2004 Dodge Grand Caravan
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Dodge › Grand Caravan › 2004
These records cover every 2004 Dodge Grand Caravan. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
3 recalls name the 2004 Dodge Grand Caravan. Newest first.
Certain curved tempered replacement glass manufactured by hangzhou safety glass ltd and supplied to safelite by auto temp inc., identified as dot-430, and sold for use on certain domestic and foreign vehicles may not break into small pieces as expected of tempered glass and fails to conform to federal motor vehicle safety standard no. 205, "glazing…
Risk and remedy
Risk
In the event of a vehicle crash, the occupant(s) may be seriously injured by shattered glass.
Remedy
Safelite will notify its retail customers and replace the glass free of charge. Retail customers can contact safelite toll free at 1-888-843-2906. Safelite will notify its wholesale customers and reimburse wholesale customers for current inventory and at a specified rate for replacing their customer's glass. Wholesale customers can contact safelite's wholesale division, service autoglass toll free at 1-888-246-6298. The recall began on january 15, 2008.
On certain minivans equipped with 3.3 or 3.8L V-6 engine, the upper power steering cooler hose may split and cause a fluid leak.
Risk and remedy
Risk
Power steering fluid leakage in the presence of an ignition source can result in an under hood fire.
Remedy
Dealers will replace the upper power steering cooler hose. this recall began on september 27, 2004. owners should contact daimlerchrysler at 1-800-853-1403.
Certain aftermarket replacement fuel filters, models wix filter part numbers 33576, 33577, 33734; napa filter part numbers 3576, 3577, 3734; and carquest filter part numbers 86576, 86577, 86734 used on 1996-2000 daimlerchrysler town & country, dodge caravan, and plymouth voyager vehicles, can cause the fuel lines to leak.
Risk and remedy
Risk
A possible fire can occur in the presence of an ignition source.
Remedy
Wix will notify its customers and replace the fuel filters free of charge. note: this does not involve any products manufactured by the daimlerchrysler corp. Nor any dailmerchrysler dealers. owner notification IS expected to begin during november 2003. owners who do not receive the free remedy within a reasonable time should contact wix at 704-864-6711.
Owner complaints
116 complaints4 involved a crash1 involved a fire2 injuries
What owners report most
Latest complaints
- Air bags
The contact owns a 2004 Dodge Grand Caravan. The contact stated that while driving at an undisclosed speed, another vehicle crashed into the rear passenger side of the vehicle. The air bags failed to deploy. The air bags warning light illuminated. The contact stated that her face hit the steering…
The contact owns a 2004 Dodge Grand Caravan. The contact stated that while driving at an undisclosed speed, another vehicle crashed into the rear passenger side of the vehicle. The air bags failed to deploy. The air bags warning light illuminated. The contact stated that her face hit the steering wheel. A police report was filed. The contact drove to the nearest hospital, however, she was unconscious upon arrival and was transported inside the hospital. The vehicle was towed to the contact's residence. The contact had been seeking medical assistance. The dealer was notified of the failure and informed the contact that her VIN was not included in a recall related to the failure. The manufacturer was not notified of the failure. The vehicle was not diagnosed or repaired. The approximate failure mileage was unknown.
- Unknown or other
Sliding door locking activator failure prevents to door from being unlocked manually which IS a big safety issue because rear passengers cannot exit them doors and therefore have to climb over the console and front seats to exit .. This IS a big problem affecting all grand caravan and caravans with…
Sliding door locking activator failure prevents to door from being unlocked manually which IS a big safety issue because rear passengers cannot exit them doors and therefore have to climb over the console and front seats to exit .. This IS a big problem affecting all grand caravan and caravans with power lock and sliding doors. I will repeat this you cannot unlock the door manually if the actuator fails which prevents passengers from exiting the vehicle in the case of an emergency and chrysler needs to recall these vehicles and repair them so the locks can be unlock under all circumstances from the inside
- Engine
TL* the contact owns a 2004 dodge grand caravan. The contact stated while driving, the vehicle overheated without warning. The failure occurred several times. The contact stated as precaution the vehicle was stopped to allow the engine to cool down. The vehicle was not taken to a dealer nor was the…
TL* the contact owns a 2004 dodge grand caravan. The contact stated while driving, the vehicle overheated without warning. The failure occurred several times. The contact stated as precaution the vehicle was stopped to allow the engine to cool down. The vehicle was not taken to a dealer nor was the manufactured notified of the failure. The vehicle was not repaired. The failure mileage was 213,000.*dt consumer stated after changing the thermostat pieces of plastic came out of the motor. Problem with overheating has occured for 4 years. *Jb*dt*jb
- Fuel/propulsion system
Hairline cracks in fuel pump outlet just before connecting to fuel line leads to strong fuel smell and fuel vapors all around vehicle. fuel pump needs replacement to repair this dangerous condition. highly suggest different fuel pump design that IS not prone to hairline cracks and potential fire…
Hairline cracks in fuel pump outlet just before connecting to fuel line leads to strong fuel smell and fuel vapors all around vehicle. fuel pump needs replacement to repair this dangerous condition. highly suggest different fuel pump design that IS not prone to hairline cracks and potential fire hazard as fuel leak IS about one foot away from a hot muffler and a tossed cigarette or other spark could cause a fire or explosion.
