Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety. Notes: Engine cradle rot is a serious problem in the 2004-05 Chrysler Pacifica. Chrysler admits they didn't apply enough coating to the vehicle's sub-frame during assembly, but only offered to cover a very small portion of the vehicles they messed up.

So what happens when your engine cradle rots? Well, the engine could fall out for starters. It could also cause problems with the suspension and other components but did I mention THE ENGINE CAN FALL OUT? The worst part is you might not know because there's no way to see the problem without getting under the car.

If you have a 2004-05 Pacifica, make sure to have your mechanic inspect your sub-frame for rust and corrosion.


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
81,534 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Chrysler Pacifica body / paint problems

body / paint problem

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2004 Chrysler Pacifica Owner Comments (Page 3 of 4)

« Read the previous 20 complaints

problem #38

Sep 242010


  • 84 miles


The subframe on the passenger side of the vehicle is severely corroded. The subframe structure is close to totally pulling away from the portion that connects to the vehicle at the subframe welds and the vehicle pulls to the right. If this happened at speed, a major accident would occur. The driver's side is fine. My analysis leads me to believe that the air conditioning condensate dripping onto the subframe has caused the corrosion.

- Canton, MI, USA

problem #37

Sep 232010


  • 87,252 miles
Was doing oil change and noticed a hole in sub frame/engine cradle. Previous oil change noticed nothing other than some rust spots on paint. Metal is very thin on the cross member for a subframe that holds engine in place. The sub frame that runs to the front mount and rear mount is much heavier. Seen hundreds of complaints online. This seems to be a design flaw rather than normal wear. If this was to fail it would cause serious injury or death. Oem part is over $3000, can buy from salvage yard but will have same problem.

- New Cumberland, WV, USA

problem #36

Sep 092010


  • 93,000 miles
I bought a used 2004 Pacifica from flagler Chrysler in palm coast, fl and the subframe has rusted through so that it is dangerous for me to drive. I contacted the dealer and they say it's because it's a New York vehicle but the salesman told me it was a Florida vehicle. I grew up in Michigan and never saw a car rust like this!

- Palm Coast, FL, USA

problem #35

Aug 142009


  • 85,000 miles


The contact owns a 2004 Chrysler Pacifica. The contact stated the front sub-frame has rusted out. The vehicle was taken to the dealer for an inspection and they confirmed that the sub frame was rusted. The dealer took pictures and inform the contact not to drive the vehicle because it was unsafe. The dealer stated they will contact the manufacturer to check if there are any warranty for this failure. The manufacturer stated they will pay 50% of the cost of the repairs but the contact would have to pay the other 50%. there are no recalls or warranty. The vehicle was not repaired. The failure mileage was 85,000.

- Morgan Town, WV, USA

problem #34

Aug 062010

Pacifica 6-cyl

  • 86,000 miles
2004 Chrysler Pacifica with 86,000 miles has a rusted out sub-frame and car was deemed unsafe to drive.

- Grayling, MI, USA

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problem #33

Aug 272010


  • 60,000 miles
Front right side of the vehicle Chrysler Pacifica 2004 shook at speeds greater than 50mph. This happened on a Friday night. Took it to Chrysler dealer on Monday morning. Dealership called at 4:45pm that day and told me that the motor mounts had rotted out and the car was dangerous to drive. Preliminary estimate $2,200. Today (Friday) I was told to come and get my vehicle as it was repaired. Cost: In excess of 2,400. Researched on the internet...similar complaints...defect? the service manager said I was lucky to have driven without a safety incident. I will ask for old part when I pick up the car.

- Saline, MI, USA

problem #32

Aug 022010


  • 86,000 miles


I'm just another owner of a 2004 Chrysler Pacifica (86,000miles)with a rusted out sub frame and have just been getting the same run-around and a bunch of sorry's from the company and dealers, someone will have to get hurt or killed before something is done that's the way it works last Chrysler I'll ever buy ever or anyone I can reach out to junk!!!!!!!!!!!!

- Grayling, MI, USA

problem #31

Aug 292010


  • 69,405 miles
The contact owns a 2004 Chrysler Pacifica. The contact stated that he put the vehicle on a ramp and noticed that the sub frame was covered with rust and falling apart. The dealer was contacted and stated that once they received a pictures of the frame that the dealer will look into his case. There were no diagnosis or repairs. The failure and the current mileages were 69405.

- Milford, DE, USA

problem #30

Jul 232010


  • 50,000 miles
I have a 2004 Chrysler Pacifica with 50,000 miles on it and I had it inspected last month 7/23/2010 and found that the front sub frame is rusted out and Chrysler doesnt want to do anything about it. This is a crock of #$*?! this is a safety issue and it needs to be corrected. I have seen there is so many Pacificas with this problem what is it going to take for them to fix it. Maybe accidents or even death this is pretty bad. Im not going to stop here because I have 5 children and this is not a safe car.

