NHTSA complaint #11739359

Owner complaint summary

My 2022 Chrysler Pacifica Hybrid has developed a dangerous rear brake system malfunction. During a dealer inspection on 4/27/26, the certified technician confirmed that the rear brake pads are only contacting approximately 50% of the rotor surface, leaving the remaining half completely unused and heavily corroded. This is not normal corrosion or wear. It is a mechanical failure in which the pads are not engaging the rotor correctly. The technician also stated that the pads were sticking in the caliper slides, which prevented full engagement. This is a functional defect in the brake hardware, not environmental corrosion. Corrosion does not selectively prevent half of a brake pad from engaging the rotor unless the caliper mechanism is not operating properly. This defect results in: Reduced rear braking force Increased stopping distance Excessive load on the front brakes Potential loss of stability during emergency braking Possible degradation of the parking brake The vehicle was serviced on 9/23/25 (tire rotation + NYS inspection) and 12/10/24 (four new tires + NYS inspection). No rear brake issues were identified at either visit. If this were normal corrosion, it would have been visible during those inspections. The sudden onset of severe partial engagement by 4/27/26 indicates a latent mechanical defect, not gradual wear. Chrysler/Stellantis has refused to classify this as a defect and instead labels it “corrosion,” despite the technician’s findings of pad binding in the slides and improper brake engagement. The manufacturer’s internal system blocks any warranty or engineering review because it incorrectly categorizes the failure as routine maintenance. This is a premature and unsafe brake system failure at only 33,000 miles. The braking system is not operating as designed, and the defect could lead to reduced braking performance or loss of control. I am requesting NHTSA’s review of this issue as a potential safety defect affecting the rear brake system