- Fuel/propulsion system
After filling the gas tank, within a few miles the vehicle will stall. Dodge already has extended the warranty on the fuel tank of vehicle built after september 2003 but mine was built august 5 2003 so it IS outside their window. This IS a very dangerous issue because it has happened to me on the…
After filling the gas tank, within a few miles the vehicle will stall. Dodge already has extended the warranty on the fuel tank of vehicle built after september 2003 but mine was built august 5 2003 so it IS outside their window. This IS a very dangerous issue because it has happened to me on the highway at 55 miles an hour and I then have no power and need to get out of the way of traffic that IS going to run me over.
- Fuel/propulsion system
Every time we fill the fuel tank the caravan cuts off and rides very rough. The recall on the dodge caravan was on vans build starting on 09/01/2003 my caravan was built on 09/29/2013.
- Fuel/propulsion system
TL* the contact owns a 2004 dodge grand caravan. The contact stated that after refueling the vehicle, it stalled without warning. After several attempts the vehicle was able to restart but the failure recurred. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 70,000.
- Fuel/propulsion system
Engine stalls out 10 or 15 seconds after filling the gas tank. usually on the highway you are turning on to. its been doing this for a couple of years.
- Fuel/propulsion system
The vehicle stalls out after filling at the gas station. reportedly due to an issue with the check valve and requires the entire fuel tank to be replaced.
- Engine and engine cooling · Fuel/propulsion system
TL* the contact owns a 2004 dodge grand caravan. While driving 45 mph, the temperature gauge on the instrument panel started going to the red side; indicating that the vehicle was having trouble regulating the engine cooling system. The contact also stated that there was a strong odor of fuel…
TL* the contact owns a 2004 dodge grand caravan. While driving 45 mph, the temperature gauge on the instrument panel started going to the red side; indicating that the vehicle was having trouble regulating the engine cooling system. The contact also stated that there was a strong odor of fuel entering the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel pump and carbon filter needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 100,000.
- Fuel/propulsion system
I went to the gas station and filled my gas tank, not topping it off, and as soon as I turned out of the station on a major road the vehicle stalled and almost resulting in an accident. After a quick restart the van ran fine and I was able to drive from nashville, tn to atlanta, ga with no…
I went to the gas station and filled my gas tank, not topping it off, and as soon as I turned out of the station on a major road the vehicle stalled and almost resulting in an accident. After a quick restart the van ran fine and I was able to drive from nashville, tn to atlanta, ga with no problems. But when I filled up again in atlanta, right after pulling out of the gas station the vehicle stalled again, in the middle of a busy intersection. This problem IS widely reported across dodge and chrysler vans, with over 100 complaints on this website. I'm hoping this issue with the gas tank/sensors will be address. Thank you.
- Fuel/propulsion system
After fueling the check engine light IS now on and indicates an emissions leak which causes vapors to now build up inside the van after every refueling. If filled to capacity the vehicle will also stutter and sometimes completely stall shortly after fueling.
- Fuel/propulsion system
Every time I fill my tank (i do not top off), within a few minutes of leaving the station, the van dies. It normally re-starts, but it takes quite a lot of gas pedal pumping. This IS dangerous when it happens in the middle of an intersection. I had the fuel pump and filter replaced and that did not…
Every time I fill my tank (i do not top off), within a few minutes of leaving the station, the van dies. It normally re-starts, but it takes quite a lot of gas pedal pumping. This IS dangerous when it happens in the middle of an intersection. I had the fuel pump and filter replaced and that did not solve the problem. Now I understand that the valve on top of the tank IS at fault, but you have to replace the entire tank. This IS a design flaw and needs to be corrected.
