The 2009 Routan is a rebadged Chrysler Town & Country built in Windsor, Ontario. It shares all the structural and powertrain DNA of the Chrysler minivan platform, meaning you inherit Chrysler's 62TE transmission issues and 3.8L V6 head gasket vulnerabilities despite the VW badge.
62TE Transmission Overheating and Failure
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Harsh or delayed shifts, especially 2-3 and 3-4, Transmission slipping or stuck in limp mode, Burnt transmission fluid smell, Check engine light with P0868 (low line pressure) or P0841 codes
Fix: Transmission oil cooler clogs internally, causing overheating and destroying clutch packs. Early intervention means cooler replacement and fluid flush (3-4 hrs labor). Once internal damage occurs, you're looking at rebuild or reman unit (12-16 hrs labor). Many shops won't touch a rebuild on these—expect replacement.
Symptoms: White smoke from exhaust on cold start, Coolant loss with no visible leaks, Oil milkshake (coolant mixing with oil), Overheating and rough idle
Fix: The 3.8L is notorious for blown head gaskets, often both banks. Job requires both heads off, machine shop resurface, new gaskets, timing components, and coolant system flush. Budget 18-22 hours labor. If heads are warped beyond spec or you find piston/ring damage from overheating, costs escalate fast into short-block territory.
Estimated cost: $2,800-4,500 head gaskets; $5,000-7,500 if short block needed
Ignition Switch and TIPM (Integrated Power Module) Failures
Common · medium severity
Symptoms: No crank/no start intermittently, Electrical accessories cutting out while driving, Fuel pump not priming, Wipers, windows, or gauges acting erratically
Fix: Chrysler's TIPM (mounted under the hood) develops internal corrosion and failed relays. Ignition switch also fails, often recalled but sometimes outside recall window. TIPM diagnosis is tricky—many techs throw parts at it. Genuine TIPM is dealer-only and expensive; aftermarket reman units available but quality varies. Ignition switch is 1.5 hrs; TIPM replacement is 2-3 hrs but diagnostic time adds up fast.
Symptoms: Clunk or thud on acceleration or deceleration, Vibration at idle, especially in Drive, Excessive engine movement visible when revving in Park
Fix: The hydraulic engine mounts and rear transmission mount wear quickly, especially the upper torque mount. Replacement is straightforward but requires supporting the engine. Upper mount is 2 hrs; lower mounts 1.5-2 hrs each. Do them all at once if one is bad—labor overlap saves money.
Estimated cost: $400-800 for all mounts
Water Pump and Thermostat Housing Leaks
Occasional · medium severity
Typical onset: 90,000-140,000 mi
Symptoms: Coolant puddle under front of vehicle, Coolant smell from engine bay, Overheating or temperature fluctuations, Visible coolant weeping from water pump or thermostat housing
Fix: Water pump bearings fail and the plastic thermostat housing cracks. Water pump is buried—requires serpentine belt, timing cover access, and coolant system refill (4-5 hrs). Thermostat housing is 2 hrs but often done together to save redundant labor. Always replace coolant hoses at this mileage—they harden and crack.
Estimated cost: $600-1,100 water pump and thermostat together
Rear Suspension Toe Link and Trailing Arm Bushings
Occasional · low severity
Typical onset: 80,000-130,000 mi
Symptoms: Clunking from rear over bumps, Unstable handling or rear-end wandering, Uneven rear tire wear, Visible rust or separation of trailing arm bushings
Fix: Rear toe links and trailing arm bushings rot out, especially in salt states. Bolts often seize, requiring cutting and drilling. Budget 3-4 hrs per side if hardware cooperates; double that if you're fighting rust. Alignment mandatory after. Recall covered rear axle crossmember cracks—check recall status before blaming bushings.
Estimated cost: $500-1,000 per side including alignment
Owner tips
Change transmission fluid every 50,000 mi with Mopar ATF+4 and replace the cooler preemptively around 80k to avoid transmission death
Watch coolant level religiously—head gasket failures start subtle and escalate fast if ignored
Keep a spare ignition switch and know where your TIPM is; carry a hammer to tap it if you get no-starts (yes, really)
Inspect rear suspension bushings annually in salt states; once they tear, alignment goes out and tire wear accelerates
Pass unless you're getting it for well under market and have a $3,000 transmission-replacement fund—this is a Chrysler minivan with VW markup on parts and zero VW engineering input.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE-INACTIVE · 16V083000
2016-02-11
Volkswagen Group of America, Inc. (VW) is recalling certain model year 2009 Volkswagen Routan vehicles manufactured February 7, 2008, to August 28, 2008. In the affected vehicles, the air bag control units may corrode and fail.
Consequence: If the air bag control unit fails, the air bags may not deploy in the event of a crash, increasing the risk of occupant injury. Additionally, the air bags may inadvertently deploy, increasing the risk of a crash.
Remedy: VW will notify owners, and dealers will replace the air bag control unit, free of charge. The recall began April 2016. Owners may contact Volkswagen customer service at 1-800-893-5298.
ELECTRICAL SYSTEM:IGNITION:SWITCH · 15V194000
2015-04-01
Volkswagen Group of America, Inc. (Volkswagen) is recalling certain model year 2009 Routan vehicles manufactured June 25, 2008, to July 8, 2009, and 2010 Routan vehicles manufactured October 1, 2009, to August 11, 2010. This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring.
