2002 Dodge Caravan Problems

What owners report

Owners of the 2002 Dodge Caravan most often write to NHTSA about the air bag warning light, steering problems (rack-and-pinion, power steering leaks, steering-wheel noises) and intermittent headlight flicker or dropout. Many complaints come in between roughly 15,000 and 80,000 miles, with a recurring theme that dealers could not duplicate the symptom, and several air bag and headlight complaints describe temperature- or weather-dependent behavior.

1. 1
   Air bags

   Air bag warning light / clock spring

   • 58 complaints (24%)
   • median 50,000 mi at 4.5 yrs old (41 state mileage)
   • 7 mention a crash, fire or injury
   • filed 2002–2016

   Owners describe the air bag readiness light coming on and staying on, or appearing only intermittently. Several say a dealer identified the clock spring as the cause and replaced it, sometimes for a charge outside warranty; others report the light returning after replacement, or that the part was backordered. A few complaints mention the horn or cruise control failing around the same time, and one describes a passenger air bag deploying without an impact. Spread from about 4,000 to 125,000 miles, with many reports in the 30,000-75,000 range; some owners note the light appears mainly in warm weather.

   What to check: With the key on, confirm the air bag light comes on briefly and then goes out; if it stays lit, ask whether the clock spring or sensors have been replaced. Ask for any repair records covering the horn and cruise control as well.

   2 excerpts from owner complaints in NHTSA records

   “The air bag warning light comes on sporadically in the beginning, then it just stayed on as long as the vehicle is running. I took the car to the dealer and they said the clock spring needed to be replaced. It wasn't under the warranty and was informed no recall. I had to pay $301.00 to fix.”

   NHTSA complaint #10232532, filed 2008-06, 55,000 miles

   “I have 2002 Dodge Caravan and have had to replace the airbag sensors for both the passenger and driver bags since the summer of 2005. Each failed at a separate time. I have a service contract on the vehicle (roughly 50,000 miles) but had to pay the deductible.”

   NHTSA complaint #10142687, filed 2005-11, 47,000 miles
2. 2
   Steering

   Steering rack, power steering leaks and noises

   • 46 complaints (19%)
   • median 48,050 mi at 4.0 yrs old (30 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2002–2017

   Complaints describe grease or fluid under the front of the van, difficulty turning one direction, and a whining or growling power steering pump when turning. Some owners were told the rack and pinion had to be replaced at relatively low mileage; others report fluid loss from the power steering hose or cooler line, which one complaint links to a prior hose recall repair. Steering column ticking on tight turns and a steering wheel that sticks at full lock also appear. Mostly reported between about 17,000 and 130,000 miles, with several under 55,000; ticking sounds are noted more on hot days.

   Recall 04V3860001 related service bulletin

   What to check: Look for fluid or grease at the front tires and under the van, listen for pump noise through full turns, and ask whether the power steering cooler hose recall work (04V386000) was completed.

   2 excerpts from owner complaints in NHTSA records

   “I noticed grease on the garage floor near the left front tire. Took to dealer for assessment and learned that I need new rack and pinion steering -- with only 17,000 miles on the 2002 Dodge Caravan! I have been told not to drive the vehicle much in the next two days, and they will replace the r&p steering at that time.what if I hadn't paid close attention to the grease near my tire????”

   NHTSA complaint #10037046, filed 2003-09, 17,500 miles

   “Steering failure. When turning the steering to the far left or right, the steering wheel sticks in that position and releases only after several attempts. In normal straight ahead operation there is a very noticeable noise and coming from the steering apparatus. I believe this to be a dangerous situation. I have contacted chrysler, they opted to do nothing--suggested that I get it repaired.”

   NHTSA complaint #10144112, filed 2005-12, 46,000 miles
3. 3
   Exterior lighting

   Headlights flicker or go out; lighting faults

   • 18 complaints (7%)
   • median 59,000 mi at 3.9 yrs old (13 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2002–2014

   Owners describe headlights flickering or going dark for a few seconds while driving, sometimes in daytime running light mode with one side working and the other not. One owner traced it to a blown fuse after a jump start, another was told the headlight switch was on backorder, and a separate complaint describes tail light lenses coming loose from their bonding. Reported from roughly 14,000 to 98,000 miles, appearing at any time with no clear mileage pattern.

   What to check: Check headlight and tail light operation, look for condensation or loose lenses, and ask whether the headlight switch, fuses or the power control module have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “2002 Dodge Caravan. The headlights on my 2002 Dodge Caravan flash off and on intermittently driving at night. I had this problem since I purchased the vehicle I have not have an accidents there has not been any property damage or police reports taken. The vehicle has the original headlights. I reported this in an earlier complaint but I found the solution to the problem. Each time this has happened to me the obd fuse has been blown. The possible cause to it has been the vehicle was jumped due to a low battery.”

