these concerns but they just keep giving me the run around and not answering my questions. i still have the old parts also.
09/13/2006300000101/05/2003
 Ball joint failure on dodge dakota 4x4. recall on other vins not mine. failure at 30000 miles. the dealer said 1200 dollars and they would put on the new modified ones. why am i paying for a dodge defect. *nm
12/20/200540000104/06/2003
 Dt: the consumer stated while driving there was noise coming from the suspension when going over bumps. the problem occurred at low speeds. the dealership determined the bushings and the upper ball joints were worn. there is a recall with the nhtsa # 04v596000. the consumer experienced the same problem as indicated in the recall; however, the vehicle identification number was not included. *jb
11/29/200564000107/11/2003
 Dt: the contact states there i nhtsa recall campaign id 04v596000 concerning the upper ball joint. the vehicle has the same problems as indicated in the recall, but it is not included in the recall due to vin. the vehicle is currently being repaired at the contact's expense.*ak
05/02/2005
 With regards to the recal # 04v596000 on the 4x4 dodge dakota truck. i am having the same noises and problems on the 2x4 truck will this recall be exspended to 2x4?
03/28/200502/12/2003
 Rear brakes howl in reverse. dealer stated needs break in. at 41.000 miles, still howls. recall on upper ball joints received in february. as of 03-29-05, dealer states there is a 2 month backorder on parts for repair.
11/01/20041
 Nhtsa campaign 04v596000; daimler chrysler issued an upper ball joint recall. this vehicle is included in the recall, but there are no parts available in order to repair, which is dangerous because the wheels can fall off. *nm
01/01/200420000109/21/2003
 2003 dakotaquad cab is having ball joint popping similar to durango. the problem is this is a highway driven truck, not an offroad truck. problem started at 20,000. could cause a serious accident if not repaired.*ak
08/01/2004109/01/2003
 Uneven tire wear led me to have truck serviced at midas tire co. they reported excessive loose play in both top and bottom frontend ball joints. vehicle is under warranty w/daimlerchrysler so took to sales/service dealer soutars in barstow, ca two different times w/same concern. they reported nothing wrong w/ball joints both times. san bernardino sun telegram 12/11/04 news reports serious problems w/ball joints in dodge dakota 2003 models causing wheels to fall off.*ak
08/20/20048000101/05/2004
 I purchased my 2003 dakota quad cab 2wd in early january of 2004. it has approximately 21k. signs of the steering making a creaking sound when being turned were first noticed at approximately 8000. it is more pronounced when entering an elevated street or a driveway, while making the turn. i believe the same defective steering components utilized in the 4x4 dakota also apply to the 2wd versions. i would like the initiative be taken to include the 2wd dodge dakotas in the recall as well. my truck has not yet been serviced, but if study information is required, such as an analysis of the joint, i am willing to volunteer my vehicle for such a study if it would help in moving forward with the recall.*ak
12/06/200430000203/21/2003
 My 2003 dodge dakota quad cab has had the brake rotors warped at less than 20,000 miles with no severe use. and also the ball joints are worn out at 35,000 miles. these parts should last a lot longer on a ligh use vehicle.*ak
08/31/2004300001
 Vehicle would shimmy while driving 30 mph. vehicle was taken to the dealer. dealer informed that the right front upper ball joint needed to be replaced. *ak
06/01/200438001
 Pe 03-032, front suspension upper ball joint failure: after inspecting the wheels, the consumer noticed that the upper ball joints are rusting out on both side. *nm
12/23/200368700210/03/2002
 Upper ball joints joints worn out and attaching nut completely stripped out on left side. heard a noise and took it to the dealer to be checked out in november 03. dealer claimed everything checked out fine, could not find any problem. december 03 noticed tire wear on inside, took the truck to an alignment shop. it was there that the mechanic pointed out that the ball joint on the right was worn badly and the left was about to fall apart. the dealers knew of this problem in this type of vehicle. i was to leave an hour after the alignment on an eight hour trip through the mountains. i consider myself very lucky and very wronged by the dealer and manufacturer for not notifying their customers of this problem. for that matter why hasn't any safety agency stepped up to tell us of this problem???. *ak
12/21/2003200001
 Dodge dakota 2003 sport: first few months of ownership, i went to have tires rotated (20,000mi) and i was told that the ball joints were out of spec. by the mechanic and that i should take the vehicle to the dealer. after inspection, the dealer said nothing was wrong.i know something is wrong with the vehicle because since that time, everytime i turn left while applying brakes in a downhill situation, a terrible grinding sound is heard. the vehicle now has 54000mi and i hear about wheels breaking off. i am scared for my families and personal safety.*ak
11/10/2003500001