- Fuel/propulsion system
While making left the vehicle stalled while in motion in the middle of major intersection. After a 20 or so seconds, the vehicle engine turned on. another incident, approximately a year ago, while traveling 60+ miles on major interstate, the vehicle again shut down while in motion. I had to…
While making left the vehicle stalled while in motion in the middle of major intersection. After a 20 or so seconds, the vehicle engine turned on. another incident, approximately a year ago, while traveling 60+ miles on major interstate, the vehicle again shut down while in motion. I had to coast the vehicle, with loss of power, to median on the interstate. after about a minute or so, the vehicle turned on. always upon filling the gas tank, the vehicle stalls while exiting the gas station or shortly thereafter. after a minute, the vehicle IS able to turn back on. *tr
- Fuel/propulsion system
Car shuts off after filling the gas tank. This has happened several times. Always on the road and in traffic. *tr
- Fuel/propulsion system
After filling my '04 grand caravan with fuel and attempting to leave the pump my caravan shuts off. this has been on an ongoing issue for over 2 years. after several repair attempts I was told today that the vapor separator valve located on top of the gas tank IS faulty. a valve that dodge does…
After filling my '04 grand caravan with fuel and attempting to leave the pump my caravan shuts off. this has been on an ongoing issue for over 2 years. after several repair attempts I was told today that the vapor separator valve located on top of the gas tank IS faulty. a valve that dodge does not make available for repair. the only "fix" that IS offered IS to replace the entire tank of which I was told today would be $1600. *tr
- Fuel system, gasoline
Every time I fill up the van, as soon as I pull out of the gas station it will idle rough, hesitate, or die all together. I could have 1/2 tank and add maybe 5 gal of gas and it will do the same thing. I saw online that I am not the only one that had this issue. It ranges for different years and…
Every time I fill up the van, as soon as I pull out of the gas station it will idle rough, hesitate, or die all together. I could have 1/2 tank and add maybe 5 gal of gas and it will do the same thing. I saw online that I am not the only one that had this issue. It ranges for different years and come to find our it has to do with a valve above the tank and cant be replaced singly but the whole tank for $1600 plus labor. This IS a safety issue because this thing has happen in the middle of an intersection while turning. I called melloy dodge here in albuquerque nm and they right shot me down about as quick it took to dial the phone number. *tr
- Air bags
I was driving and the passenger side airbag deployed. there was no one in the passenger seat and no accident to cause the airbag to blow. *tr
- Fuel/propulsion system
The fuel pump has hair line fractures in multiple places of fuel pump in and IS leaking gas looks like its been there for awhile but I just noticed it in july IV been reading up on it and there's. Been alot of people with the same problem with 04 dodge grandcare vans sxt and others models also...... Thanks. *tr
- Engine · Fuel/propulsion system
After taking on gas, engine will sometimes stumble and most of the time quit running. Tried not over filling it and it still will just die sometime after taking on gas. On two occasions, it did this after hitting highway speeds. It would suddenly lose power and you had to pull off the road. It…
After taking on gas, engine will sometimes stumble and most of the time quit running. Tried not over filling it and it still will just die sometime after taking on gas. On two occasions, it did this after hitting highway speeds. It would suddenly lose power and you had to pull off the road. It would normally start back up and have no more problems until next fill up. because of this, we don't fill up and hit the road. We drive around before driving at highway speeds. once, it died in front of several cars and a big truck had to brake hard and swerve off the road. So far, there has not been any known accidents but feel it IS a matter of time before someone gets hurt. The mechanic said it was something wrong with a valve in gas tank and that you can't buy the part. we don't loan our van to the kids anymore since my oldest daughter almost caused a wreck and almost got hit when the van lost power. *tr
- Engine · Fuel/propulsion system
For the past four years or so, almost every time after filling up the gas tank, the 2004 dodge grand caravan anniversary edition stalls. I can be just pulling away from the pump when it happens, or stopped at a stop light within a few minutes from leaving the gas station. you can feel the car…
For the past four years or so, almost every time after filling up the gas tank, the 2004 dodge grand caravan anniversary edition stalls. I can be just pulling away from the pump when it happens, or stopped at a stop light within a few minutes from leaving the gas station. you can feel the car 'jump' like someone IS pressing the gas pedal quickly and it jerks the van a bit forward. then it stalls. it takes a few turns of the key and pressing the gas pedal very quickly and forcefully to get it started again. I have gotten into the habit of driving the van around a parking lot for a few minutes until it feels back to normal before pulling out into traffic, as I'm concerned it will stall out in the middle of traffic. this only happens right after filling up the gas tank. it concerns me now more than ever since my son IS learning how to drive and I want him to be safe. *tr
- Engine
TL* the contact owns a 2004 dodge grand caravan. After refueling the vehicle and driving at various speeds, the engine stalled. The contact was able to restart the vehicle, but the failure recurred on numerous occasions. The vehicle was taken to an independent mechanic who was unable to diagnose…
TL* the contact owns a 2004 dodge grand caravan. After refueling the vehicle and driving at various speeds, the engine stalled. The contact was able to restart the vehicle, but the failure recurred on numerous occasions. The vehicle was taken to an independent mechanic who was unable to diagnose the cause of the failure. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was unknown.
