2004 Chrysler Pacifica Problems

What owners report

Owners of the 2004 Chrysler Pacifica report most often about the front subframe/engine cradle rusting through, typically discovered during inspections or routine service at higher mileage. Complaints also describe intermittent stalling or hesitation, motor mount failures, and various electrical faults such as dash and gauge failures.

1. 1
   Body and structure

   Engine cradle / subframe rust-through

   • 390 complaints (44%)
   • median 113,225 mi at 10.4 yrs old (352 state mileage)
   • 3 mention a crash, fire or injury
   • owner-quoted repair $3,000 (median of 47 quotes)
   • filed 2003–2021

   Complaints describe the front engine cradle (subframe) corroding through, sometimes with holes large enough to put a finger through, often found by a mechanic during routine service or a state inspection. Owners commonly say the dealer or shop advised that further driving was not advisable because the cradle supports the engine, and some report being told the repair would cost several thousand dollars. Several owners say they contacted Chrysler and received no assistance because the vehicle was outside warranty, while a few report repairs covered under an extended warranty. Reported mostly between about 75,000 and 180,000 miles, frequently in vehicles driven in snowy, road-salt regions.

   2 related service bulletins

   What to check: Inspect the front subframe and engine cradle from underneath for rust perforation, especially on vehicles from salt-belt states, and ask whether any cradle repair or replacement has been done.

   2 excerpts from owner complaints in NHTSA records

   “My 2004 chrylser Pacifica was purchased new in aug 2003. I brought the car in for an oil change at dealership. Dealer contacts me to have me see the car while on a lift so that I may view the extensive rot of the engine cradle. The underside of the vehicle is totally fine as far as rust except the cradle that is full of holes. Cost to fix $2400. …”

   NHTSA complaint #10558758, filed 2014-01, 97,284 miles

   “I took my car in for annual inspection today....omg.....it's uninspectable.....too dangerous to drive.....there are holes in the front sub frame, rear bushings are gone in rear sub frame and the rockers have holes in them.....the engine may well fall out.....! This car has only 113,000 miles on it.....has been regularly maintained and now, how am I supposed to get to work?? …”

   NHTSA complaint #10432402, filed 2011-10, 113,450 miles
2. 2
   Engine

   Intermittent stalling and hesitation

   • 150 complaints (17%)
   • median 82,872 mi at 7.0 yrs old (130 state mileage)
   • 10 mention a crash, fire or injury
   • owner-quoted repair $2,100 (median of 8 quotes)
   • filed 2003–2020

   Owners describe the engine shutting off unexpectedly while driving, cornering, slowing to a stop, or idling, sometimes with a loss of power steering and electrical assistance, and often restarting after being shifted to neutral or park. Complaints also describe delayed or no response when pressing the accelerator, with the vehicle lurching once power returns. Several owners report dealers could not reproduce the problem or diagnosed items such as the powertrain control module or air intake, with mixed results. Spread across the mileage range, from very low mileage up to about 160,000 miles, with no clear seasonal pattern.

   Recall 04V1130003 related service bulletins

   What to check: Ask whether the powertrain control module software has been updated under the related campaign and whether the vehicle has a history of stalling or check-engine codes; a road test including stop-and-go and cornering is worthwhile.

   2 excerpts from owner complaints in NHTSA records

   “Its throwing a PCM code an the car is stalling so bad in the moddle of driving I have been stuck severeal times an I thunk there is a fuel leak I smeell gas so bed its throing po300 code an wont chanfe even when I got all the parts I see there is a recall on my year of car can somwonw hwlp mw I cant keeo cutting off ill wreck”

   NHTSA complaint #11353350, filed 2020-09, 65,000 miles

   “After replacing a both motor mounts in july of 2012. They broke again in november 2012!! This time it was so bad that when I turned the corner the engine died and would not start back up. Eventually after trying to turn it over so many time the battery died. We had to have it towed to the shop after the holidays to find out how much it would cost to fix ($1200) and exactly what the issue was. …”

   NHTSA complaint #10544705, filed 2013-09, 77,000 miles
3. 3
   Fuel system

   Fuel smell, gauge reading and fuel leaks

   • 209 complaints (23%)
   • median 88,500 mi at 7.6 yrs old (172 state mileage)
   • 31 mention a crash, fire or injury
   • owner-quoted repair $958 (median of 11 quotes)
   • filed 2003–2021

   Complaints describe a strong fuel smell, fuel gauge readings that drop to empty despite a full tank, and fuel pump shutoff issues during refueling. Some owners report fuel leaking from under the vehicle, and a few describe engine compartment or underbody fires attributed to fuel line problems by inspectors. Reported from about 40,000 to 200,000 miles, with several cases noted around refueling or shortly after driving.

