2004 Dodge Grand Caravan Problems

What owners report

Owners of the 2004 Dodge Grand Caravan most often describe an engine that stumbles, bucks or quits shortly after refueling, and many link it to the fuel tank venting hardware; several say the repair requires replacing the whole tank. Steering (loose feel, leaking rack), short-lived front brakes, sliding-door latch and power-lock faults, and coolant leaks around the engine are the other recurring themes, usually appearing well past 50,000 miles.

1. 1
   Fuel system

   Stalls or stumbles right after refueling

   • 27 complaints (23%)
   • median 100,000 mi at 8.7 yrs old (24 state mileage)
   • filed 2007–2016

   Owners describe the engine bucking, sputtering or dying within a minute or two of leaving the gas station, even when the tank was filled only until the pump shut off. Several say it restarts after a short wait and then runs normally until the next fill-up. Complaints often point to the tank-mounted vent or check valve, and report that dealers either could not duplicate the problem or said the fix is a new fuel tank; a few mention a purge solenoid or fuel pump replacement that did not solve it. Reported from roughly 31,000 to 150,000 miles, with many clustered between 50,000 and 110,000 miles and a few starting soon after low-mileage purchases.

   3 related service bulletins

   What to check: Drive the van immediately after a fill-up, not before, and see whether it hesitates or dies; also ask whether the fuel tank or its vent valve has ever been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Our 2004 Dodge Grand Caravan will stall out driving down the road if you fill the gas tank until the gas pump nozzles stops automatically. The only way to stop this is to replace the gas tank because of a bad valve in the top of the tank in the emissions system. I found this information on line. It has done it several times and we now under fill the tank which is not easy to do.”

   NHTSA complaint #10394063, filed 2011-04, 112,000 miles

   “The 3.8l engine stalls after almost every fuel fill-up and began in early 2010. Within 1-2 miles after a fuel up, the vehicle will buck and sputter and often turn off completely. It gets better after 3-5 miles. It apparently is a known issue with many Dodge owners, not just minivans. I had two 2006 Dodge chargers (r/t and srt8) that both did the same thing. I no longer own the chargers but still have the 2004 caravan. …”

   NHTSA complaint #10513147, filed 2013-05, 100,000 miles
2. 2
   Latches, locks and linkages

   Power sliding doors and locks fail or stick

   • 7 complaints (6%)
   • median 30,000 mi at 3.5 yrs old (7 state mileage, few)
   • filed 2005–2021

   Complaints describe power sliding doors that stop halfway, close only partway, pop ajar while driving, or cannot be opened from the inside, sometimes worse after the van sits in the sun. Owners also report door lock actuators failing so the doors can only be locked or unlocked manually, and a body control module fault where the door lock switch stops working. Dealers are described as replacing latches and motors without resolving the problem, or being unable to identify the failing part. Reported from about 13,000 to 200,000 miles, including several vans under 35,000 miles.

   2 related service bulletins

   What to check: Operate both sliding doors several times with the power buttons and from the inside handles, and confirm the door-ajar warning comes on when a door is not fully latched.

   2 excerpts from owner complaints in NHTSA records

   “3 months after buying my van the drivers door is giving a heavy shock. This LED up to the replacement of the body control mod (bcm). My car was repaired but after 11 months the same problem happened and Dodge will not cover it. The symptoms are as follows the drivers door lock switch does not lock but will unlock all the other switches are fine .”

   NHTSA complaint #10154334, filed 2006-04, 12,000 miles

   “Both of the slider doors are impossible to open from the inside the vehicle. I have to physically get out of the vehicle and open them from the outside. It seems that this happens after the car has been sitting in the sun all day. I brought it to my dealers attention, but all that could be explained is the latch inside must have swelled. I feel that this is a very dangerous problem, because in the event of an accident how are people supposed to open the doors, if needed. …”

   NHTSA complaint #10184065, filed 2007-03, 30,000 miles
3. 3
   Steering

   Loose or leaking steering rack and power steering

   • 8 complaints (7%)
   • median 37,750 mi at 3.5 yrs old (8 state mileage, few)
   • filed 2004–2010

   Complaints describe a loose front end, pulling to one side, or heavy steering, traced by dealers to a worn or leaking rack-and-pinion assembly, sometimes replaced more than once at low mileage. One owner reports the power steering reservoir filter clogging and assist dropping out, worse in cold weather. Dealers are described as replacing the rack, strut bearings or sway bar parts under warranty in some cases and declining repairs in others. Mostly reported under 60,000 miles, several of them within the first 20,000 miles.

   Recall 04V386000

   What to check: Check the power steering fluid level and look for wetness on the rack and cooler hoses, and ask whether the power steering cooler hose recall was performed.

