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2004 Dodge Caravan

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2004 Dodge Caravan do not stand out strongly from the model-year median of 182.

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How this year compares

Owner complaints by model year

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Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

All reported categories

Tap a category to read its complaints. One report may name several components.

When problems were reported

Mileage at the reported incident

50 reports with mileage · 15 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Fuel/propulsion System. Review the 12 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 8 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Gasoline. Review the 7 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

2 crash reports3 fire reports2 injury reports

What owners actually said

65 reports
101,224 miles · Aug 27, 2013
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 DODGE CARAVAN. THE CONTACT STATED THAT WHILE AT A STOP, THE VEHICLE STALLED AS THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. …

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TL* THE CONTACT OWNS A 2004 DODGE CARAVAN. THE CONTACT STATED THAT WHILE AT A STOP, THE VEHICLE STALLED AS THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 101,224. THE VIN WAS NOT AVAILABLE.

NHTSA ODI #10537545

Mileage unknown · Aug 26, 2013
Service Brakes, HydraulicFire

I REPLACED THE BRAKES ON MY 2004 DODGE CARAVAN WITH DURALAST BRAKES FROM AUTO ZONE. THERE IS A SEVERE PROBLEM WITH THE TOLERANCES ON THE PADS. I HAVE BEEN INSTALLING BRAKES FOR 50 YEARS. THERE IS A SEVER DEFECT WITH THESE REPLACEMENT PARTS. THE PADS WILL NOT ALLOW THE CALIPER TO RETRACT THE PADS WEDGE AGAINST THE ROTOR-DISC. TH…

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I REPLACED THE BRAKES ON MY 2004 DODGE CARAVAN WITH DURALAST BRAKES FROM AUTO ZONE. THERE IS A SEVERE PROBLEM WITH THE TOLERANCES ON THE PADS. I HAVE BEEN INSTALLING BRAKES FOR 50 YEARS. THERE IS A SEVER DEFECT WITH THESE REPLACEMENT PARTS. THE PADS WILL NOT ALLOW THE CALIPER TO RETRACT THE PADS WEDGE AGAINST THE ROTOR-DISC. THEY CAUSED A VEHICLE FIRE FROM THE EXTREME HEAT. I CONTACTED AUTO ZONE AND INSTALLED ANOTHER SET . THIS TIME IT CAUSED THE BRAKE ON THE OPPOSITE SIDE TO OVERHEAT. I GOT A THIRD SET THIS TIME I MEASURED THE PADS WITH A VERNIER CALIPER ACCURATE TO 1/1000 INCH AND THEY VARIED BY A 1/10 OF AN INCH WHICH IS OUTRAGEOUS. THAT JUST ACCOUNTS FOR UNACCEPTABLE MEASUREMENTS AND NOT SPECIAL OR ORIENTATIONAL DEFECTS WHICH I SUSPECT EXIST BUT HAVE NO EXACT PATTERN TO COMPARE. THESE BRAKES ARE AN EXTREME HAZARD. *TR

NHTSA ODI #10537280

108,882 miles · Jul 31, 2013
Wheels

I HAD MY TIRES ROTATED AT COSTCO WHERE THEY WERE PURCHASED IN 2012. IN THE SPRING OF 2013, I WAS GOING TO PUT NEW BRAKES ON THE REAR OF MY 2004 MINIVAN, AND COULD NOT GET TWO OF THE LUG NUTS OFF. SO I JUST PUT IT OFF FOR A WHILE. ON JULY 30, 2013, I WENT OUT TO GET IN MY VAN AND HAD A FLAT TIRE ON THAT SAME WHEEL. I ATTEMPTED TO…

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I HAD MY TIRES ROTATED AT COSTCO WHERE THEY WERE PURCHASED IN 2012. IN THE SPRING OF 2013, I WAS GOING TO PUT NEW BRAKES ON THE REAR OF MY 2004 MINIVAN, AND COULD NOT GET TWO OF THE LUG NUTS OFF. SO I JUST PUT IT OFF FOR A WHILE. ON JULY 30, 2013, I WENT OUT TO GET IN MY VAN AND HAD A FLAT TIRE ON THAT SAME WHEEL. I ATTEMPTED TO REMOVE THE TIRE AND TWO OF THE STUD BOLTS BROKE. I REMOVED THE REST OF THE LUGNUTS AND TOOK THE TIRE TO BE REPAIRED AT COSTCO. ON THE 31ST, I TOOK MY VAN TO AN AUTO REPAIR SHOP AND TOLD THEM OF THE PROBLEM, SO I WANTED THEM TO PUT NEW BRAKES ON AND REPLACE THE WHEEL STUDS. AS THEY WERE DOING THE REPAIR, TWO MORE OF THE STUDS BROKE. THIS IS NOW 4 WHEEL STUDS ON THE SAME WHEEL. NONE OF THE LUG NUTS WERE REMOVABLE FROM THESE BOLTS. I THOUGHT THAT COSTCO HAD OVERTIGHTENED THE LUG NUTS. AFTER LOOKING ONLINE AND SEEING THAT SO MANY PEOPLE HAVE HAD THE SAME PROBLEM, I AM WONDERING IF THE BOLTS ARE DEFECTIVE. IN 50 YEARS OF DRIVING CARS AND REPAIRING A LOT OF THEM MYSELF, I HAVE NEVER HAD A BROKEN WHEEL STUD. I AM THANKFUL THIS DID NOT HAPPEN ON THE ROAD SOMEWHERE IN THE MIDDLE OF NOWHERE. IF THESE BOLTS ARE DEFECTIVE, HOW STRONG ARE THEY WHEN I AM DRIVING AT A HIGH SPEED ON THE FREEWAY. *TR

