Problems owners report
Complaints filed with NHTSA about the 2004 Dodge Grand Caravan, by the system named in each complaint. One complaint can name several.
- Fuel/propulsion system25
- Engine and engine cooling14
- Service brakes, hydraulic14
- Electrical system13
- Steering13
- Fuel system, gasoline11
- Latches/locks/linkages9
- Engine6
- Air bags5
- Structure4
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 2 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 17 2004 Grand Caravan vehicles were involved in crashes on US public roads in which someone died; 12 people died inside them, and 1 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2004 Dodge Grand Caravan failed the safety check 2.08% of the time — 6% less often than the average 2004 passenger car (2.21%). Median odometer at inspection: 150,805 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Fuel consumption
Official Canadian test results for 3 variants: combined 11.9–12.8 L/100 km (about 18–20 mpg US), CO₂ 274–294 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Grand Caravan C/V · Minivan · Regular gasoline | 13.7 | 9.7 | 11.9 |
| Grand Caravan · Minivan · Regular gasoline | 14.5 | 10.1 | 12.5 |
| Grand Caravan · Minivan · Regular gasoline | 14.8 | 10.3 | 12.8 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
2 Transport Canada recalls for the 2004 Dodge Grand Caravan.
| 2019420 21 Aug 2019 | Other Issue: This recall is for aftermarket replacement rear window glass produced by Vitro Automotriz. Certain rear window glass may not have been properly tempere… |
| 2004276 4 Aug 2004 | Steering On certain minivans equipped with a 3.3L or 3.8L engine, the upper power steering cooler hose could split, causing a fluid leak. Power steering fluid leakage i… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
ON CERTAIN MINIVANS EQUIPPED WITH 3.3 OR 3.8L V-6 ENGINE, THE UPPER POWER STEERING COOLER HOSE MAY SPLIT AND CAUSE A FLUID LEAK.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Dodge told its dealers about the 2004 Dodge Grand Caravan: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 10229256 | KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicle, use the "AC" NIC level part and submit a part warranty. |
| 10229181 | Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications. An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine. |
| 10223854 | Service - Four Piece Oil Pan Gasket All Cummins Equipped Vehicles ONLY - The replacement oil pan gasket can be a four piece gasket rather than a single piece gasket. This applies to Cummins 5.9L and 6.7L engines only. Installation: 1. Clean the oil pan T-joints.~ 2. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar Silicone Rubber Adhesive Sealant or equivalent. 3. Apply a 2-mm [0.063-in] bead of Mopar Engine Sealant RTV Silicone Rubber Adhesive, to the oil pan flange.~ 4. The four piece gasket will need to be assembled to make |
| 10223602 | Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications. An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine. |
| 10221686 | KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicle, use the "AC" NIC level part and submit a part warranty. |
| 10220101 | Use of Aftermarket Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of aftermarket parts. |
| 10220099 | Use of Salvage/Recycled Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of recycled or salvage parts. |
| 10220097 | Repair Parts Used For Structural Repairs This bulletin involves discussing FCA US LLC position with regard to structural repair parts usage. |
| 10219763 | Extended Warranty on the Fuel Tank/Vapor Cannister |
| 10209634 | Extended Warranty on the Fuel Tank/Vapor Cannister |
| 10191460 | Valve Body. These may cause over drive cycling. |
| 10189392 | MIL Illumination - DTC P1776 Solenoid Switch Valve Latched in LR Position |
| 10175743 | Disinfectant Solution Recommended for COVID-19 |
| 10175735 | Charging System, Battery Diagnostic Tools and Warranty This information only bulletin discusses using the correct test equipment for testing batteries and charging systems, and also warranty reimbursement when battery replacements are necessary. |
| 10169249 | Use of Aftermarket Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of aftermarket parts. |
| 10169247 | Use of Salvage/Recycled Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry awareness regarding the use of recycled or salvage parts. |
| 10169245 | Repair Parts Used For Structural Repairs This bulletin involves discussing FCA US LLC position with regard to structural repair parts usage. |
| 10129008 | 82212076, 82203694 - Fabric Cleaner This "fabric cleaner" is not intended for sale in California, the otc states (Connecticut, Delaware, Massachusetts, Maine, New Hampshire, New Jersey, New York, Pennsylvania, Virginia, and Washington dc), and some ladco states (Illinois, Michigan, and Ohio). Mopar offers an alternative product (82213192) which is a water based product approved for sale in the aforementioned states.~ ~ Please inform the customer & your prep dept that spraying excessive amounts of the fabric protector on load floors will result in the breaking down of the adhesive (glu |
| 10076430 | (X60) FUEL TANK/VAPOR CANISTER - 2004-2005-TOWN AND COUNTRY (RS) AND CARAVAN/GRAND CARAVAN (RS) |
| 10005354 | POWERTRAIN CONTROL MODULE (PCM) ELECTRICAL CONNECTOR SEAL CUSTOMER SATISFACTION NOTIFICATION NO. C30. *TT |
NHTSA manufacturer communications (public domain)
NHTSA investigations
Engine Stall After Refueling
NHTSA Office of Defects Investigation