2004 Dodge Caravan

65 complaints on file, page 1 of 4.

1. Filed Sep 9, 2026Failure Sep 2, 2026Port Reading, NJTires

   Hello, After installing 4 new tires on my van I immediately noticed a jerk my vehicle was experiencing at highway speeds. mostly when turning , changing lanes or moving the steering wheel like adjusting lane positions. I had double checked the tire air pressure and lug nuts, even added extra 5 lbs. to the tires but still has this strange feel when driving. I am returning the tires for an exchange tomorrow, I do not trust these tires, makes me very nervous to drive with them at higher speeds, my alignment is perfect as I had that checked at purchase also (lifetime vehicle alignments)

   NHTSA complaint 11763187
2. Filed May 1, 2019Failure Apr 30, 2019140,000 milesStrongsville, OHSeats

   THE VEHICLE WAS STATIONARY. I WAS LEAVING WORK, WHEN I SAT IN THE DRIVER'S SEAT THE SEAT BROKE AND FELL BACK. THE BROKEN PART IS ACTUALLY THE FRAME OF THE SEAT, NOT THE TILT MECHANISM. THE TUBULATION THAT COMPRISED THE SEAT FRAME CATASTROPHICALLY BROKE ADJACENT TO THE WELDMENT. THIS PART SHOULD NEVER FAIL.

   NHTSA complaint 11205007
3. Filed Aug 13, 2017Failure Jul 9, 201772,000 milesNEW Providence, PAFuel/propulsion system

   FUEL LEAKING FROM TOP OF FUEL TANK

   NHTSA complaint 11014921
4. Filed Jan 14, 2017Failure Jan 20, 2016145,000 milesClemson, SCFuel/propulsion system

   ENGINE OFTEN HESITATES AFTER YOU HAVE DRIVEN A FEW BLOCKS AFTER REFUELING. THIS FORM ASKS FOR A SINGLE SPECIFIC DATE BUT THIS PROBLEM HAS HAPPENED EVERY FEW WEEKS FOR THE LAST YEAR OR SO. DEPENDING UPON THE TRAFFIC SITUATION WHEN THE HESITATION OCCURS, AND ACCIDENT COULD EASILY OCCUR. MY MECHANIC SAYS THAT THE LIQUID/VAPOR SEPARATOR VALVE ON THE GAS TANK IS NOT OPERATING PROPERLY. THIS VALVE IS A PART OF THE TANK AND CANNOT BE REPLACED AS A SEPARATE ITEM, SO THE COST OF THE REPAIR IS SUBSTANTIAL. A BRIEF SEARCH ON THE INTERNET INDICATES THAT MANY OTHER OWNERS OF DODGE CARAVANS MANUFACTURED BETWEEN ABOUT 2004 AND 2007 ARE REPORTING THIS SAME PROBLEM.

   NHTSA complaint 10945306
5. Filed May 12, 2016Failure Nov 4, 2009Glencoe, ILEngine and engine cooling, Fuel system, Gasoline

   2004 DODGE CARAVAN. CONSUMER WRITES IN REGARDS TO FUEL TANK EXTENDED WARRANTY COVERAGE THAT APPLIES TO VEHICLE STALLING AFTER REFUELING. *SMD THE CONSUMER STATED THE VEHICLE BEGAN STALLING SHORTLY AFTER IT WAS PURCHASED AND HAS SINCE CONTINUED. THE STALLING OCCURRED AT HIGHWAY SPEEDS AND WHILE MAKING LEFT TURNS. ALSO, THE CHECK ENGINE LIGHT ILLUMINATED. THE DEALER REPLACED THE EGR SENSOR.*JB

   NHTSA complaint 10864907
6. Filed Jan 7, 2016Failure Jan 2, 2016118,652 milesPensacola, FLAir bags, Electrical system, Unknown or other

   INTERMITTENT HORN TURNING ON. CLOCKSPRING WAS REPLACED ALONG WITH FRONT CONTROL MODULE. THEY THINK HORNPAD IS AT FAULT AND WILL FURTHER SHORT CLOCKSPRING AND FRONT CONTROL MODULE

   NHTSA complaint 10818683
7. Filed Nov 6, 2015Failure Apr 4, 2015240,000 milesEllsworth, WIAir bags

