Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
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).
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 own a 2004 Chrysler Pacifica with around 117K miles on it. My daughter drives it. While changing the engine oil on it last weekend, I noticed severe corrosion (perforation actually) of the vehicle engine cradle. The passenger side of the cross member is rusted completely through on the bottom and the driver side is about 70% rusted through. As this cross member is what holds the engine in the vehicle and acts as the base of the front suspension, I don't believe this vehicle is safe to drive anymore. Should this structural component fail during highway driving, I believe the vehicle would become unstable and uncontrollable which would be a hazard to the driver, passengers and other motorists. Yes, we live in wisconsin (part of the salt belt), but this amount of corrosion on such a crucial structural component is crazy! …
While in for an oil change I was informed that the engine cradle has rusted through. I was told the same thing last year also. I was informed that now it has rusted through to where it May not be safe to drive since the engine could shift on the rusted engine cradle and cause an accident. Looking online I see that many 2004, 2005 pacificas have this problem and many have been told by Chrysler corp., as I was last year, that my vehicle was not manufactured within the 2 months where they say they had manufacturing problems and had fixed those that they say were defective. Chrysler has repaired many Pacifica engine cradles, according to information online, but only after having an outside investigating agency like a tv station or other entity getting involved. This apparently is a dangerous situation that Chrysler does not want to address with a recall or repair. …
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.
After taking my Pacifica in for service I was notified by the mechanic that my engine cradle has large rust holes in it. I called the customer service number at Chrysler and was told that yes they had an issue with this rusting cradle but only a very narrow range of vehicles were affected. And my mfr date fell outside that date range. How can I have the exact issue that they admit to but refuse to make the repairs because they created an arbitrary date range. I also cannot believe that so many complaints have been lodged and we are being ignored ! Nbc news in chicago did an investigative piece on this issue in 2014 and it is still a very dangerous issue. I refuse to scrap my mint condition Pacifica ! I had heard of a class action suit in ohio and will look into that.
The front subframe known as the "engine cradle" is severely rusting out. This is a known issue by Chrysler on 2004-2005 pacificas. There was an inadequate coating of the metal which leads to premature rusting. In 2010 Chrysler issued an extended warranty for this, but only for cars built in a six week period in 2004. This only covered a small fraction on the cars affected. Chrysler never sent information to owners warning of this or offering suggestions on maintenance of this issue. As a result, thousands of Pacifica owners like myself are left with cars unsafe to drive and unable to sell because of the severity of the issue. The response from Chrysler (fac) when you contact them is "sorry, it is not under warranty".
Sub frame engine cradle rusted to the point the mechanic advised it was not safe to drive any longer. Japanese metal coating issue or Chrysler recall needed? I brought the vehicle in thinking I have a cv shaft going out as it made noise when turning. The mechanic showed me the frame on both side are rusted through and the frame is twisting. The repair would cost more than the worth of the vehicle. We have owned this vehicle since brand new and taken very good care of it. Even the body is rusting badly. Check out the attached news investigation on this issue. Http://www.wfsb.com/story/26363027/problem-pacificas-a-danger-despite-lack-of-recall
Today I went to get a state inspection at the same dealership since I purchased in the vehicle in 2007, went to pick up car and it failed due to the suspension. Mechanic explained that the sub framed had rotted out and it would cost $3500 to repair. Said it would be unsafe to drive car due to that part is what holds the engine up in the car. Looks as if its going to fall straight to the ground. However Chrysler has been having issues with this part so it would be in my best interest to call them. 9/12 called the [phone] recall # no help said no recalls on my recalls. Gave another # [phone] still on hold.
Was driving down the street and heard a load bang when drivers side of car dropped down onto front tire. Car abruptly swerved into lane with approaching traffic. Vehicle stopped against the curb and oncoming traffic stopped in time. We towed vehicle to a friends business for inspecting and it was discovered the engine cradle had rotted out from rust. We called local dealer and was asked for our v.I.n # and was told our car was not part of recall because it was not built within a few weeks window. In searching more information online we found this is a huge issue on these cars. Please advise
Suspension complaints in other Pacifica years
Frequently asked questions
How common are suspension problems on the 2004 Chrysler Pacifica?
NHTSA has 125 complaints about the suspension of the 2004 Chrysler Pacifica, 14% of the model year's 896 complaints. The component named most often is front (5 mentions).
Is there a recall for 2004 Chrysler Pacifica suspension problems?
No. NHTSA lists no suspension 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 suspension problems start?
Half of the complaints with a recorded mileage happened before about 110,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 0 injuries to suspension 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.