NHTSA ODI #10532945

165,000 miles · Jul 28, 2013
Electrical SystemExterior Lighting

MYSTERIOUSLY MY HEADLIGHTS STOPPED WORKING LAST NIGHT. HAD TO DRIVE HOME IN THE DARK WHICH WAS VERY DANGEROUS. AS WELL AS MY WINDSHIELD WASHER FLUID PUMP WILL NOT TURN ON. THIS SEEMS TO BE A RECURRING PROBLEM WITH THIS MAKE AND YEAR. WHY HASN'T DODGE DONE A RECALL IT SEEMS TO BE THE PROBLEM IS FAR TOO WIDESPREAD AND COMMON IN TH…

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MYSTERIOUSLY MY HEADLIGHTS STOPPED WORKING LAST NIGHT. HAD TO DRIVE HOME IN THE DARK WHICH WAS VERY DANGEROUS. AS WELL AS MY WINDSHIELD WASHER FLUID PUMP WILL NOT TURN ON. THIS SEEMS TO BE A RECURRING PROBLEM WITH THIS MAKE AND YEAR. WHY HASN'T DODGE DONE A RECALL IT SEEMS TO BE THE PROBLEM IS FAR TOO WIDESPREAD AND COMMON IN THESE VANS. *TR

NHTSA ODI #10532219

38,000 miles · May 14, 2013
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 DODGE CARAVAN. THE CONTACT STATED THAT OVER THE COURSE OF FIVE YEARS, WHENEVER HE FILLED THE FUEL TANK THE VEHICLE WOULD STALL IMMEDIATELY AFTER. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO A DEALER ON THREE DIFFERENT OCCASIONS BUT THE NO CAUSE FOR THE FAILURE WAS DETERMINED. THE VEH…

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TL* THE CONTACT OWNS A 2004 DODGE CARAVAN. THE CONTACT STATED THAT OVER THE COURSE OF FIVE YEARS, WHENEVER HE FILLED THE FUEL TANK THE VEHICLE WOULD STALL IMMEDIATELY AFTER. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO A DEALER ON THREE DIFFERENT OCCASIONS BUT THE NO CAUSE FOR THE FAILURE WAS DETERMINED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 38,000 AND THE CURRENT MILEAGE WAS 91,000.

NHTSA ODI #10511988

51,000 miles · Feb 21, 2013
Fuel System, GasolineFuel/propulsion System

MY FAMILY BEGAN NOTICING A GAS SMELL SEVERAL MONTHS AGO. IT WAS MORE NOTICEABLE WHEN EXITING THE VEHICLE AND WHEN IN A CLOSED GARAGE. AT FIRST I THOUGHT IT MIGHT BE FROM SOME GAS SPILL ON FUELING. I DID NOT SEE ANY LEAKS ON THE GROUND OR IN THE ENGINE AREA. I JUST HAD THE VAN SERVICED AT THE DEALER AND WAS TOLD THERE WAS A GAS…

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MY FAMILY BEGAN NOTICING A GAS SMELL SEVERAL MONTHS AGO. IT WAS MORE NOTICEABLE WHEN EXITING THE VEHICLE AND WHEN IN A CLOSED GARAGE. AT FIRST I THOUGHT IT MIGHT BE FROM SOME GAS SPILL ON FUELING. I DID NOT SEE ANY LEAKS ON THE GROUND OR IN THE ENGINE AREA. I JUST HAD THE VAN SERVICED AT THE DEALER AND WAS TOLD THERE WAS A GAS LEAK. UPON CLOSER INSPECTION IT APPEARS THERE IS A VERY SLOW LEAK (SEEPAGE) COMING AT THE CONNECTION OFF THE FUEL PUMP AND FUEL LINE. THIS LOOKS LIKE A TWIST-OFF CONNECTION. THE DEALER TOLD ME IT WOULD COST $96/HR TO PINPOINT AND DIAGNOSIS THE EXACT PROBLEM. I JUST FOUND ANOTHER PERSON ON THE WEB WITH THE EXACT SAME COMPLAINT. I HAVE NOT YET HAD AN "EXACT DIAGNOSIS" OR REPAIR MADE. *TR UPDATED 03/26/13*LJ THE CONSUMER STATED THE FUEL PUMP WAS INSPECTED AND REPLACED BY A LOCAL DEALER. THEY CONFIRMED THE PUMP WAS LEAKING THROUGH A CRACKED HOUSING. THE GAS TANK WAS STAINED BY THE FUEL LEAKING DOWN UPON IT.

