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NHTSA Defect Investigations for the 2007 Chrysler Pacifica

The Office of Defects Investigations (ODI) is an office within the NHTSA which investigates serious safety problems in the design, construction or performance of vehicles. The NHTSA is authorized to order manufacturers to recall and repair vehicles, if the ODI finds a safety issue. NHTSA investigations for the 2007 Chrysler Pacifica, both ongoing and closed, are listed below:


    NHTSA Engineering Analysis #EA08006

    • Status:
    • Date Opened: February 21, 2008
    • Date Closed: April 15, 2009
    • Recall: No recall issued

    Component(s): Electrical System
    Electrical System:Wiring:Front Underhood
    Electrical System:Wiring:Interior/Under Dash
    Engine And Engine Cooling
    Steering:Hydraulic Power Assist:Power Steering Fluid

    Summary: The Agency has closed this investigation based on its review of consumer complaints, field reports, warranty claims and other data regarding engine compartment fires and power steering fluid leakage in model year (MY) 2007 Chrysler Pacifica vehicles with 4.0L engines.the available evidence indicates that power steering fluid leaks in the subject vehicles and the fires that may result from these leaks, occurred early in the vehicle's service life.moreover, changes in the assembly process appear to have remedied the condition causing the leaks.the available data confirms a declining trend for both complaints and warranty claims as the subject vehicles remain in service. The closing of this investigation does not constitute a finding by the Agency that a safety-related defect does not exist.the Agency reserves the right to take further action if warranted by the circumstances. (see document file for additional information regarding this resume.)


    NHTSA Preliminary Evaluation #PE07052

    • Status:
    • Date Opened: October 19, 2007
    • Date Closed: February 21, 2008
    • Recall: No recall issued

    Component(s): Steering:Hydraulic Power Assist:Power Steering Fluid

    Summary: Complainants allege that a fire erupted under the hood, near the front of the Chrysler's response to ODI's November 2, 2007 information request, Chrysler asserts that the alleged defect occurs only in the 4.0L engines and the consumer will experience a loss of power steering fluid or a noisy power steering pump before seeing any evidence of smoke or fire.Chrysler also states that "a tube nut on the high pressure power steering line was discovered to be cross threaded during the assembly process and did not allow proper sealing of the O-ring."the power steering system in the 4.0L engine is assembled at the Chrysler plant.the power steering system for the 3.8L engines arrives at the Chrysler plant pre-assembled.Chrysler found that in the 4.0L engine, "it was possible to cross-thread the tube nut on the high pressure line during its attachment to the steering gear, thus creating an improper seal."Chrysler implemented assembly plant process changes to eliminate the possibility of cross-threading, and applied additional quality control measures to detect power steering fluid leaks.Chrysler stated that "warranty and field data suggests that these process changes have minimized the possibility of cross-threading."with regard to the vehicles produced prior to the production change, a review of the warranty claims indicates that the alleged defect has not declined in the 4.0L population.ODI is upgrading this preliminary evaluation to an engineering analysis, EA08-006, to further evaluate the issue.

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