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Dodge minivan rated 'poor'
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July 17, 2001: 11:08 a.m. ET
Top-selling Grand Caravan gets low rating from IIHS following crash tests
By CNN Consumer Safety Editor Julie Vallese
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WASHINGTON (CNN) - The nation's top selling minivan -- the 2001 Dodge Grand Caravan -- received the Insurance Institute for Highway Safety's (IIHS) lowest rating after crash tests crumpled the area beneath the driver's feet and caused a fuel leak.
In the first round of crash tests, the institute recorded high levels of intrusion into the driver's foot well, where the accelerator and brake pedal rest. Because the results were higher than Dodge's own tests, engineers went back and made changes to the vehicle. The vehicle was tested an unprecedented three times.
The leg compartment of the vehicle fared much better in the second round of testing, but a new problem was discovered. The top part of the gas tank allowed fluid to leak. To identify leaks without the risk of fire, testers used a substitute fuel rather than gasoline in crash tests. Chrysler went back and redesigned the fuel tank and asked the IIHS for another test.
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Dodge Grand Caravan 2001 crash test. | |
"The overall performance of the Grand Caravan was similar in all three tests, except for the fuel tank," Insurance Institute President Brian O'Neill said. "Based on these tests, the 2001 models manufactured before the redesigned fuel systems are rated poor for crashworthiness because of the leak."
"We are disappointed that the IIHS chose to also issue a 'poor' rating for 2001 MY (model year) minivans because of a hairline fracture in the fuel pump mounting flange that occurred after the actual impact of the crash test," DaimlerChrysler (DCX: up $0.34 to $49.10, Research, Estimates) -- which makes the Dodge -- said. "We feel that it would be extremely unlikely for this leak to occur in a 'real-world' crash. We stand behind the safety and structural integrity of Chrysler Group minivans."
DaimlerChrysler said more than 50 tests were conducted to simulate the results of the IIHS test and that they were unable to produce the same results.
Chrysler has sold more than 300,000 Dodge Grand Caravans and its sister vehicle, the Chrysler Town & Country, for the 2001 model year. Models made after July 6, 2001, and Caravans for the 2002 model year have been redesigned. The IIHS rates these vehicles as acceptable and no fuel leak has been found.
The IIHS shared its information with the federal agency responsible for vehicle defect investigations. The National Highway Traffic Safety Administration (NHTSA) said while they welcome information from the IIHS, there is nothing in their records to initiate an investigation.
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"I think the government needs to take another look. They have really not paid much attention to this issue," O'Neill said. "We (identified) the problem in a crash test. The reason there are not many cases in the real world, or no cases, is because this is a new design."
While the Dodge Caravan went from poor to acceptable in the passenger van category, the 2001 Hyundai Elantra, in the small car category, did not fare as well in a retest, going from acceptable to poor.
In the first round of tests the overall structural performance of the Elantra was good, but Hyundai engineers weren't happy with the test results. After some redesign, the IIHS conducted a second test.
The changes worked and test results for leg injury improved. However, these tests revealed a new problem.
"What our tests have revealed are that in some crash circumstances the airbag sensors are not detecting the crash severity early enough, so we're getting airbags firing late," O'Neill said. "That means you will not get the most effective protection you should from the belts and the airbags."
The late deployment caused high head injury to the dummy. A third test was run and once again the airbag deployed late, giving the Elantra a poor rating.
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I think the government needs to take another look. They have really not paid much attention to this issue.
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Brian O'Neill
President
Insurance Institute for Highway Safety |
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"The Elantra is not one of the best small cars. There are many better small cars than the Elantra," O'Neill said.
"In Europe, the 2001 Elantra has received some of the highest safety ratings possible," Hyundai said. "Neither IIHS nor Hyundai can reconcile the difference in the results at this time and at Hyundai we are continuing to work to resolve this apparent contradiction."
The IIHS rated the Honda Civic and Volkswagen's new Beetle as the best picks in the small car category.
The Insurance Institute for Highway Safety conducts high speed 40 mph frontal offset crash tests to complement the government's 35 mph high-speed crash tests. Vehicle ratings are based on measurements of occupant compartment intrusion, injury measurements on the dummy in the driver seat and analysis of slow motion film to assess the restraint system. The IIHS is an independent vehicle safety group funded by the insurance industry. 
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