Model year record

2004 Dodge Grand Caravan recalls & problems

The 2004 Dodge Grand Caravan has 3 safety recalls and 116 owner complaints on file with NHTSA. The most-reported problem area is fuel/propulsion system (25 complaints).

Recalls3safety recalls

Complaints116filed by owners

Crashes · fires4 · 1reported in complaints

Injuries · deaths2 · 0reported in complaints

2004 Dodge Grand Caravan in an NHTSA crash test — NHTSA crash test

Safety recalls

VisibilityDec 11, 2007

Glass, side/rear

Recall 07E1040001,657 vehicles

Problem: 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 MATERIALS."
Risk: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.
Fix: 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.

SteeringAug 5, 2004

Hydraulic power assist › Hose, piping, and connections

Recall 04V386000681,000 vehiclesopened after NHTSA action (ODI)

Problem: 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: POWER STEERING FLUID LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN AN UNDER HOOD FIRE.
Fix: 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.

Fuel system, gasolineOct 24, 2003

Fuel system, gasoline

Recall 03E05300068,563 vehicles

Problem: 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: A POSSIBLE FIRE CAN OCCUR IN THE PRESENCE OF AN IGNITION SOURCE.
Fix: 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.

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

Crash test ratings

2004 Dodge Grand Caravan w/SAB

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

2004 Dodge Grand Caravan

OverallNot Rated

Frontal crash	Not Rated
Side crash	Not Rated
Rollover	Not Rated

2004 Dodge Grand Caravan NHTSA side crash test — NHTSA side barrier crash test

2004 Dodge Grand Caravan NHTSA side pole crash test — NHTSA side pole crash test

NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.

What owners report

Problem area	Complaints	Crashes	Fires	Injuries	Typical mileage*
Fuel/propulsion system	25	0	0	0	104,000 mi
Service brakes, hydraulicFoundation components › Disc › Rotor; Foundation components › Disc › Pads	18	2	0	0	54,655 mi
Engine and engine coolingEngine; Engine › Gasoline › Belts and associated pulleys	14	0	1	0	80,000 mi
SteeringRack and pinion; Hydraulic power assist › Hose, piping, and connections	14	0	0	0	23,000 mi
Electrical systemWiring › Rear compartment/trunk; Wiring	13	0	0	0	99,680 mi
Fuel system, gasolineStorage › Tank assembly; Delivery	11	0	0	0	90,000 mi
Latches/locks/linkagesDoors › Latch	9	0	0	0	85,000 mi
Engine	6	0	0	0	87,500 mi
Air bagsFrontal	5	2	0	2	73,900 mi
StructureBody › Door; Body › Hatchback/liftgate › Support device/strut	4	0	0	0	86,440 mi
Exterior lighting	4	0	1	0	110,340 mi
SuspensionFront; Front › Macpherson strut	3	0	0	0	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Air bagsCrash1 injury
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…
May 15, 2021
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 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
Mar 19, 2021 · 200,000 miles
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 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
Mar 20, 2017 · 213,000 miles
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 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.
Aug 30, 2019 · 260,000 miles
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 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.
Nov 3, 2016 · 115,000 miles
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.
Nov 1, 2014 · 150,000 miles
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.
Apr 20, 2012 · 70,000 miles
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.
Jan 11, 2016 · 160,000 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

Engine Stall After RefuelingClosed
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…
DP14002 · opened Sep 5, 2014 · closed Apr 6, 2015