- Electrical system · Fuel/propulsion system · Power train
Engine started missing, vibrations from engine. diagnosis electrical fault. wiring harness brittle form harness being placed on, over and next, snaked around exhaust manifold, causing premature wiring failure. Fuel injector wiring harness unshielded in side of intake manifold / plenum. wiring…
Engine started missing, vibrations from engine. diagnosis electrical fault. wiring harness brittle form harness being placed on, over and next, snaked around exhaust manifold, causing premature wiring failure. Fuel injector wiring harness unshielded in side of intake manifold / plenum. wiring harness poorly shielded. this IS a deliberate, intentional design / engineering to snake wiring harness around exhaust manifold. causing wiring harness failure. using sub-standard wiring components and not using shielding to cause pre-mature failure. installing pcm (computer) in wheel well for pre-mature failure exposed to salt, road debris, water, etc. pcm installed in open area of vehicle prone to failure. consequential safety issues. *tr
- Fuel/propulsion system
TL* the contact owns a 2004 dodge grand caravan. The contact stated that the vehicle would stall immediately after refueling. The contact indicated that the failure had occurred on multiple occasions and in some instances the vehicle would stall up to two times before operating as normal. The manufacturer was notified of the failure but no solution was offered. The failure mileage was 115,000.
- Seats
I was sitting in front driver seat turned to place an item into passenger seat and where the lower springs attach to seat back rest of the driver seat the seat frame snapped in half and the lower support arm that connects the two lower parts of the back rest together split. *tr
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Engine Stall After Refueling
This defect petition evaluates July 7, 2014 allegations from an owner of a model year (MY) 2007 Dodge Grand Caravan minivan that engine stall occurs in these vehicles without warning after refueling.The petitioner's vehicle is a Chrysler RS platform minivan.The RS platform includes MY 2003 through 2007 Dodge Grand…
This defect petition evaluates July 7, 2014 allegations from an owner of a model year (MY) 2007 Dodge Grand Caravan minivan that engine stall occurs in these vehicles without warning after refueling.The petitioner's vehicle is a Chrysler RS platform minivan.The RS platform includes MY 2003 through 2007 Dodge Grand Caravan, Dodge Caravan, Chrysler Town and Country and Chrysler Voyager minivans.NHTSA evaluated the petition by analyzing consumer complaints submitted to the Agency, analyzing field data, reviewing technical information provided in Chrysler's response to an Agency information request and testing an RS minivan identified by its owner as experiencing post-refuel engine stalls.After completing this evaluation, NHTSA has concluded that further investigation is unlikely to result in a finding that a defect related to motor vehicle safety exists.The stalls occurring in these vehicles only occur immediately after filling up the fuel tank and happen at low engine speeds. The failure rate is low, even after 8 to 13 years of the vehicles being in service, and there are no reports of crashes or injuries resulting from the stall condition.In the Agency's view, additional investigation is unlikely to result in finding the existence of a safety-related defect in the subject vehicles.Given the need to allocate and prioritize NHTSA's limited resources to best accomplish the Agency's safety mission, the petition is denied.This action does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency will take further action if warranted by future circumstances. More details concerning our review can be found in the Federal Register Notice for this action.The following 161 VOQs are included in the petition evaluation: 10209242, 10229468, 10240708, 10260923, 10275939, 10276532, 10296487, 10298175, 10328669, 10330144, 10346517, 10349789, 10354758, 10363689, 10372112, 10372368, 10372514, 10378031, 10379764, 10382938, 10387448, 10394063, 10398877, 10413918, 10418652, 10420924, 10427063, 10437525, 10445392, 10446902, 10470028, 10471249, 10473733, 10502231, 10503114, 10504260, 10509862, 10511988, 10512120, 10512385, 10512650, 10513147, 10538154, 10549841, 10551763, 10555188, 10555418, 10556754, 10565367, 10574012, 10574398, 10586555, 10587212, 10587559, 10593433, 10607841, 10607913, 10608922, 10615810, 10622468, 10628141, 10632112, 10632128, 10632172, 10632175, 10632231, 10632262, 10632266, 10632270, 10632305, 10632316, 10632326, 10632370, 10632385, 10632399, 10632492, 10632542, 10632765, 10632833, 10632928, 10633197, 10633281, 10633409, 10633421, 10633483, 10633507, 10637752, 10637804, 10637950, 10637975, 10638032, 10638289, 10638290, 10638401, 10638968, 10639218, 10639623, 10641157, 10641603, 10641614, 10641836, 10644339, 10644705, 10649713, 10649895, 10649932, 10650313, 10652590, 10653147, 10653783, 10654533, 10655226, 10658900, 10659679, 10660320, 10662588, 10662645, 10662662, 10663473, 10667056, 10667437, 10668081, 10668094, 10668131, 10668612, 10668969, 10668970, 10669584, 10669678, 10669729, 10669775, 10669866, 10669895, 10669992, 10670422, 10670506, 10676348, 10676732, 10677120, 10679795, 10679934, 10680057, 10680290, 10680342, 10680714, 10681512, 10682584, 10682906, 10683022, 10683114, 10683549, 10683620, 10683697, 10683743, 10689898, 10690761, 10691284, 10691556, 10691751, 10693061, 10694300
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10229256KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicle, use the "AC" NIC level part and submit a part warranty.
