1996 Dodge Grand Caravan Problems

What owners report

Owners of this model year most often describe automatic transmission failures and a persistent airbag/clock-spring problem that leaves the airbag light on and the horn or cruise control dead. Electrical gremlins (wipers running by themselves, sudden loss of power, stalling) and rusted front strut towers are also frequently mentioned, usually on vans well past 80,000 miles.

1. 1
   Transmission and drivetrain

   Transmission failure or harsh shifting

   • 150 complaints (13%)
   • median 90,000 mi at 8.5 yrs old (25 state mileage)
   • owner-quoted repair $1,711 (median of 17 quotes)
   • filed 1997–2007

   Complaints describe automatic transmissions that stop shifting, slip, stick in a gear or hit limp-home mode, sometimes with a pinhole worn through the case and fluid loss. Several owners report the transmission was replaced or rebuilt, in some cases more than once, and that shops attributed the failures to a known weakness in these vans. Costs cited are typically in the range of a rebuilt unit. Reported from roughly 35,000 to 170,000 miles, with several failures noted well under 100,000 miles and repeat failures shortly after a rebuild.

   1 related service bulletin

   What to check: Ask for service records of any transmission rebuild or replacement and its date and mileage, and test drive at highway speed to feel for slipping, delayed engagement or harsh 2-3 shifts.

   2 excerpts from owner complaints in NHTSA records

   “I bought a 1996 Dodge Grand Caravan 3 years ago. This past july I had to take a loan out to pay $2000 for a transmission. After speaking to quite a few mechanics, I was told that the dodges that have the 3.3 liter engines in them have trouble with the transmissions. The mechanics stated that have had a lot of dodges that they have to replace the transmission in and the Dodge is aware of this problem and has done nothing about it. …”

   NHTSA complaint #10093085, filed 2004-09, 115,450 miles

   “Automatic transmission broke for the third time in just 30,000 miles, this time my wife and 4 kids were nearly killed on a busy interstate because we were almost hit . This vehicle is a 1996 Dodge Grand Caravan.”

   NHTSA complaint #10177453, filed 2007-01, 126,000 miles
2. 2
   Electrical system

   Erratic wipers and electrical dropouts

   • 286 complaints (25%)
   • median 95,000 mi at 8.3 yrs old (26 state mileage)
   • 8 mention a crash, fire or injury
   • owner-quoted repair $537 (median of 12 quotes)
   • filed 1996–2012

   Complaints describe windshield wipers that turn on by themselves or cannot be switched off, along with instrument displays, power windows or locks failing, and occasional sudden loss of power or stalling while driving. Owners say dealers replaced sensors, relays or the body control module, sometimes repeatedly, without a lasting fix; one notes a body module controls the wipers, windows, locks and gauges together. Reported from very low mileage up to about 170,000 miles; several owners describe repeat visits over months or years.

   1 related service bulletin

   What to check: Cycle the wipers through all speeds and the intermittent setting, check that every gauge and window works, and ask whether the body control module or multi-function switch has been replaced.

   2 excerpts from owner complaints in NHTSA records

   “While driving approximately 50 MPH on major highway my 1996 Dodge Grand Caravan shut down, and lost all power. Same thing occurred 1 month later. I was almost involved in a major accident with 4 children aboard. Mechanic has changed 2 relay switches. Do not know if and when it will happen again.”

   NHTSA complaint #10093341, filed 2004-09, 105,500 miles

   “When driving on the highway and going 65 to 70 MPH, the car loses RPM's, backfires, jerks, loses speed. I am unable to give it gas. I have to pull off into the emergency lane and it slows to a stop and stalls. I cannot start it back, however if I set for a few minutes, open and slam the hood, it will start back. My service engine light comes on and the code that was found said that a misfire was found in cylinder 6. It has happened since fixing that problem, but the service engine light went off. …”

   NHTSA complaint #10062547, filed 2004-03, 120,000 miles
3. 3
   Electrical system

   Rusted front strut towers

   Mentioned in 10 of 60 sampled complaints

   Owners report corrosion, cracking or separation of the front strut towers, often found at inspection or when suspension or brake work was attempted. Complaints say shops refused some repairs because of the rust and that a dealer offered a repair kit; owners describe concern about the spring assembly pushing through the tower. Mostly described on vans with roughly 76,000 to 156,000 miles, discovered during inspection or unrelated service.

   What to check: Look under the hood at both front strut towers for rust-through, cracks or separation, and ask whether a strut tower repair kit has been installed.

