Chrysler Aspen

Overview

The Chrysler Aspen was a short-lived luxury SUV built on Dodge Durango bones, marketed to buyers who wanted upscale trappings without stepping up to a full-size truck platform. The reliability story here is dominated by two serious issues: widespread fuel tank cracks that took years to recall, and Takata airbag inflators that can explode. Beyond those headline problems, the Aspen shows typical mid-2000s Chrysler weak points in electronics and drivetrain components.

What Breaks

Nearly 30% of complaints involve fuel tank failures, typically appearing around 75,000 miles. Owners report cracks forming in the plastic fuel tank that cause gasoline leaks and fire risk. Chrysler eventually recalled these tanks in 2017—up to 11 years after some vehicles were sold—but many owners experienced dangerous fuel leaks before the recall was issued.

The Body Control Module (BCM) fails around 104,000 miles, causing erratic electrical behavior: gauges go dark, doors won't lock, windows stop working, or the vehicle won't start at all. Replacement costs $400-800 depending on whether you reprogram the module yourself or pay dealer rates.

The rear differential develops bearing noise and leaks around 135,000 miles. The all-wheel-drive system can fail to engage properly at similar mileage, leaving owners effectively stuck in two-wheel drive. Some airbag deployments have been reported as overly aggressive, causing injuries even in minor collisions—these occur around 98,000 miles on average.

Safety Recalls

Two recalls address Takata airbag inflators (driver and passenger side) that can rupture and spray metal fragments into the cabin during deployment—a potentially fatal defect. The fuel tank crack recall (NHTSA 17V-224) covers model years 2007-2009 and addresses the fire risk described above. A recall for the rear differential cover involves potential separation that could lock up the rear axle while driving. One recall addresses parking brake cables that can corrode and fail to hold the vehicle on inclines.

Warranty Extensions and TSBs

No warranty extensions appear in the data, which is unusual given the severity of the fuel tank and electrical issues—Chrysler appears to have waited for federal pressure rather than proactively addressing known defects. The 50 technical service bulletins cover routine issues: door latch adjustments, HVAC blend door failures, transmission shift calibrations, and various squeaks and rattles. Several TSBs address false warnings from sensors (tire pressure, airbag, check engine light) that require software updates to resolve.

Owner Watch-Outs

• Inspect the underside of the fuel tank for cracks or wetness during every oil change—gasoline leaks are a fire hazard even if you've already had the recall repair done
• Verify that both Takata airbag inflator recalls have been completed; these are do-not-ignore safety defects
• Budget for BCM replacement after 100,000 miles if you experience intermittent electrical gremlins; aftermarket modules exist but require programming
• Listen for rear differential whine or grinding, especially in AWD models—these bearings fail and can strand you if the axle seizes
• Check that the parking brake actually holds the vehicle on a hill; cable corrosion is common and the recall may not have been performed

Data Notes

This analysis draws from 270 owner complaints filed with NHTSA between 2006 and 2009, covering all Aspen model years. The Aspen was discontinued after 2009, so the sample represents the entire production run. NHTSA currently has 8 open investigations into this vehicle, indicating ongoing safety scrutiny.