THE VEHICLE: About 623,000 Dodge Caravan and Chrysler Town and Country minivans in the U.S. from the 2005 and early 2006 model years.
THE PROBLEM: In September of 2011, the National Highway Traffic Safety Administration began investigating complaints that the headlights could go dark while the vans were being driven. The problem was traced to the headlight switch, where friction between metal and plastic parts can cause bits of plastic to fall onto an electrical contact, causing the lights to fail. In some cases the headlights wouldn't come on or could not be shut off. The problem, which worsens as the minivans age, can normally be fixed by turning the lights on and off. Chrysler applied a lubricant to newer minivans, which have far fewer problems.