   NHTSA complaint #10176997, filed 2006-12, 40,001 miles

   “7/31/05 consumer products safety commission daimler chrysler motors corporation to whom it may concern: I have a 2002 Dodge grand Caravan se that was designed and built with a dangerous defect. The tail light lenses or covers have been glued on but the glue has failed on both tail lights and both covers have fallen off onto the freeway exposing the bright white light bulbs and dropping a large plastic lens onto the freeway. When the first one fell off my wife stopped on the freeway and picked up the lens. What a great way to get killed. …”

   NHTSA complaint #10131372, filed 2005-08, 98,000 miles
4. 4
   Transmission and drivetrain

   Torque converter and transmission shifting problems

   • 23 complaints (9%)
   • median 53,000 mi at 3.6 yrs old (13 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2002–2014

   Complaints describe the van sticking in second gear or refusing to go above 30 mph, slipping between gears, and locking up at low speed. One owner reports a transmission that rolled backward on a hill and was rebuilt, then went into first-gear-only operation because of a sensor. Dealers replaced transmission control modules or performed transmission work, and in some cases the same fault returned. Reported from about 10,000 to 72,000 miles, with several complaints under 35,000.

   3 related service bulletins

   What to check: Test drive from a cold start through all gears, including a slow-speed shift and a hill start, and ask for service records on transmission fluid changes, sensor replacements or control module programming.

   2 excerpts from owner complaints in NHTSA records

   “Car was bought used form kia deal 7/1/2003 a little under 2 yrs left on warranty have done regular maint. Per mfg spec. Went on vacation to main 5/12/05 came back 5/21/05 and found transmission fuild on garage floor. Went to I went to mech (pep boys) because thougth when I had transmission flush per Dodge spec that someting wasnt right. Mech said that it wasn't anything thay had done and that thay coundnt fix it I had to go to Dodge it was a spec. Valve that was leaking and thay need tools that thay didn't have. …”

   NHTSA complaint #10122273, filed 2005-05, 35,851 miles

   “My transmission failed thanksgiving day 2006. Van was parked on hill. I placed it in drive and it rolled backwards down the hill. Was able to cautiously drive it to transmission shop. They had to rebuild the unit. The check engine light never came on. After picking it up I had to take it back to the shop because it wouldn't go out of first gear. Shop stated it was due to a sensor problem. A couple of month's later it did the same first gear. Shop replaced the sensor again. Luckily the rebuilt transmission was still under warranty. …”

   NHTSA complaint #10186596, filed 2007-03, 70,800 miles
5. 5
   Brakes

   Brakes sticking or not releasing

   • 13 complaints (5%)
   • median 40,000 mi at 4.4 yrs old (9 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 2003–2017

   Owners report brakes that stay applied after the pedal is released, requiring repeated forward and reverse attempts to free the van, along with a loud noise. Several mention brake drums or rotors running extremely hot and discolored, calipers sticking and repeated rotor and pad replacements. In some cases dealers could not identify a fault and replaced rotors and pads. Mostly reported between about 40,000 and 90,000 miles, occasionally earlier.

   What to check: After a test drive, feel the wheels for uneven heat, check for dragging when rolling slowly, and ask whether calipers, rear brake hardware or drums have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “I heard a banging noise while driving on the highway at 50 MPH. So I called my dealer to schedule an appt for multiple of reasons and they found the following issues again with my car; my front brakes (shoe pades, rotor's turned) needed to be replaced again since I've had this car and the car only has 45,000 miles on it and previous to that, the dealer replaced the shoe pades again at 19,000 miles?? Also at 19,000 miles, the dealer had to replace the bushings and links for the front end and again at 45,000 miles two days ago. …”

   NHTSA complaint #10146342, filed 2005-12, 19,000 miles

   “When applying the brakes it felt as if vehicle ran over something in the road. The rotors were replaced twice since last summer, and vehicle's performance was not changed. .. Had to replace front brake rotors/pads due to brake calipers sticking and not releasing. The two front tires also wore out and needed to be replaced.”

   NHTSA complaint #10115767, filed 2005-03, 39,000 miles

Buying note. Check the air bag light, headlight operation and steering for leaks or noise before buying, and ask for receipts showing whether the power steering hose recall and any clock spring or transmission work were done. A pre-purchase inspection that includes a cold-start test drive and a look at the brake and steering components is worthwhile on a van of this age.

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.