Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Chrysler Pacifica owners, lightly cleaned up (personal details are redacted by NHTSA).
Subframe/Engine Cradle failed due to rust. Subframe is available for inspection upon request. My safety or the safety of others is put at risk due to the failed (rusted, corroded, rotted) subframe/engine cradle. Vehicle's engine is at risk of falling through the vehicle's frame at any moment whether the vehicle is parked or being driven. This problem has been reproduced or confirmed by a dealer or independent service center. The vehicle and the subframe component has been inspected by a Master ASE Certified Mechanic. No symptoms of the problem prior to the failure that owner has ever been made aware of.
Took a short drive. Turned off the vehicle. After a couple minutes smoke and flames were coming out of the hood. Grabbed a fire extinguisher opened the hood and put out the fire on the passenger side. The air filter housing was melted.embers were still spreading along the insulation attached to the hood. Manually removed the spreading embers with some tools. Not sure the cause. Also why is the insulation made of a material that is not fireproof?
Was looking underneath my 2004 Chrysler Pacifica and noticed a hole in the engine cradle (sub frame). Took vehicle to my local Chrysler service department for evaluation of engine cradle. Service manager stated after evaluation of vehicle that engine cradle has a perforation (hole) in it. This is a safety issue because engine cradle could break while driving and cause an accident.. He looked up service bulletin number 13-001-12 . The service bulletin states Chrysler will fix vehicles built between February 23, 2004 through March 31, 2004. When service manager looked up build date for my vehicle, it was built on February 16, 2004. Since my vehicle was built 6 days before February 23 he could not fix vehicle under warranty. He advised me to call Chrysler customer service. I did so on May 29,2015. They refused to fix it under warranty because it was built 6 days before febraury 23. …
We took our very well maintained 2004 Chrysler Pacifica into the mechanic to replace the shocks (thinking that might be the cluncking noise we heard) and he called us and told us the car's engine frame was completely rotted out and the car was horribly unsafe to drive and didn't want us to even drive it home. He told us the frame replacement would be in the range of $4,000 to $5,000. Our car was in otherwise perfect condition and perfectly maintained (I have the records to prove it). My husband called Chrysler to complain about the situation and was basically told to take a hike by a customer service rep there named "leah" and wouldn't put us in contact with any superiors, etc. No notice from Chrysler about this horrible/deadly issues whatsoever. I've been driving our child around in this car with all of his friends, on the highways all around chicagoland. …
In April 2016 I had the brakes replaced on my car, while at the repair shop they noticed the engine cradle was rusted. I was told that the motor could fall out but the repair should be covered by Chrysler. I called the dealer and was told it was not covered, I continued to look online and found a number to call for recalls. I called on July 1st and was told it was built 3 days out of warranty but he would see what he could do and would call me back. On July 6th after I made numerous phone calls I was told they are unwilling to help me. I asked to speak to a supervisor but was told they couldn't transfer calls but one will call be back. I still have not received a phone call nor do I expect any help from them. I do question how they can put a time limit on a warranty when they failed to undercoat my car properly even if it was 3 days out of their time frame. …
I have Chrysler Pacifica 2004. Have taken good care of vehicle, no accidents. Vehicle began shaking violently when driving down road. I have brand new tires . Had them rebalanced couple of times . Still vibrating violently. My mechanic could not find any problems except that engine cradle for engine is badly rotted out with rust. I looked on line for problem and see that Chrysler had not properly coated the engine cradle and has LED to frequent problems and dangerous driving conditions, due that the engine could fall out of vehicle. This is of no fault to owner. I didnt feel safe driving a vehicle that the motor could fall out of. This is a safety issue that Chrysler should be responsible for. …
Vehicle was taken to service. Shop would not work on vehicle stating the deterioration of the subframe was to extensive and they would not work on it. Upon closer inspection showed the frame in a great state of decay, with some places only being held together with thin strips of metal. These vehicles were recalled in the past for defective frames however not all were recalled and this is one vehicle that was not. The motor in these vehicles will fall out and could cause an accident which could result in serious injury or loss of life. These frames are defective in workmanship from the factory and should be handled by the factory across all 2004-2008 Chrysler Pacifica's affected by defective equipment knowingly installed by the factory that will lead to an accident and cause serious injury or death. …
Upon inspection for noise related to the front struts, I notice that the engine cradle, leading edge was rusted almost completely away. I parked the vehicle and looked on "https://vinrcl.safercar.gov/VIN/vinlookup" website and entered the VIN ([redacted]), but didn't find a recall notice. I have had no fewer than 4 individuals who previously owned a 1994 Pacifica tell me that there was a recall and that the dealer fixed the problem by replacing the cradle with a new one. Can anyone help me? I am hesitant to drive the vehicle in its current condition and have been advised by 2 mechanics not to. I bought the vehicle used in 2008 and drove it for almost 5 years, but it's been parked since 2013. Looking for advice on preserving my $13,000 investment. I was expecting to get 200,000 miles out of this vehicle. It has ~115,000.
Does the nhs care about all the complaints on the Chrysler Pacifica to have the million dollar company pay to fix this family car right or recall the car in general. I called the company and because where my car was manufactured its not entitled to replacement because it shouldn't have rusted subframes which is totally inaccurate my car has had nothing but issues is a 2004 and I'm not the only one my neighbor has a 2006 Chrysler Pacifica and its subframe is rotted out are we going to sit back and let them not take responsibility do we know what it means when the some subframe is rotted that means if you are unaware of this you can be driving down the road with your kids in the back of the car in your engine drops out of your car which could cause serious serious serious accidents is this what we want.their only answer was to contact the national highway transportation safety …
Took our 2004 Pacifica in today for an alignment to fix the shaking when the car is driven on the highway and was told that an alignment would be a waste of money due to the rusted out frame under the car. Hadn't heard a single word about this issue until today. We've had this car since 2005, bought with 12, 000 miles on it and now it has 85, 000. Still not bad for a car that is 11 years old and the body and interior are in very good shape. Now what to do?!!! Thank you Firestone for being honest and not charging us for your time. (can I mention that the car has been in for repairs about a year ago for another issue to a Chrysler dealership and not a word was spoken about this!!!) the engine mounts, k-frame is badly rusted to the point the suspension is out of alignment and cannot be adjusted. The car is unsafe to drive.
Body complaints in other Pacifica years
Frequently asked questions
How common are body problems on the 2004 Chrysler Pacifica?
NHTSA has 323 complaints about the body & structure of the 2004 Chrysler Pacifica, 36% of the model year's 896 complaints. The component named most often is body (129 mentions).
Is there a recall for 2004 Chrysler Pacifica body problems?
No. NHTSA lists no body & structure recall for the 2004 Chrysler Pacifica, though it has 2 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Chrysler Pacifica body problems start?
Half of the complaints with a recorded mileage happened before about 110,000 miles, and 2% before 25,000 miles.
Is it dangerous?
Owners linked 3 crashes, 1 fire and 6 injuries to body & structure problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.