NHTSA ODI #10499573

35,700 miles · Aug 28, 2012
Fuel/propulsion System

WHEN ONE DRIVES AWAY AFTER REFUELING THE GAS TANK THE VEHICLE QUITS RUNNING. IT WILL RESTART. THIS WILL HAPPEN FOR THE FIRST TEN MILES OR SO. OTHER DODGES ARE HAVING THE SAME PROBLEM. *TR

NHTSA ODI #10472793

160,000 miles · Jan 22, 2012
Electrical SystemVisibility

WHEN DRIVING DOWN THE INTERSTATE AT 60MPH THE WINDSHIELD WIPERS TURNED ON ALL BY THEMSELVES AND WOULD NOT SHUT OFF EVEN WHEN WE STOPPED AND TURNED THE VAN CONPLETELY OFF THEY WERE STILL GOING. EVERYTHING WAS POSITIONED ON OFF THERE WAS NO POWER ON IN THE VAN AT ALL. *TR

NHTSA ODI #10444775

87,645 miles · Sep 3, 2011
Service Brakes, Hydraulic

WHILE DRIVING IN CITY TRAFFIC, I FELT SLUGGISH ACCELERATION FROM A STOP LIGHT. THE NEXT STOP LIGHT THE BRAKES FELT HARD, AND AGAIN ACCELERATION WAS SLOW. AFTER A FEW MINUTES OF DRIVING I SMELLED MY BRAKES BURNING AND I TOOK THE CAR IN TO THE CLOSEST REPAIR SHOP. SMOKE WAS POURING OUT OF BOTH FRONT WHEEL WELLS. BRAKES LOCKED, PAD…

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WHILE DRIVING IN CITY TRAFFIC, I FELT SLUGGISH ACCELERATION FROM A STOP LIGHT. THE NEXT STOP LIGHT THE BRAKES FELT HARD, AND AGAIN ACCELERATION WAS SLOW. AFTER A FEW MINUTES OF DRIVING I SMELLED MY BRAKES BURNING AND I TOOK THE CAR IN TO THE CLOSEST REPAIR SHOP. SMOKE WAS POURING OUT OF BOTH FRONT WHEEL WELLS. BRAKES LOCKED, PADS AND ROTORS BURNT, MASTER CYLINDER NOT ALLOWING FLUID TO RETURN. MASTER CYLINDER REPLACED WITH FRONT PADS AND OTHER WORK. EXACT SAME PROBLEM OCCURRED 15 WEEKS LATER. DIFFERENT SHOP. REPLACED ABS UNIT. SAME PROBLEM ENCOUNTERED 8 WEEKS LATER AFTER MINIMAL DRIVING. SHOP FIXED THE PROBLEM, BUT NO WRITE UP BECAUSE HE FIXED FOR FREE. 1 YEAR LATER, SAME PROBLEM. BRAKES LOCKED, BRAKES BURNING, BRAKES SMOKING. IT SITS IN MY DRIVEWAY AS I TRY TO DETERMINE WHAT TO DO ABOUT THIS CAR. *TR

NHTSA ODI #10423137

83,351 miles · Aug 22, 2011
Fuel System, Gasoline

THIS COMPLAINT IS ABOUT ANOTHER 2004 DODGE CARAVAN THAT STALLS AFTER FILLING UP THE TANK. THE PROBLEM IS THAT THE STALLING OCCURS WITHOUT WARNING-I.E. IN THE MIDDLE OF CROSSING AN INTERSECTION OR,SAY, PULLING OUT OF THE GAS STATION INTO TRAFFIC! SPOKE WITH CHRYSLER THIS MORNING ABOUT IT AND THEY SEEM OBLIVIOUS TO THE PROBLEM. …

