Summary
The Chrysler PT Cruiser has 13 recalls covering 2001 through 2006, with the most serious being a 2005 brake tube issue on vehicles equipped with the 2.4L turbocharged engine, ABS, and a 5-speed manual transaxle, where the left front brake tube can rub against the transaxle housing, eventually wearing through and causing a loss of braking force.
The 2006 model year has a separate issue where rear quarter glass fasteners can pull free from their mounts and allow the glass to separate from the vehicle while driving, posing a hazard to nearby traffic and pedestrians. The same fastener problem affects 2005 models as well. On 2003 manual-transmission models, a pin inside the dual-mass flywheel assembly can come loose and wedge between the flywheel and clutch disc, preventing the clutch from disengaging when the pedal is pressed.
The 2001 model year carries the heaviest share of recalls, several of them fire-related. The fuel supply line on 2001 vehicles can contact the air conditioning service port, chafe through, and leak fuel near ignition sources. A separate 2001 issue involves the fuel pump module, where both the top flange and the mounting flange can crack or leak fuel in a frontal collision or rollover, again creating a fire risk. On 2001 models with the 2.4L non-turbocharged engine and automatic transaxle, the power steering pressure hose can contact the transaxle differential cover, wear through, and leak fluid onto hot engine components, which can result in an underhood fire. Also on 2001 models, the right rear child seat lower anchor was manufactured with a wire diameter outside the allowable specification, which can prevent a latch-type child restraint from connecting correctly and reduce crash protection for a child.
On 2002 models, a software error in the instrument cluster can cause most gauges, warning lights, and illumination to go dark while driving, removing critical vehicle information from the driver's view.