- 10229181Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications. An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine.
- 10223854Service - Four Piece Oil Pan Gasket All Cummins Equipped Vehicles ONLY - The replacement oil pan gasket can be a four piece gasket rather than a single piece gasket. This applies to Cummins 5.9L and 6.7L engines only. Installation: 1. Clean the oil pan T-joints.~ 2. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar Silicone Rubber Adhesive Sealant or equivalent. 3. Apply a 2-mm [0.063-in] bead of Mopar Engine Sealant RTV Silicone Rubber Adhesive, to the oil pan flange.~ 4. The four piece gasket will need to be assembled to make a complete oil pan gasket. 5. Lay the oil pan gasket(s) onto the oil pan flange.~ 6. Ensure the oil pan gasket segment joints are properly aligned. 7. Apply a 2-mm [0.063-in] bead of Mopar Engine Sealant RTV Silicone Rubber Adhesive, to the top of the oil pan gasket.~ 8. Install the oil pan. Starting from the center and working outward, tighten the oil pan bolts to 28 Nm [21 ft. lbs.].
- 10223602Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications. An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine.
- 10221686KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicle, use the "AC" NIC level part and submit a part warranty.
- 10220101Use of Aftermarket Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of aftermarket parts.
- 10220099Use of Salvage/Recycled Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of recycled or salvage parts.
- 10220097Repair Parts Used For Structural Repairs This bulletin involves discussing FCA US LLC position with regard to structural repair parts usage.
- 10219763Extended Warranty on the Fuel Tank/Vapor Cannister
- 10209634Extended Warranty on the Fuel Tank/Vapor Cannister
- 10191460Valve Body. These may cause over drive cycling.
- 10189392MIL Illumination - DTC P1776 Solenoid Switch Valve Latched in LR Position
- 10175743Disinfectant Solution Recommended for COVID-19
- 10175735Charging System, Battery Diagnostic Tools and Warranty This information only bulletin discusses using the correct test equipment for testing batteries and charging systems, and also warranty reimbursement when battery replacements are necessary.
- 10169249Use of Aftermarket Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of aftermarket parts.
- 10169247Use of Salvage/Recycled Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of recycled or salvage parts.
- 10169245Repair Parts Used For Structural Repairs This bulletin involves discussing FCA US LLC position with regard to structural repair parts usage.
- 1012900882212076, 82203694 - Fabric Cleaner This "fabric cleaner" is not intended for sale in California, the otc states (Connecticut, Delaware, Massachusetts, Maine, New Hampshire, New Jersey, New York, Pennsylvania, Virginia, and Washington dc), and some ladco states (Illinois, Michigan, and Ohio). Mopar offers an alternative product (82213192) which is a water based product approved for sale in the aforementioned states.~ ~ Please inform the customer & your prep dept that spraying excessive amounts of the fabric protector on load floors will result in the breaking down of the adhesive (glue) that is used to create the bond between the fabric (carpet) and the load floor. This will apply to any vehicles equipped with rear load floors such as WK, WD, PM, MK, KA, KK. The carpet will appear to be loose, wrinkly, or bunch up~
- 10076430(X60) fuel tank/vapor canister - 2004-2005-town and country (RS) and caravan/grand caravan (RS)
- 10005354Powertrain control module (pcm) electrical connector seal customer satisfaction notification no. C30.
Every Dodge Grand Caravan model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.