 My ball joints have worn out at about 55,000 miles. it is not covered in my 7 year 70,000 mile bumper to bumper warranty. *la
SUSPENSION - FRONT - STABILIZER BAR
03/04/20071
 To whom it may concern, i own a 2003 dodge dakota quad cab slt. and i have run into a lot of problems with this truck that people i know say they had very similar problems with the same make of vehicle. to start with my truck only has about 62,184 miles on it, for a 2003 model truck, that is considered low mileage. the problems i have run into is as follows: both front wheel hub bearing sets have prematurely failed, in particular, the right front hub tried to lock up on me and almost caused me to loose control of the truck, i have since replaced that hub but still need to replace the left front before it locks up:second is that the steering and suspension system has no provisions for preventative maintenance, i.e. no grease zircs for the ball joints, tie rods,upper and lower control arm bushings, wheel bearings, etc...causing rapid wear and failure:third big issue, i have already replaced all four brake rotors due to warpage. the brake calipers were built with some type of composite plastic pistons that distort due to excessive heat build up in the brakes. which in turn causes uneven pad contact, that then causes excessive heat, accelerated pad wear, brake fade, rotor warpage, and an awful squeal when the brakes are applied. i have noticed that my brand new brake pads are actually cracked now because of a combination of the calipers and the hubs going bad: fourth issue is that the transmission causes the engine to over rev in the highway passing gear especially with the over drive and cruise control on. when you're driving down the highway and you give it a little more gas to get around somebody, the engine rpm's shouldn't go up to sometimes around 7000, that in turn could cause premature engine or transmission failure. i have been in contact with daimler-chrysler about these concerns but they just keep giving me the run around and not answering my questions. i still have the old parts also.
SUSPENSION - FRONT - WHEEL BEARING
03/04/20071
 To whom it may concern, i own a 2003 dodge dakota quad cab slt. and i have run into a lot of problems with this truck that people i know say they had very similar problems with the same make of vehicle. to start with my truck only has about 62,184 miles on it, for a 2003 model truck, that is considered low mileage. the problems i have run into is as follows: both front wheel hub bearing sets have prematurely failed, in particular, the right front hub tried to lock up on me and almost caused me to loose control of the truck, i have since replaced that hub but still need to replace the left front before it locks up:second is that the steering and suspension system has no provisions for preventative maintenance, i.e. no grease zircs for the ball joints, tie rods,upper and lower control arm bushings, wheel bearings, etc...causing rapid wear and failure:third big issue, i have already replaced all four brake rotors due to warpage. the brake calipers were built with some type of composite plastic pistons that distort due to excessive heat build up in the brakes. which in turn causes uneven pad contact, that then causes excessive heat, accelerated pad wear, brake fade, rotor warpage, and an awful squeal when the brakes are applied. i have noticed that my brand new brake pads are actually cracked now because of a combination of the calipers and the hubs going bad: fourth issue is that the transmission causes the engine to over rev in the highway passing gear especially with the over drive and cruise control on. when you're driving down the highway and you give it a little more gas to get around somebody, the engine rpm's shouldn't go up to sometimes around 7000, that in turn could cause premature engine or transmission failure. i have been in contact with daimler-chrysler about these concerns but they just keep giving me the run around and not answering my questions. i still have the old parts also.
SUSPENSION - REAR
02/16/2006320003512/04/2003
 I was caught in an ice storm in my 2003, dodge dakota, 4x4 quad cab. the truck went into a slight spin and bumped a small curb then slid up over the curb. i was only traveling at approx. 5 mph when i bumped the curb. the axle sheared off and broke the hub, rotor, wheel, tire, and bent the axle housing. the truck was rendered undrivable and was towed to a dodge dealership for repairs. i called daimlerchrysler and asked for the parts to be tested for defectiveness. i had seen several web sites devoted to axles put into dodge trucks that were known to daimlerchrysler to be defective due to poor heat treating. i was treated very rudely and the problem was not addressed. since the accident, i have had several mechanics and machinists look at this axle and all say that it should have never broken under the circumstances it was subjected to. i am now afraid to drive this vehicle, fearing that the rest of the axles are also defective. i am getting no satisfaction in solving this problem and my own insurance had to pay the $3,000. damage caused by a 5 mph bump. *nm
11/21/20038976999909/05/2003
 Rearend whines under power from 50-60 mph and while decelerating from 45-40 mph. *la