1996 Dodge Caravan Problems

What owners report

Complaints about this model year cluster around a handful of recurring problems: air bag warning lights with a failed horn and cruise control, fuel smells and leaks from the tank and underhood fuel rail, and windshield wipers that stop or run at random. Many reports come from vans past 90,000 miles, though several faults — wiper and body-control-module failures, fuel leaks, sliding-door and seat issues — appear well before that. Water intrusion and rust in the front strut towers come up repeatedly as gradual conditions that worsen over years.

1. 1
   Air bags

   Air bag light on, horn and cruise control dead (clockspring)

   • 189 complaints (13%)
   • median 100,629 mi at 7.4 yrs old (22 state mileage)
   • 3 mention a crash, fire or injury
   • owner-quoted repair $1,072 (median of 8 quotes)
   • filed 1998–2015

   Owners describe the air bag warning light coming on and staying on, usually together with a horn that stops working and cruise control that quits. Dealers commonly traced this to the clockspring assembly in the steering column; some owners had it replaced more than once, and a few report the light returning or an air bag deploying without an impact. Several owners say they learned about the clockspring recall only after paying for the repair themselves and had trouble getting reimbursed; a few were told the repair was not covered once the van was past a mileage limit. Mostly reported between roughly 65,000 and 125,000 miles, often years after purchase, with many owners filing reimbursement requests.

   Recall 02V293000

   What to check: Turn the key to accessory and confirm the air bag light goes out after the self-test, then test the horn and cruise control. Ask whether campaign 02V293000 (clockspring) was performed and keep any receipt.

   2 excerpts from owner complaints in NHTSA records

   “The horn on my 1996 Caravan has stopped working; the air-bag warning light stays on all the time; the cruise control system is starting to fail. I saw the report that there have been complaints on newer models. I think the range of model years needs to be broadened. I have also seen reports of other 1996/1997 models with the same problems on internet auto repair web sites.”

   NHTSA complaint #10056434, filed 2004-02, 125,000 miles

   “I submitted a request for reimbursement for the clock spring repair (safety recall) in my then 1996 Dodge Caravan on january 28, 2003. I have not heard from daimler chrysler since. I have telephoned and sent them a second letter requesting reimbursement but again have not heard from them. I am disappointed and frustrated that they take this position. What can I do to get their attention.”

   NHTSA complaint #10018991, filed 2003-05, 65,000 miles
2. 2
   Air bags

   Rust and cracking at the front strut towers

   Mentioned in 7 of 60 sampled complaints

   Owners describe rust eating through the front strut mounting towers, in some cases to the point where the strut pushes through or the tower separates from the body. Several reports say the rust was found during routine service or an oil change, and dealers were reported as offering a repair kit or declining work because of age and mileage. Complaints also mention a rusty cross member and popping or wandering behavior over bumps. Typically found on vans with 80,000 to 175,000 miles, and complaints tie the rust to long-term exposure rather than a single event.

   What to check: Open the hood and inspect both strut towers and the surrounding sheet metal for bubbling paint, flaking or soft spots, and check the front cross member from below. Ask whether repair plates or kits were installed.

   2 excerpts from owner complaints in NHTSA records

   “Left front strut mtg tower rusted through by the time the rust was seen the metal in the strut tower had failed chrysler refused to do anything stating it was over 3 year 36,000 mile for manifacturers deffect repair yet this is known as a common problem and can cause loss of control if it fails on the highway.”

   NHTSA complaint #10071030, filed 2004-01, 103,000 miles

   “I own an 1996 Dodge grand Caravan. The strut towers, especially the driver side, are rusting horribly and will need repair to avoid a catastrophic failure. If the rust gives way, the struts will go up through the tower which best case causes huge damage to the vehicle and worst case could result in a fatal traffic accident. Reading around the internet, this is a common problem from 1996 through 2000 vans and repair kits are back ordered at dealerships around the nation. …”

   NHTSA complaint #10161042, filed 2006-06, 134,000 miles
3. 3
   Visibility (wipers, defrost, mirrors)

   Windshield wipers stop or run intermittently

   • 63 complaints (4%)
   • median 89,000 mi at 7.6 yrs old (10 state mileage)
   • 1 mention a crash, fire or injury
   • filed 1996–2009

   Owners describe wipers that quit mid-stroke, start and stop on their own, or fail entirely in rain, sometimes leaving them driving with poor visibility. Several complaints point to the body control module as the part that had to be replaced, while others mention a multi-function switch or wiring; a few owners report the problem returning after repairs. Complaints also note that the module was available mainly through dealers at significant cost. Reported from about 60,000 to 150,000 miles, with several owners describing repeated failures over years.