Road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine.
Consequence: If the ignition key inadvertently moves into the OFF or ACCESSORY position, the engine will turn off, which will then depower various key safety systems including, but not limited to, air bags, power steering, and power braking. Loss of functionality of these systems may increase the risk of crash and/or increase the risk of injury in the event of a crash.
Remedy: Volkswagen will notify owners, and dealers will replace the ignition switch and key FOBs, free of charge. The recall began on June 23, 2015. Owners may contact Volkswagen customer service at 1-800-822-8987. Volkswagen's number for this recall is 28H1. Note: This recall supersedes recalls 11V151 and 14V396. Vehicles that previously received an ignition switch trim ring as a recall remedy must have their vehicles remedied again under this campaign. Vehicles that have already received a new ignition switch are not covered by this campaign.
ELECTRICAL SYSTEM:IGNITION · 14V396000
2014-07-01
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring.
Volkswagen Group of America, Inc. (Volkswagen) is recalling certain model year 2009 Routan vehicles. Road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine.
Consequence: If the ignition key inadvertently moves into the OFF or ACCESSORY position, the engine will turn off, which will then depower various key safety systems including but not limited to air bags, power steering, and power braking. Loss of functionality of these systems may increase the risk of crash and/or increase the risk of injury in the event of a crash.
Remedy: Volkswagen will notify owners, and dealers will modify the ignition switch, free of charge. Owners may contact Volkswagen customer service at 1- 800-822-8987. An interim notice was mailed to owners on August 29, 2014. Volkswagen's number for this recall is 28G1/U8. Note: This campaign is an expansion of NHTSA Recall No. 11V-151.
Freedom Motors Inc., (Freedom Motors) of Savaria Vehicle Group (formerly The Liberty Motor Company) is recalling one model year 2009 Volkswagen Routan and certain model year 2008-2010 Dodge Grand Caravan and Chrysler Town & Country wheelchair accessible vehicles modified by The Liberty Motor Company from February 2008 through January 2011. Over time and with use, the vehicle's rear axle may develop cracks which could lead to axle failure.
Consequence: Failure of the rear axle may increase the risk of a crash.
Remedy: Freedom Motors will notify owners, and dealers will replace the affected axles, free of charge. The recall began on April 1, 2014. Owners can contact Freedom Motors at 1-800-561-9600. Freedom Motors' number for this recall is ENGF0216-3.
ELECTRICAL SYSTEM:WIRING · 10V252000
2010-06-10
VOLKSWAGEN IS RECALLING CERTAIN MODEL YEAR 2009 ROUTAN VEHICLES MANUFACTURED FROM JUNE 2008 THROUGH JULY 2009. THESE VEHICLES MAY HAVE BEEN BUILT WITH AN IMPROPER ROUTED WIRE HARNESS THAT MAY HAVE A CONDITION WHERE THE LOWER SLIDING DOOR HINGE BRACKET CAN MAKE CONTACT AND WEAR THROUGH THE WIRE INSULATION. CONTACT WITH A 12V POWER FEED CIRCUIT WITHIN THE HARNESS MAY CAUSE A HIGH RESISTIVE SHORT CIRCUIT WITHIN THE LATCH MECHANISM LOCATED INSIDE OF THE SLIDING DOOR.
Consequence: THIS COULD RESULT IN AN OVERHEATED LATCH AND A FIRE WITHIN THE REAR SLIDING DOOR COULD OCCUR.
Remedy: VOLKSWAGEN WILL INSPECT THE SLIDING DOOR WIRE TRACK WIRE ASSEMBLY AND THE SLIDING DOOR POWER DRIVE UNIT WIRE ASSEMBLY FOR DAMAGE, REPAIR/REPLACE AS NECESSARY, TIE STRAP THE TWO HARNESSES TOGETHER AND ROUTE THE HARNESSES UNDER THE SLIDING DOOR WEATHER STRIP. THIS SERVICE WILL BE PERFORMED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 15, 2010. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.
VOLKSWAGEN IS RECALLING 18,500 MY 2009 ROUTAN VEHICLES FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, "OCCUPANT CRASH PROTECTION." THE OWNER'S MANUAL WAS PRINTED WITHOUT THE FMVSS NO. 208 REQUIRED INFORMATION EXPLAINING THAT NO OBJECTS SHOULD BE PLACED OVER THE OR NEAR THE AIR BAG ON THE INSTRUMENT PANEL.
Consequence: ANY SUCH OBJECTS COULD CAUSE INJURY TO THE VEHICLE'S OCCUPANTS IN THE EVENT OF A CRASH SEVERE ENOUGH TO CAUSE THE AIR BAG TO INFLATE.
Remedy: DEALERS WILL SEND AN OWNER'S MANUAL INSERT CONTAINING THE REQUIRED AIR BAG INFORMATION FOR OWNER INSTALLATION OR DEALERS WILL INSTALL IN THE EVENT THE OWNER PREFERS ASSISTANCE FROM THE DEALER. THE RECALL BEGAN ON JULY 31, 2009. OWNERS MAY CONTACT VOLKSWAGEN AT 1-800-822-8987.
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