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THIS COMPLAINT IS ABOUT ANOTHER 2004 DODGE CARAVAN THAT STALLS AFTER FILLING UP THE TANK. THE PROBLEM IS THAT THE STALLING OCCURS WITHOUT WARNING-I.E. IN THE MIDDLE OF CROSSING AN INTERSECTION OR,SAY, PULLING OUT OF THE GAS STATION INTO TRAFFIC! SPOKE WITH CHRYSLER THIS MORNING ABOUT IT AND THEY SEEM OBLIVIOUS TO THE PROBLEM. KIND OF HARD TO BELIEVE SINCE ALL YOU HAVE TO DO IS GOOGLE "CARAVAN STALLS AFTER FILLING UP" AND THERE ARE THOUSANDS OF COMPLAINTS ONLINE. MECHANICS ARE AWARE OF THE PROBLEM BUT THE GENERAL PUBLIC ONLY SEEMS TO BE AWARE AFTER THE OCCURRENCE! PLEASE TAKE SOME TIME TO CHECK INTO THIS BEFORE SOME LITTLE KID GETS HURT. *TR

NHTSA ODI #10420924

Official recalls

1

04V386000 · Steering:hydraulic Power Assist:hose, Piping, And Connections

Aug 5, 2004

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.

Consequence & remedy

Consequence: POWER STEERING FLUID LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN AN UNDER HOOD FIRE.

Remedy: DEALERS WILL REPLACE THE UPPER POWER STEERING COOLER HOSE. THIS RECALL BEGAN ON SEPTEMBER 27, 2004. OWNERS SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

1

DP14002 · Engine Stall After Refueling

Opened Sep 5, 2014 · Closed Apr 6, 2015

Status: closed (inferred from source dates) · Fuel System, Gasoline:storage:tank Assembly

This defect petition evaluates July 7, 2014 allegations from an owner of a model year (MY) 2007 Dodge Grand Caravan minivan that engine stall occurs in these vehicles without warning after refueling.The petitioner's vehicle is a Chrysler RS platform minivan.The RS platform includes MY 2003 through 2007 Dodge Grand Caravan, Dodge Caravan, Chrysler Town and Country and Chrysler Voyager minivans.NHTSA evaluated the petition by analyzing consumer complaints submitted to the Agency, analyzing field data, reviewing technical information provided in Chrysler's response to an Agency information request and testing an RS minivan identified by its owner as experiencing post-refuel engine stalls.After completing this evaluation, NHTSA has concluded that further investigation is unlikely to result in a finding that a defect related to motor vehicle safety exists.The stalls occurring in these vehicles only occur immediately after filling up the fuel tank and happen at low engine speeds. The failure rate is low, even after 8 to 13 years of the vehicles being in service, and there are no reports of crashes or injuries resulting from the stall condition.In the Agency's view, additional investigation is unlikely to result in finding the existence of a safety-related defect in the subject vehicles.Given the need to allocate and prioritize NHTSA's limited resources to best accomplish the Agency's safety mission, the petition is denied.This action does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency will take further action if warranted by future circumstances. More details concerning our review can be found in the Federal Register Notice for this action.The following 161 VOQs are included in the petition evaluation: 10209242, 10229468, 10240708, 10260923, 10275939, 10276532, 10296487, 10298175, 10328669, 10330144, 10346517, 10349789, 10354758, 10363689, 10372112, 10372368, 10372514, 10378031, 10379764, 10382938, 10387448, 10394063, 10398877, 10413918, 10418652, 10420924, 10427063, 10437525, 10445392, 10446902, 10470028, 10471249, 10473733, 10502231, 10503114, 10504260, 10509862, 10511988, 10512120, 10512385, 10512650, 10513147, 10538154, 10549841, 10551763, 10555188, 10555418, 10556754, 10565367, 10574012, 10574398, 10586555, 10587212, 10587559, 10593433, 10607841, 10607913, 10608922, 10615810, 10622468, 10628141, 10632112, 10632128, 10632172, 10632175, 10632231, 10632262, 10632266, 10632270, 10632305, 10632316, 10632326, 10632370, 10632385, 10632399, 10632492, 10632542, 10632765, 10632833, 10632928, 10633197, 10633281, 10633409, 10633421, 10633483, 10633507, 10637752, 10637804, 10637950, 10637975, 10638032, 10638289, 10638290, 10638401, 10638968, 10639218, 10639623, 10641157, 10641603, 10641614, 10641836, 10644339, 10644705, 10649713, 10649895, 10649932, 10650313, 10652590, 10653147, 10653783, 10654533, 10655226, 10658900, 10659679, 10660320, 10662588, 10662645, 10662662, 10663473, 10667056, 10667437, 10668081, 10668094, 10668131, 10668612, 10668969, 10668970, 10669584, 10669678, 10669729, 10669775, 10669866, 10669895, 10669992, 10670422, 10670506, 10676348, 10676732, 10677120, 10679795, 10679934, 10680057, 10680290, 10680342, 10680714, 10681512, 10682584, 10682906, 10683022, 10683114, 10683549, 10683620, 10683697, 10683743, 10689898, 10690761, 10691284, 10691556, 10691751, 10693061, 10694300