   1 related service bulletin

   What to check: Run the wipers at every speed and with the washer, watching for hesitation or a stall mid-swipe. Ask whether the body control module has ever been replaced or repaired.

   2 excerpts from owner complaints in NHTSA records

   “1996 Dodge Caravan suffers from intermittent body control module . One of the possible symptoms of this failure is random failures of the windshield wipers. This failure is unpredictable and apparently widespread over several model years. The body control module is replaceable only at chrysler dealers who charge over $700 to replace this module. …”

   NHTSA complaint #10080509, filed 2004-07, 60,000 miles

   “While driving, the wiper stopped working. Upon turning the windshield washer on, they will work for a minute and then stop again. The consumer has made several repairs which has not corrected the problem. Please provide any further information. The consumer stated that traveling at 65 MPH in a rain storm was dangerous. Problem still exists.”

   NHTSA complaint #10099029, filed 2004-11, 150,000 miles
4. 4
   Transmission and drivetrain

   Transmission slips, hesitates or loses gears

   • 70 complaints (5%)
   • median 75,500 mi at 8.2 yrs old (8 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1996–2006

   Owners report the transmission hesitating or slipping, especially going into second gear, delayed engagement when shifting into drive or reverse, and in some cases fluid loss after the case was breached by a loose internal pin. Complaints describe towing and dealer diagnostics that reset codes without a lasting fix, and owners often report being told the van was out of warranty. Reports range from about 22,000 to 120,000 miles, with a small group of early failures under 30,000.

   1 related service bulletin

   What to check: Test drive from cold through all gears and watch for delayed engagement or slipping. Check transmission fluid level and color, and look for fluid trails under the bellhousing and case.

   2 excerpts from owner complaints in NHTSA records

   “Transmission at 91,000 miles essentially exploded without warning. Chysler refused to help me I also had to call them back to be informed of the denial. I asked for the name and number of the zone manager and was told I could only get that from the dealer. Tom addis Dodge refuse to identify the zone manager or give me his number. …”

   NHTSA complaint #10098916, filed 2004-11, 91,000 miles

   “Vehicle leaked transmission fluid. The vehicle was taken to a service station where it was determined that the transmission case was breached by a drive pin which was coming loose from the assembly. The consumer contacted the manufacturer but since the vehicle was no longer under warranty they refused any assistance.”

   NHTSA complaint #10057179, filed 2004-01, 22,926 miles
5. 5
   Fuel system

   Fuel smell and leaks at tank or fuel rail

   • 102 complaints (7%)
   • median 88,000 mi at 12.4 yrs old (10 state mileage)
   • 6 mention a crash, fire or injury
   • filed 1995–2023

   Owners report a strong gasoline smell inside or around the van, sometimes with fuel visible on top of the engine or dripping under the tank. Complaints describe the fuel pump module/tank connection and the underhood fuel rail as the places where leaks appear, and some owners had the tank replaced more than once. Repairs were often done at the owner's expense, and some owners who had recall work done reported the leak returning later. Reports span roughly 46,000 to 150,000 miles, with several near or above 120,000.

   Recall 00V268000Recall 99V216000Recall 95V236000Recall 96V002000

   What to check: Smell around the filler neck and under the hood after a drive, and look for dampness or staining at the fuel tank and the injector rail. Ask whether recall 00V268000 (fuel rail O-rings) and 99V216000 (fuel pump module) were completed.

   2 excerpts from owner complaints in NHTSA records

   “The contact owns a 1996 Dodge Caravan. The vehicle was repaired according to a recall, but the failure has resurfaced. Fuel is leaking from the fuel rail into the engine compartment, which is a fire hazard. The dealer stated that the contact would be responsible for the repair cost. Nhtsa campaign id number 00v268000 the failure mileage was 150,000. Updated 03/23/09. The consumer stated the dealer fixed the recall for recall. Updated 03/23/09.”

   NHTSA complaint #10257178, filed 2009-02, 150,000 miles

   “The contact owns a 1996 Dodge grand Caravan. The contact stated that fuel was leaking from his tank in large amounts. The vehicle was inspected by a independent mechanic and they advised him that he needed to replace the tank and the fuel pump. The vehicle has not been repaired. The manufacturer was contacted and advised him that the recall was expired and could not assist him. The failure mileage was approximately 151,000. Updated 03/24/11 updated 05/02/11”

   NHTSA complaint #10383216, filed 2011-02, 151,000 miles

Buying note. On a van of this age, service history and a close look at the strut towers and fuel system matter more than mileage; confirm any open campaigns were completed and budget for wear items at this age. A pre-purchase inspection by an independent shop is worthwhile given how often these complaints were found during routine service.

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.