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.

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hardly worth mentioning
Crashes / Fires:
0 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
85,302 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 Dodge Grand Caravan engine problems

engine problem

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2004 Dodge Grand Caravan Owner Comments

problem #7

Jun 142014

Grand Caravan

  • 100,000 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. The failure mileage was 100,000.

- Baytown, TX, USA

problem #6

Oct 152009

Grand Caravan

  • 85,000 miles
Periodically, the engine of our 2004 Grand Caravan sputters and dies without warning. Typically this happens right after filling the gas tank. Upon leaving the gas station, the van runs normally for a minute or two, then cuts out all together. Usually this happens just as we are pulling out of the station into traffic. Once the van is re-started, it runs roughly for a minute, then quite normally. This first occurred in late 2009 and happened infrequently for a time. The older the van becomes, the more frequently it happens - now on almost every fill-up. Related to this issue, periodically after starting the van at home, with a nearly full tank of gas, it runs fine for a minute or two, then the engine seems to go into idle and completely fails to respond to the gas pedal. Typically this happens after stopping at a stop sign near home. The engine runs, but there is no acceleration. We drift to the side of the road, brake to a stop, wait a minute (sometimes shift to park), then try the gas pedal again. The van will respond normally at that point and run for the rest of the day without further trouble. (this seems to happen more often when outside temperatures are between 50 and 65 degrees.) we have had the vehicle examined a number of times by several very reputable auto services and none have been able to identify or correct the problem.

- Pasadena, MD, USA

problem #5

Jan 112011

Grand Caravan 6-cyl

  • 111,114 miles
In January 2011, I had to replace the catalytic converter in my vehicle and it has been running fine until now. Last week, my check engine light came on and I made a service appt. With mckinney Dodge in easley SC to get it checked out. I was called today (04/02/2013) and was advised the same part needed to be replaced again. The service department advised the part only had a 12 month warranty. I told him this was unacceptable for a part that was very expensive to only have a 12 month warranty. He provided the Chrysler customer service # (1-800-992-1997). I called them and the lady reviewed the record, and restated they could not assist, as it only had a 12 month warranty. The vehicle mileage is now a little over 156,000. I have put around 45,000 miles on the car since January 2011. I have had this van for years, and how could the original part on the vehicle last for many years, and then a replacement part only last a little over 2 years. I asked had the quality of their vehicle parts gone down from when the original vehicle was made. She had no response, but provided your website and to find out if there were any similar complaints on the catalytic converters on other Chrysler or Dodge vehicles. I told them I would not be purchasing another Chrysler or Dodge product. [xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Greer, SC, USA

problem #4

Dec 192011

Grand Caravan 6-cyl

  • 180,000 miles


After going through water puddles, the car became difficult to steer. The wheel turned but as if the engine was off. The car also hesitates as if the engine will stall.

- Shreveport, LA, USA

problem #3

Jan 192012

Grand Caravan

  • 121,000 miles
The contact owns a 2004 Dodge Grand Caravan. The contact was driving 15 mph when the smell of burned rubber emitted inside of the vehicle and flames were visible from under the hood. In addition, the head lights failed to illuminate intermittently. The vehicle was destroyed and the fire was extinguished. The vehicle was taken to the dealer but not repaired. The cause of the failure was unknown. The manufacturer was not contacted. The vehicle was not repaired and the VIN was unavailable. The failure and the current mileages were 121,000.

- Abington, MA, USA

problem #2

Jun 052011

Grand Caravan

  • miles
The contact owns a 2004 Dodge Grand Caravan. The contact stated that the vehicle would intermittently stall without warning. The vehicle would immediately restart and the contact stated that the failure only seemed to occur when the fuel tank was full. The contact planned to have the vehicle inspected or repaired, if needed. The failure mileage was unknown and the current mileage was 72,000.

- Wayne, PA, USA

problem #1

Mar 012007

Grand Caravan 6-cyl

  • Automatic transmission
  • miles
2004 Dodge Grand Caravan customer has concerns with the timing belt** the crank was undersized on the bearings and the bearings were undersized creating a large gap between the bearings and the crank which was causing the noise knocking noise in the engine. A foreign piece of metal was found under the main bearing cap which caused extra clearance. And the crack was only touching two-thirds of the bearing surface.

- Tucson, AZ, USA

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