- York, PA, USA

problem #29

Aug 022010


  • Automatic transmission
  • 80,000 miles
The contact owns a 2004 Chrysler Pacifica. The contact was attempting a turn while depressing the brakes when there was an abnormal thump from the front. The vehicle was taken to an authorized dealer where the contact was informed that the welding of the sub frame was fractured and severely rusted. The authorized dealer also speculated that there was a possibility that the engine could fall out from under the vehicle. The vehicle was not repaired. The VIN was not available. The failure and current mileages were 80,000. Updated 11/19/10. The consumer stated when the frame was removed, the steel was very thin and some of the steel had completely rusted away. Updated 11/26/10

- Pickerington, OH, USA

problem #28

Dec 302009


  • 81,499 miles


2004 Chrysler Pacifica sub-frame is completely rusted through on the right side in front. Was told by dealership that the vehicle is unsafe to drive. Chrysler needs to take responsibility of this major issue. I am not the only owner who is experiencing this problem, something is drastically wrong!

- Philadelphia, PA, USA

problem #27

Aug 072010


  • 76,400 miles
The contact owns a 2004 Chrysler Pacifica. The contact stated that the frame (engine cradle) was rusted through which could have caused the engine to fall out. He noticed the rust when he was checking the vehicle himself. The vehicle was taken to an authorized dealership where the vehicle was repaired according to the extended warranty. The contact had not spoken with the manufacturer at the time of the complaint. The current mileage was 76,503. The failure mileage was approximately 76,400.

- South Beloit, IL, USA

problem #26

Jul 122010


  • 85,000 miles
The contact owns a 2004 Chrysler Pacifica. The vehicle was taken to the dealer for routine maintenance when the contact was informed that the passenger side sub-frame was severely rusted and corroded. The dealer provided pictures of the failure to the manufacturer. The contact was awaiting a response from the manufacturer to determine how to proceed with repairs. The vehicle was not repaired. The failure mileage was 85,000.

- Morgan Town, WV, USA

problem #25

Jul 302010


  • 80,000 miles
Front subframe of our Chrysler Pacifica is rusted all the way through car is making a clank noise and is unsafe to drive with 80,000 miles have heard of many many cases of this, the suspension call break off the car or the motor can fall down.

- Pickerington, OH, USA

problem #24

Jun 062010


  • miles
Loud noises heard in the front of our 2004 Chrysler Pacifica. Went to our dealership to have the noise investigated and learned that our subframe had rusted out. The cost to repair would be nearly $3500. Chrysler was contacted, but refused to fix the problem, saying the manufacturers warranty had run out. I am stuck with a car that is unsafe to drive, and no recourse. I know I am not alone, that this is a serious problem for many other 2004 Pacifica owners as well. The subframe of a car that is 6 years old should not be rusted through. My father dabbles in old car restoration, and his 40-50 year old cars do not have the rust issues I have! Chrysler needs to acknowledges this defect, and fix it before someone is seriously hurt.

- Augusta, ME, USA

problem #23

Jul 222010


  • 85,000 miles
Took my 2004 Chrysler Pacifica to the inspection point for inspection and reregistration. The inspector pulled the vehicle over the pit and said we've got a major problem, the front end sub-frame is rusted through and the vehicle is "unsafe to operate". I went into the pit so the inspector could show me the problem and the whole passenger side of the sub-frame beam had rusted through. The inspector stated that the piece held the engine and front end to the vehicle and if it broke I'd lose it all. I took the vehicle to the Chrysler dealer and got the word back this morning that neither Chrysler nor the military exchange new car sales would cover the repairs since the car was almost 6 years old (current mileage: 85600). No sign of damage or rust was reported at the inspection two years ago.

- Apo, AE, USA

problem #22

Jul 052010


  • 85,000 miles
The contact owns a 2004 Chrysler Pacifica. While having a routine oil change performed on the vehicle, the contact was informed that the front sub frame was covered with rust. The vehicle was taken to a local mechanic who stated that the entire sub frame needed to be replaced. Prior to the failure, the contact noticed that when driving over a bump in the road or any uneven road surface at 60 mph, the vehicle would sway back and forth. The vehicle was not repaired. The current and failure mileages were 85,000.

- Syracuse, NY, USA

problem #21

Jun 092010

Pacifica 6-cyl

  • 79,169 miles
Front sub frame of my 2004 Chrysler Pacifica is rusted to the point where safety is an issue.

- Lakeville, MA, USA

problem #20

May 192010

Pacifica 6-cyl

  • 108,000 miles
After bringing my vehicle in for a clunking noise in the front end the mechanic discovered my engine cradle on my 2004 Chrysler Pacifica with 108,000 miles is falling apart and rusting through. I contacted Chrysler and they would not do anything as the vehicle is over their 5 year/100,000 mile warranty. Upon further research I have seen several cases of this same issue in Canada that is being completely fixed by Chrysler. Also there was a case in the United States that was repaired by Chrysler as well. At 6 years old and only 108,000 miles my vehicle can fall apart underneath at any moment and that is unacceptable, especially since this problem is being fixed without question in Canada.

- Gifford, PA, USA

problem #19

Apr 292010

Pacifica 6-cyl

  • 94,550 miles
Flat tire led us to the mechanic only to find the sub-frame/engine cradle was completely rotted through on passenger side. It was also rotted and about to break on driver side.

- Stockholm, NJ, USA

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