   Recall 03V471000

   What to check: Ask whether the fuel supply tube campaign was completed, check for fuel odors around the tank and lines, and verify the fuel gauge reads correctly after a fill-up.

   2 excerpts from owner complaints in NHTSA records

   “Driving on the road doing about 35 MPH and I ran over a piece of metal with my tire. By the time I got home I smelled gas, looked under my car, and the gas was gushing out of my tank under the car.”

   NHTSA complaint #10254059, filed 2009-01, 40,000 miles

   “The vehicle does when in reverse and you step on the accelerator. Gas gauge reads empty even with fuel in it and fluctuates between empty and full. Vehicle stalls when going around a corner or coming to a stop.. Foul smell coming from the exhaust into the cab. All dash gauges go off. Check engine light is on. Received two different codes 1) o2 sensor bad & 2) p1861.”

   NHTSA complaint #11351956, filed 2020-08, 158,500 miles
4. 4
   Engine

   Motor mount failure / engine movement

   • 104 complaints (12%)
   • median 77,500 mi at 6.8 yrs old (88 state mileage)
   • 2 mention a crash, fire or injury
   • owner-quoted repair $1,856 (median of 8 quotes)
   • filed 2004–2019

   Complaints describe loud popping or clunking from the front end and visible engine movement when accelerating, traced by mechanics to worn or broken motor mounts. Some owners report mounts failing again shortly after replacement, and in a few cases a failed mount allowed the engine to move enough to damage wiring or other components. Owners also mention difficulty sourcing replacement mounts. Reported from roughly 75,000 to 150,000 miles, often noticed as a noise or vibration during acceleration or braking.

   What to check: Have a mechanic check the motor mounts for cracks or separation, and listen for popping or clunking from the front end during a test drive with hard acceleration and braking.

   2 excerpts from owner complaints in NHTSA records

   “I was driving on a city street and I was turning at a stop light when my car made a very strange sound. I could not steer the car so I pulled over and upon looking underneath the vehicle and under the hood the motor had shifted due to a rotting cradle mount.”

   NHTSA complaint #11119746, filed 2018-08, 160,000 miles

   “We were told last week that the motor mounts on our 2004 Chrysler Pacifica were gone. Not broken.... Gone. I had noticed some front end shaking when I hit the brakes at a high rate of speed. I also noticed that the engine was loud when I would hit the accelerator from a stop. Our mechanic discovered that the motor mounts were missing and causing the issues. Every time I hit the gas, the engine jumps up a couple of inches. My mechanic called around and was unable to get his hands on any motor mounts at this time. …”

   NHTSA complaint #10278716, filed 2009-07, 107,692 miles
5. 5
   Electrical system

   Electrical faults: dash, gauges and warning lights

   • 120 complaints (13%)
   • median 85,000 mi at 7.1 yrs old (108 state mileage)
   • 10 mention a crash, fire or injury
   • owner-quoted repair $1,200 (median of 8 quotes)
   • filed 2004–2020

   Owners describe instrument panel lighting, gauges and accessories cutting out or fuses blowing repeatedly, and in some cases the speedometer and other electrical functions failing. Complaints also mention warning lights flashing along with wipers stopping or the engine cutting out, and dealers having difficulty identifying the cause. Several owners report repairs to the control module or wiring without a lasting fix. Reported from very low mileage up to about 150,000 miles, often as intermittent faults with no consistent trigger.

   3 related service bulletins

   What to check: Check that all gauges, interior lights and accessories work, ask about any repeated fuse failures or warning-light history, and confirm the wireless control module and key programming are functioning.

   2 excerpts from owner complaints in NHTSA records

   “Fuse for dashlights,guages,GPS system,A/C systms. And radio burns out while driving and when it happens at nite, it causes quite a frite, dealer has had it now three times in two months . This last time for 7 days and still has'nt a clue. I myself have replaced the burned fuses at least 10 times.”

   NHTSA complaint #10065750, filed 2004-04, 3,596 miles

   “A follow up to earlier safety complaint.just ordered a computer for the affected vehicle and while describing the problem to the tech was informed that it is a well known problem affecting not only my Pacifica but their town and country mini van as well.”

   NHTSA complaint #10456566, filed 2012-04, 129,000 miles

Buying note. Have any 2004 Pacifica inspected underneath for subframe and engine cradle corrosion before purchase, since that is the most frequently reported concern and can be costly to repair. Also budget for wear items such as motor mounts and check for a history of stalling or electrical faults.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.