   2 excerpts from owner complaints in NHTSA records

   “96 Grand Caravan strut mount rust couldn't pass inspection and they said my kids could have died if I had a accident. This should be a major recall. The government involves in every aspect of our lives to keep our children safe until it makes corporation pay money to fix a known problem let see what you guys do with this. …”

   NHTSA complaint #10275319, filed 2009-06, 120,000 miles

   “My 1996 Dodge Grand Caravan has a left front strut tower that is cracked around the top where the spring sits. There isn't a spot of rust or structural damage on this vehicle except that strut tower. From my discussion with a chrysler body shop manager, it appears that they had a problem with these strut towers. I think this is a safety risk because if one of these lets go at highway speed, it will immediately impact steering and driveability potentially leading to a crash. …”

   NHTSA complaint #10020645, filed 2003-05, 116,552 miles
4. 4
   Air bags

   Airbag light on; horn and cruise control stop working

   • 230 complaints (20%)
   • median 97,675 mi at 7.8 yrs old (18 state mileage)
   • 17 mention a crash, fire or injury
   • owner-quoted repair $500 (median of 11 quotes)
   • filed 1996–2009

   Owners describe the airbag warning light staying on, often together with the horn and cruise control quitting, and a few report airbags that did not deploy in a collision. Complaints say the clock spring assembly in the steering column was diagnosed as the cause and replaced. Some owners note the repair was not covered by warranty or was paid for before the related recall was issued. Appears across a wide mileage range, from roughly 60,000 to over 160,000 miles, often noticed as a light that stays on after starting.

   Recall 02V293000

   What to check: Start the van and confirm the airbag light goes out, then test the horn and cruise control switches; ask whether the clock spring recall (02V293000) was completed.

   2 excerpts from owner complaints in NHTSA records

   “I have a 1996 Dodge Grand Caravan and my airbag light stays on, horn and cruise control has gone out. I have 3 other friends with the same problem and I feel this should be a recall fix if so many other same year vehicles have the same exact problem. I even found a website with many others listed having the same problem. I have recently returned from kuwait in the middle east and when I began driving my van again this problem was identified. This is definitely a safety hazard. …”

   NHTSA complaint #10052359, filed 2004-01, 96,000 miles

   “Clock spring has failed (diagnosed by dealer). This is not covered under extended warranty. I feel that this is a safety issue that should be covered by the dealer. It appears that this is a somewhat common failure. Request that this matter be looked into as the cost of repair is somewhat high at $88.06 for the part and 136.80 for labor. I think that this item is currently under investigation. Thank you for your help. * scc ***dimsii ivoq entry posted after 12/12/02 cut-over to artemis****750168”

   NHTSA complaint #10006451, filed 2001-08, 99,350 miles
5. 5
   Fuel system

   Fuel smell or leak at the tank and fuel rail

   • 138 complaints (12%)
   • median 122,500 mi at 9.5 yrs old (12 state mileage)
   • 8 mention a crash, fire or injury
   • owner-quoted repair $740 (median of 9 quotes)
   • filed 1997–2022

   Complaints describe a gasoline smell after refueling, fuel dripping from the top of the tank when parked on a slope, and in some cases fuel leaking under the hood. Owners report dealers dropping the tank and finding a split at the tank seam, or stating that recall work had already been done; one describes an underhood fire after recall repairs. Typically reported between about 85,000 and 180,000 miles, often noticed after filling the tank or parking on an incline.

   Recall 00V268000Recall 99V216000Recall 96V002000Recall 95V236000

   What to check: Fill the tank fully and check underneath for drips, smell for fuel after parking, and ask for documentation that the fuel-system recalls were performed.

   2 excerpts from owner complaints in NHTSA records

   “Occasional fuel smell from car for many months. After filling and parking car with rear end on up hill incline noticed gas pouring out from under car from top of gas tank. Took to dealer they said all recalls were performed. They dropped tank and informed me the plastic tank was splitting at the seam on top. Not a Dodge problem . My cost to replace $900.00. I think this is a manufacturer defect since I have been informed by several outside mechanics that they have replaced quite a few of these chrysler fuel tanks. …”

   NHTSA complaint #10135283, filed 2005-09, 85,000 miles

   “- the contact's vehicle was taken to the dealer for recall 00v268000 repairs. The dealer told the contact that the recall repairs had already been made on the vehicle per recall requirements. This repair was done on december 11, 2006. On january 2, 2007 after driving approximate 6 miles the driver smelled gas fumes so he drove the vehicle back home. The contact stated that the gas fumes killed 14 of the birds that were housed in his garage. The contact opened the hood and gas was leaking. …”

   NHTSA complaint #10177640, filed 2007-01, 140,000 miles

Buying note. Have any candidate van inspected for transmission condition and front strut tower rust before purchase, and confirm the airbag and fuel-system recall work was completed. Service records showing transmission work and electrical repairs are worth asking for on a vehicle 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.