2004 Dodge Caravan Problems

What owners report

Complaints from owners of the 2004 Dodge Caravan center on a post-refueling stall and hesitation pattern, along with assorted brake, steering and electrical faults. Reports are spread across the model's life rather than clustered in the first years, and many are filed at high mileage, so a buyer should expect wear-related repairs on top of the fuel-fill behavior.

1. 1
   Fuel system

   Stall or hesitation right after filling the fuel tank

   • 13 complaints (20%)
   • median 74,000 mi at 7.5 yrs old (12 state mileage)
   • filed 2010–2017

   Owners describe the engine stumbling, hesitating or quitting within the first few minutes or miles after refueling, then running normally again. Several say it has happened repeatedly for months or years, with some noting a service department could not find a stored code, and one describing a repair involving the fuel tank's liquid/vapor separator valve. A bulletin in the input describes replacing the fuel tank and vapor canister for an engine stumble or stall immediately after filling, under an extended warranty. Reported from roughly 35,000 to about 145,000 miles, in some cases recurring for years after the first occurrence.

   5 related service bulletins

   What to check: Ask the seller whether the van has ever stalled after refueling and whether the fuel tank/vapor canister work under the extended warranty was done. After a test-drive fill-up, drive a few miles and watch for hesitation.

   2 excerpts from owner complaints in NHTSA records

   “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. …”

   NHTSA complaint #10638401, filed 2014-09, 73,000 miles

   “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.”

   NHTSA complaint #10695523, filed 2015-03, 118,000 miles
2. 2
   Brakes

   Rear brakes rusted or dragging, front brakes overheating

   • 8 complaints (12%)
   • median 32,850 mi at 3.0 yrs old (6 state mileage, few)
   • 3 mention a crash, fire or injury
   • filed 2004–2013

   Owners describe rear drum brakes rusted internally, wheels that will not turn in cold weather, and front brakes that drag or lock with smoke and heat from the wheel wells. Several say the dealer found nothing abnormal or only sanded surfaces, and others had a master cylinder or ABS unit replaced without a lasting cure. A bulletin in the input addresses snow and water getting into the rear brake drum. Reported from very low mileage up to about 100,000 miles, with several cases tied to cold or wet weather.

   3 related service bulletins

   What to check: Have the rear drums pulled and inspected for rust and seized hardware, and check front pads and rotors for uneven wear or heat damage; ask whether the master cylinder or ABS unit has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “2004 Dodge Caravan sxt, both rear brakes are all rusty inside. Springs, backing plate,brake shoes, drums, adjusters every thing is rusty. I called my dealer and told them and he said that all they do is sand the surface of the brake pad and put them back together. Well today it's 25 deg outside and both wheels are froze up. The van will not move, both back wheels just slide. When I drive the van I can tell that the back brakes are not working because the van will nose dive when I put the brakes on.”

   NHTSA complaint #10142843, filed 2005-11, 10,000 miles

   “While driving in city traffic, I felt sluggish acceleration from a stop light. The next stop light the brakes felt hard, and again acceleration was slow. After a few minutes of driving I smelled my brakes burning and I took the car in to the closest repair shop. Smoke was pouring out of both front wheel wells. Brakes locked, pads and rotors burnt, master cylinder not allowing fluid to return. Master cylinder replaced with front pads and other work. Exact same problem occurred 15 weeks later. Different shop. Replaced ABS unit. …”

   NHTSA complaint #10423137, filed 2011-09, 87,645 miles
3. 3
   Fuel system

   Fuel smell or leak at the fuel pump and lines

   • 5 complaints (8%)
   • median 61,500 mi at 10.0 yrs old (4 state mileage, few)
   • filed 2005–2017

   Complaints describe a gasoline smell around the vehicle, especially after parking or in a closed garage, sometimes traced to seepage at the fuel pump or line connection; one reports a visible spill and a tow. Another describes a leak at the fuel pump attributed to corrosion, and one mentions a fuel gauge that no longer reads below half. Spread from about 38,000 to over 155,000 miles, with no single mileage band standing out.