   2 excerpts from owner complaints in NHTSA records

   “The day after I bought my 2004 Dodge Grand Caravan/se it started making funny noises and the steering felt funny. I took it to the dealer and they replaced the rack and pinion system. Since then the vehicle continues to pull to the right and the front tires are wearing fast. I took it back and they did a front end alignment. It is still pulling and I took it somewhere else and they checked the alignment and said it was off. I took it back to the dealer and told them and they said it was not and they did nothing. …”

   NHTSA complaint #10088654, filed 2004-08, 60 miles

   “After approx. 15,000 miles the front suspension and steering felt very loose. I took it to the dealer and was told the front rack and pinion steering system was worn out it was fixed under warranty. I was told by the dealer that chrysler had purchased these parts from 2 sources and one of the suppliers parts were wearing out rapidly. The steering system was replaced. After 3 months and 6,000 miles later the steering system was again worn out and had to be replaced a second time. This is ridiculous for a vehicle that cost over $30,000.”

   NHTSA complaint #10103067, filed 2004-12, 15,000 miles
4. 4
   Brakes

   Front brakes wear quickly, rotors warp

   • 11 complaints (9%)
   • median 54,655 mi at 3.2 yrs old (9 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 2004–2014

   Owners report front pads wearing out in short intervals, sometimes metal to metal within about 7,000 miles, along with warped rotors that are resurfaced or replaced repeatedly. Symptoms include squealing, grabbing when the pedal is released, brake dust and a shaking front end under braking. One complaint describes a master cylinder failure in the rear brake circuit that led to a collision, and another describes the pedal going to the floor. Reported from near-new mileage up to about 158,000 miles, with several repeat repairs logged between 39,000 and 55,000 miles.

   What to check: Have the front rotors checked for runout and the pads measured, and ask for service records showing how often brakes and rotors were replaced.

   2 excerpts from owner complaints in NHTSA records

   “The brakes have been sqeaking and when I let off of them they feel like they are grabbing. There is also lots of brakes dust on my front rims. This has been since I bought the car 3/15/04. The service department at the dealers said the brake noise is normal. They checked the brakes on 3/17 and said they were fine. I took the vehicle back 8/17 because of the front end pulling and asked that they check my brakes again. The rotors were warped so they turned the front rotors . …”

   NHTSA complaint #10088662, filed 2004-08, 15 miles

   “My front brakes have to be changed every three months , my van will stall or act like its going to stall I have to give it gas and after I move for a few it stops, my van is constantly out of line which wears on the tires ,the metal coolant lines that go for the rear heat was rusted and corroded badly causing a huge leak , also the transmission cooler bracket locates in front of radiator broke causing a hole in the radiator, this has not only happened in my 2004 Grand Caravan but also in my elderly parents 2004 caravan. …”

   NHTSA complaint #10620733, filed 2014-08, 158,000 miles
5. 5
   Engine cooling

   Coolant leaks and overheating

   Mentioned in 4 of 60 sampled complaints

   Owners describe the temperature gauge climbing toward the red, coolant loss from rusted metal lines running to the rear heater, and a transmission cooler bracket rubbing a hole in the radiator. Some report plastic debris found in the cooling system after thermostat work. Repairs described include replacing the corroded lines, the radiator and the thermostat. Mostly reported between about 75,000 and 213,000 miles, often on vans used in areas where road salt is common.

   What to check: Look for crusty or wet rear heater lines underneath, check the coolant level and condition, and watch the temperature gauge during a test drive.

   2 excerpts from owner complaints in NHTSA records

   “1. Metal coolant lines going to rear heater failed ,massive corrosion where the heater hose attaches to the pipe completely rotted/rusted out, the vehicle had 75k miles on it. 2. If the coolant level gets too low of course my engine will overheat and seize. 3. The steel pipes need to be replaced for aluminum pipes or corrosion protection from the factory that's needed to withstand harsh climes, especially ones where salt is used to deice roadways.”

   NHTSA complaint #10318434, filed 2010-03, 75,000 miles

   “The contact owns a 2004 Dodge Grand Caravan. While driving 45 MPH, the temperature gauge on the instrument panel started going to the red side; indicating that the vehicle was having trouble regulating the engine cooling system. The contact also stated that there was a strong odor of fuel entering the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel pump and carbon filter needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. …”

   NHTSA complaint #10731299, filed 2015-06, 100,000 miles

Buying note. Test the van right after a fuel fill-up and check the steering, brakes, sliding doors and rear heater lines before buying, since these are the areas owners write about most. Service records showing brake, rack and cooling-system work are worth asking for.

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.