NHTSA complaint #11592920

Owner complaint summary

Component Failure: Around 45,000 miles, my vehicle equipped with the 5.7L HEMI E-torque V8 had both exhaust manifolds cracked with large exhaust leaks pre-catalytic convertor Safety Risk: My vehicle equipped with the 5.7L HEMI E-torque V8 was idling in a parking lot for around 1 hour while I waited inside the vehicle. Cold ambient temperature with windows up and heater on. I noted having a slight headache and started smelling what seemed to be pre-catalytic convertor exhaust fumes (rich fuel smell). I stepped out of the vehicle and smelled the exhaust at the rear of the vehicle, which did not match. I attributed the smell to a nearby vehicle. One week later, the same event occurred with no other vehicles parked around me. The exhaust leak was large enough to pull exhaust fumes into the cabin through the HVAC system. High risk of carbon monoxide poisoning if the vehicle was to sit long enough, risking both myself and my child's safety while we sat in the vehicle. Problem Reproduced: Yes, brought the vehicle CJDR dealer who diagnosed the vehicle with "both exhaust manifolds cracked" and replaced both exhaust manifolds under warranty. Has component been inspected: Unknown. Parts were removed from vehicle as covered under warranty at dealer and replaced with new parts. Any Warnings: No warning lights on dashboard or DTCs for catalytic convertor performance, lean/rich banks, or other exhaust/emissions related. Exhaust seemed slightly louder on cold start. Smelling of unburnt/pre-cat exhaust fumes that prompted dealer visit.