   What to check: Smell around the rear of the van and under the hood after it sits, and look for staining or dampness at the fuel pump area and lines; ask whether the pump or lines have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “My family began noticing a gas smell several months ago. It was more noticeable when exiting the vehicle and when in a closed garage. At first I thought it might be from some gas spill on fueling. I did not see any leaks on the ground or in the engine area. I just had the van serviced at the dealer and was told there was a gas leak. Upon closer inspection it appears there is a very slow leak (seepage) coming at the connection off the fuel pump and fuel line. This looks like a twist-off connection. …”

   NHTSA complaint #10499573, filed 2013-02, 51,000 miles

   “Consumer smelled gas, the passenger became ill. Consumer parked the vehicle and a passerby told the consumer not to start the vehicle because, gas was all over the street. The vehicle was towed.”

   NHTSA complaint #10117845, filed 2005-04, 38,200 miles
4. 4
   Steering

   Power steering hose leak and whine

   Mentioned in 4 of 60 sampled complaints

   Complaints describe power steering fluid leaks, a whine or vibration felt through the steering wheel especially in cold weather, and one case of a pressure hose replaced twice in three years. A dealer reportedly called the hose repair a frequent job. A recall in the input covers an upper power steering cooler hose that may split on vans with the 3.3 or 3.8L V-6. Reported from very low mileage up to roughly 120,000 miles, with some noise complaints more noticeable in cold weather.

   Recall 04V3860002 related service bulletins

   What to check: Check the power steering fluid level and look for oil residue on the cooler hose and lines, and confirm with a dealer whether recall 04V386000 was completed for this van. Listen for whine while turning the wheel when cold.

   2 excerpts from owner complaints in NHTSA records

   “2004 Dodge Caravan sxt. ' whine' noise and high frequency vibration in the steering wheel. Noise is most noticeable in cold weather and when wheel is turned right or left. Vehicle has 54 thousand miles now. Dealer did a factory bulletin on this issue at about 30 thousand, did not fix problem and resulted in the smell of fluid/chemical in the passenger compartment that was very slow to go away. Disgusting !”

   NHTSA complaint #10259411, filed 2009-02, 32,000 miles

   “Power steering pressure hose leaking - replaced two times in three years - no recall on this item, advised by dealer that this is a frequent repair and is serious.”

   NHTSA complaint #10390390, filed 2011-03, 120,088 miles
5. 5
   Air bags

   Airbag light on from a failing clockspring

   • 6 complaints (9%)
   • median 37,000 mi at 5.0 yrs old (5 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2004–2016

   Owners report the airbag warning light staying on, diagnosed as a broken clockspring in the steering column, which also affects horn function; one also describes the horn sounding on its own. Complaints mention the repair was not covered by an extended warranty, and one notes the light flickering as the wheel is turned. Mostly reported from about 35,000 miles upward, including vans well past 100,000 miles.

   2 related service bulletins

   What to check: Turn the key on and confirm the airbag light goes out, and test the horn and steering-wheel buttons; ask whether the clockspring has been replaced and whether the horn has ever sounded unexpectedly.

   2 excerpts from owner complaints in NHTSA records

   “I own a 2004 Dodge Caravan. The airbag light illuminated two days ago. Brought it to the chrysler dealer for repair. The dealer diagnosed the problem as a broken airbag clockspring which is housed inside the steering column and also not covered under the extended warranty that I purchased at time I bought the car new at the dealer. This item controls the proper airbag and horn function and should not break under normal driving conditions. I was charged 450.00 for this repair. …”

   NHTSA complaint #10245726, filed 2008-10, 35,000 miles

   “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, filed 2015-11, 240,000 miles

Buying note. Check the fuel system carefully, including a fill-up test drive and a look for fuel smells, and confirm whether the fuel tank and vapor canister bulletin and the power steering hose recall were handled. Budget for brake and steering wear items, and verify the airbag light and horn work before purchase.

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.