   THE AIRBAG WARNING LIGHT IS ILLUMINATED DUE TO A MALFUNCTIONING CLOCKSPRING. THIS DISABLES THE AIRBAG SYSTEM. THIS WAS RECALLED ON EARLIER MODEL CARAVANS BUT HAS NOT BEEN COMPLETED ON 2001 AND NEWER MODELS WHICH HAVE THE SAME ISSUE. THE LIGHT HAS BEEN ILLUMINATED SINCE VEHICLE PURCHASE AND HAS HAD INACTIVE AIRBAGS. RECENTLY, WHILE TURNING THE STEERING WHEEL HARD DURING A POWER STEERING RESERVOIR REPLACEMENT, THE AIR BAG LIGHT BEGAN TO TURN ON AND OFF CLEARLY DUE TO SHORTED WIRING AT THE CLOCKSPRING TERMINALS.

   NHTSA complaint 10788770
8. Filed Oct 31, 2015Failure Oct 9, 2015105,000 milesEnglewood, FLWheelsCrash

   AS I WENT TO STOP THE FRONT WHEELS SLID LIKE THEY WERE ON ICE. I WAS ON A PUBLIC RD. [BLACK TOP] I HIT THE CAR IN FRONT OF ME.

   NHTSA complaint 10787411
9. Filed Mar 19, 2015Failure Mar 19, 2015118,000 milesGoldsboro, NCFuel/propulsion system

   I PURCHASED MY VEHICLE IN THE FALL OF 2013 AND AM STARTING TO COME TO THE CONCLUSION THAT EVERY TIME I FILL MY GAS TANK UP MY VEHICLE SHUTS OFF! TODAY I FILLED UP MY GAS TANK. MY CHILDREN WERE IN THE BACK SEAT AND WHEN I PULLED OUT INTO THE HIGHWAY THE VAN SHUT OFF AND THE STEERING WHEEL LOCKED UP! I HAD NO CONTROL OVER THE VEHICLE. THIS SEEMS TO BE A COMMON PROBLEM WITH THESE VANS AND SOMETHING NEEDS TO BE DONE BEFORE SOMEONE GETS HURT! I CAN'T FILL MY GAS TANK UP BECAUSE OF THIS ISSUE. *TR

   NHTSA complaint 10695523
10. Filed Dec 12, 2014Failure Dec 11, 2014155,755 milesPortsmouth, VAFuel/propulsion system

    TL* THE CONTACT OWNS A 2004 DODGE CARAVAN. THE CONTACT STATED THAT THE VEHICLE WAS LEAKING FUEL. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THERE WAS A LEAK IN THE FUEL PUMP DUE TO CORROSION. AS A RESULT, THE FUEL PUMP ASSEMBLY NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 155,755.

    NHTSA complaint 10663938
11. Filed Oct 13, 2014Failure Aug 31, 2014112,000 milesLiverpool, ILElectrical system

    WHEN I CHANGED MY VEHICLE BATTERY TO A NEW ONE THE GAS ONLY DROPS TO A HALF A TANK ITS WILL NOT GO DOWN TO EMPTY BUT MY LOW FUEL LIGHT WORKS STILL MY GAS GAUGE DOES NOT. HOW DO I FIX IT OR RESET IT. *TR

    NHTSA complaint 10644304
12. Filed Sep 26, 2014Failure Jun 13, 201275,000 milesGreen Isle, MNFuel/propulsion system

    EVERY TIME VEHICLE IS FUELED UP, THE VEHICLE PUTTERS AND SHUTS OFF, CAUSING ALL POWER STEERING TO LOCK UP WHILE DRIVING. OCCURS THE FIRST COUPLE MILES. *TR

    NHTSA complaint 10639218
13. Filed Sep 23, 2014Failure Oct 20, 201073,000 milesFountain Hill, PAEngine, Power train, Steering

