This is the second time I had a failure of the rear air lines in 10 DAYS. The first time was repaired by local mechanic (single leak), total cost was $340. This time, they found FOUR leaks in the rear air line, so I had to replace the entire lines. I was loathe to replace with the factory system, since I'd probably end up in the same place in another 4-5 years. So I did some research, The first thing that I found was that this is a common issue with this series (2008-2016 Dodge & Chrysler minivans). Yet I never had a failure of this line with my '99 Town & Country! What was different with this van? - The '99 had high-pressure rubber hoses carrying the freon to/from the rear A/C unit. - The 2012 has aluminum tubes. The leaks were not at support points, but in the middle of the pipe. The whole underside was oiled, and there was no visible signs of corrosion on the pipes. What could be happening? As an engineer, I wanted to know.

The problem had to be coming from within. Four leaks? At the same time? 10 days after another leak was fixed?

My first thought was that there was an adverse chemical reaction happening between the freon and the aluminum piping. Could it be? HIghly unlikely; that's something that the manufacture would test for before allowing aluminum as the pipe material.

Then I started thinking about how I use the A/C. Especially on moderately hot days, I'll turn the A/C on until the interior is cool, then turn it off and let recirc keep the van cool. Then turn the A/C back on when it warms up too much. My logic? Save gas by not using the A/C all the time.

Remember how the hoses used to be rubber and are now aluminum? Think about airplanes with aluminum skins. They can only take so many flight segments (expansion at altitude, return to size on landing) before the aluminum becomes fatigued and starts to crack. Could this be the problem? Every time I turn on the A/C, I'm hitting it with a pressure increase, stretching the aluminum tubes containing the freon; then the tubes shrink back when I turn the unit off. I'm guess that high frequency on and off is probably not something the designers were counting on when they specified the thickness / longevity of the aluminum tubes! I figure that I might turn the A/C on and off as much as 30 times an hour on a long trip (i.e. on for 15-30 seconds, off for 90-105 seconds).

The only solution that could resolve the issue permanently is to replace the aluminum tubes with rubber hoses. Fortunately there is a cost-effective aftermarket kit that does exactly that. It's manufactured by http://www.autocoolingsolutions.com/ and comes with a lifetime warranty. It's a complete replacement kit for my vehicle, with all the O rings and everything.

FYI the rear air heating tubes don't have this same problem, because there's no sudden change in pressure hen you turn the heat on - and you wouldn't constantly cycle it on and off, the way I do with the A/C.

A rhetorical question: given all the refrigerant that's leaking into the atmosphere because of this DESIGN FLAW - let alone the millions of dollars in repairs borne by Dodge and Chrysler (and VW) minivan owners, is there a case here for a class-action lawsuit against FCA?

We just replaced the rear evaporator at the cost of $1,086.40 on 9/16/15 and now the rear A/C lines are leaking and the dealer wants to charge me somewhere around 850 dollars to fix this problem. What is wrong with Chrysler that they can't fix this problem. The least they could do is extend the warranty on it like they did when we had a 2006 Chrysler van do the same thing. Someone needs to hire someone that could redesign the rear A/C in these vans and get it right, or put a longer warranty on it. It is a shame that we have this problem with Chrysler van, I used to like it but now all I want to do is sell it and NEVER, NEVER buy another Chrysler again!!!