    MY FIRST GAS TANK FILL AFTER PURCHASING THE USED VEHICLE RESULTED WITH CONSTANT STALLING FOR THE NEXT 1/2 MILE. THIS HAS BEEN GOING ON FOR THE LAST 4 YEARS. I DO NOT OVERFILL THE TANK. THE VEHICLE NOW STALLS ABOUT 80% OF THE TIME AFTER I FILL THE TANK. AFTER ABOUT 6/10TH OF A MILE ,THE PROBLEM CORRECTS ITSELF. ONE TIME I COME VERY CLOSE TO HAVING AN ACCIDENT WHEN AFTER LEAVING THE GAS STATION I WAS GOING DOWN A HILL AND HAD TO MAKE A RIGHT TURN AT AN INTERSECTION, THE VEHICLE STALLED OUT & I HAD TO PUT THE GEAR SELECTOR IN NEUTRAL TO TRY TO RESTART THE VEHICLE WHILE IT WAS MOVING & MAKING A RIGHT TURN AT THE SAME TIME ! I AM NOW FORCED TO PARK THE CAR FOR A FEW MINUTES AFTER FILL UP BEFORE I CAN SAFELY TAKE IT BACK ON THE ROADWAY. THIS IS AN ONGOING PROBLEM FOR THE 2004 -2007 CHRYSLER & DODGE MINIVANS. I HAVE VIEWED MANY COMPLAINTS ON LINE ABOUT THE SAME ISSUE. DOES SOMEONE HAVE TO GIVE UP THEIR LIFE BEFORE A RECALL IS ISSUED? THERE IS A DEFECTIVE VALVE IN THE GAS TANKS & THE TANKS HAVE TO BE REPLACED ! *TR

    NHTSA complaint 10638401
14. Filed Sep 13, 2014Failure Sep 1, 200839,000 milesOwosso, MIEngine, Fuel/propulsion system, Steering

    NOT 100% BUT PROBABLY 40% - 60% OF THE TIME I REFUEL - ESPECIALLY A FULL TANK - THE CAR WILL TEND TO HESITATE AND STALL WITHIN THE FIRST 90 SECONDS OF GETTING BACK ON THE ROAD. SEEMS LIKE IT HAS NOT DONE IT A LOT LATELY BUT I JUST HAD SOME WORK DONE BY THE LOCAL DODGE DEALER INCLUDING NEW WIRES AND PLUGS. WHEN I LEFT THE DEALERSHIP IT RAN FINE. I PUT IN PROBABLY 3/4 TANK OF GAS IN IT AND IT BEGAN HESITATING AND STALLING WORSE THAN IT HAD IN SOME TIME. THE WEATHER WAS ALSO QUITE A BIT COOLER THAN IT HAD BEEN IN 6 MONTHS. I ALSO READ AN ARTICLE IN USA TODAY ABOUT THIS ISSUE WHICH I HAVE BEEN EXPERIENCING SINCE 2007 WHEN I PURCHASED THE CAR USED. I HAVE HAD THE DEALER LOOK AT IT IN THE PAST AND THE COULD IDENTIFY NOTHING SPECIFIC. FIGURED I WOULD REGISTER THE COMPLAINT SINCE I HEARD OTHERS WERE HAVING THE SAME ISSUE. *TR

    NHTSA complaint 10632928
15. Filed Sep 4, 2014Failure Sep 1, 2014Washington, DCFuel system, Gasoline

    2004 DODGE CARAVAN. CONSUMER WRITES IN REGARDS TO GAS GAUGE PROBLEMS. *SMD THE CONSUMER ALSO STATED THE VEHICLE IS LEAKING GAS.*JB

    NHTSA complaint 10629757
16. Filed Feb 9, 2014Failure Feb 9, 201494,000 milesDowney, CABody

    PASSENGER SIDE SLIDING DOOR KEEPS COMING OFF TRACK FOR NO APPARENT REASON. JUST OPERATING THE DOOR CAUSES THIS TO HAPPEN, AND IT HAS HAPPENED WHILE VEHICLE IS IN MOTION TOO, WHICH CAN BE VERY DANGEROUS, BECAUSE OUR VEHICLE IS MODIFIED BY BRAUN FOR HANDICAP ACCESSIBILITY. THERE IS A METAL RAMP WHICH WILL COME DOWN IF THE DOOR OPENS. *TR

    NHTSA complaint 10563602
17. Filed Dec 10, 2013Failure Apr 18, 201296,000 milesDamascus, MDFuel/propulsion system

    AS MENTIONED BY SEVERAL OTHER POSTINGS, THE CARAVAN ENGINE WILL STALL OUT AFTER THE GAS TANK IS FILLED. THIS HAPPENS ALMOST EVERY TIME THE VEHICLE IS FUELED. IT WILL STALL OUT WITHIN A FEW MINUTES OF DRIVING AFTER LEAVING THE GAS STATION. IT HAS STALLED OUT IN TRAFFIC, AT STOP LIGHTS, AND NOW I AVOID TRAVELING ON THE ROADWAY FOR SEVERAL MINUTES AFTER FUELING IF POSSIBLE, CHOOSING INSTEAD TO TRAVEL THROUGH PARKING LOTS OR BACK ROADS BEFORE ENTERING ANY MAIN ARTERIES. A SERVICE REPAIRMAN AT THE DEALERSHIP SAID HE HAD NEVER HEARD OF SUCH A THING AND HAD NO IDEA WHAT THE PROBLEM COULD BE. ANOTHER MECHANIC MENTIONED IT MIGHT BE A VALVE IN THE TOP OF THE TANK THAT IS DEFECTIVE BUT THE ONLY REPAIR IS TO REPLACE THE WHOLE GAS TANK AS THE PART IS NOT A SEPARATE PIECE. BASED ON MY OWN ONLINE RESEARCH, I THINK THIS IS A DEFECT WITH THIS MAKE AND MODEL. *TR

    NHTSA complaint 10555418
18. Filed Nov 15, 2013Failure Nov 12, 2013172,874 milesMission Viejo, CAEngine, Fuel system, Gasoline

    I WAS TRAVELING ON THE FREEWAY AT SPEED OR SLIGHTLY ABOVE WHEN MY GAS LIGHT WENT ON AND THE VAN STARTED TO SPUTTER. THEN THE ENGINE LIGHT WENT ON AND MY SPEED DECREASED TO APPX 40 MPH. I IMMEDIATELY GOT TO THE SIDE OF THE ROAD DURING RUSH HOUR AND CARS SPEEDING BY ME. IT WAS EXTREMELY DANGEROUS AND SCARY. A POLICE OFFICER STOPPED TO ASSIST ME AND TRY TO GET ME TOWED. I MADE IT TO THE NEXT GAS STATION. I ADDED GAS AND OIL. HOWEVER, DUE TO THE FACT THAT IT WAS SHAKING AND NOT ABLE TO MAKE IT ABOVE 40 MPH, I DECIDED TO HAVE IT TOWED HOME UNTIL A DECISION COULD BE MADE ABOUT WHAT TO DO. THE NEXT MORNING WE TOWED TO OUR MECHANIC AND IT WAS DISCOVERED THAT THE ENGINE DROPPED. THE BOLTS THAT HELD IT IN FAILED. I AM LUCKY. NOW WE HAVE THE ENGINE BACK UP IN PLACE AND ARE DETERMINING WHAT ELSE IS BROKEN DUE TO THIS FAILURE. *TR

    NHTSA complaint 10552485
19. Filed Sep 13, 2013Failure Jul 9, 201360,000 milesNorth Fort Myers, FLService brakesFire

    I ORIGINALLY FILED A COMPLAINT AGAINST THE PAD MANUFACTURER BUT IT SEEMS TO BE THE COMPOSITE PISTON IN THE CALIPER THAT IS INTERMITTENTLY CAUSING THE BRAKES TO OVERHEAT. THE PEDAL TRAVEL GOES TO ZERO AND THE BRAKE IS LOCKED. THIS IS A MANUFACTURES DEFECT AND A HAZARD. IT WOULD BE EASY FOR THESE BRAKES TO FAIL IN HIGHWAY CONDITIONS AND HAVE THE GREASE MELT OUT OF THE BEARINGS FROM THE HEAT AND BRAKE FLUID TO BOIL. THIS CAR HAS BEEN GARAGED ITS ENTIRE LIFE AND MAINTAINED. IT IS CHRYSLER THAT IN THE INTEREST OF PROFIT CREATED A SAFETY HAZARD. *TR

    NHTSA complaint 10543445
20. Filed Aug 28, 2013Failure Sep 7, 200940,000 milesNorth Adams, MAFuel/propulsion system

    AFTER FUELING THE VEHICLE STALLS NUMBERIOUS TIMES IN TRAFFIC CAUSING A HAZZARD. THIS WOULD BE EXCEPTABE HOWEVER THERE SEEM TO BE MANY OF THE VEHICLE THAT DOES THE SAME THING SEE HTTP://FORUM.CHRYSLERMINIVAN.NET *TT .

    NHTSA complaint 10537756