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 2005 Chrysler Pacifica owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2005 Chrysler Pacifica. The contact took the vehicle to an independent mechanic and was informed that the sub-frame was corroded. The vehicle was not diagnosed or repaired. A dealer was not contacted. The manufacturer had not been informed of the failure. The failure mileage was 166,544.
Took our 2005 Chrysler Pacifica in for oil change and they informed us that the engine cradle is rotting out and that our engine could fall out and that would result in a bad accident. We called Chrysler and they would do nothing!!! We found out that many other people who own this same car had the same problem on the internet because the Chrysler manufacturer of this car did not coat the frame correctly when it was built. This was chryslers mistake when this car was made and it is no fault of the owners that purchased these cars to have this terrible costly and dangerous problem. This should be under a recall but it is "not" and now it will cost us $3000.00 to have it repaired to make our car safe. We are the original owners of this car and it has always been keep in a garage. There is only 4800 miles on this car and this should never have happened. …
We had our car inspected this week and were told we had a rotted body frame. We were sent to a Dodge dealer and they told us we had a rotted subframe. The cost of repair will be $1885.40 for the part and $600 for labor. It will not be ready to drive till April 6 as the dealer requires the parts money up front before they will even order the part so we have to save the money for this. So we have no car for the next 10 days at least. We have researched and understand that Chrysler knows of this problem and did a limited amount of repairs as it was their fault but apparently they are not helping the majority of car owners who have this problem. This does not seem fair to the other owners. We can barely afford to come up with this money to fix something that is this company's fault. I cannot believe they are not being forced to fix all these cars when it is a danger issue. …
Rust through of engine cradle at various spots on engine cradle. I'm the original owner. The car had 92,080 miles. Contacted Chrysler/FCA via email. Chrysler/FCA says my Pacifica does not fit the narrowly defined manufacture date of 02/28/2004 to 03/31/2004, even though Chrysler form letter csc-10045080-7364 makes no mention of the narrowly defined manufacture date!. My Pacifica was purchased on 1/26/2005 and therefore does not qualify for extended warranty coverage per Chrysler customer assistance. My local FCA dealer gave me an estimate of about $ 2600 to replace. This problem was noticed during a routine oil change recently. I reported this issue to Chrysler back on October 2014 email case #3052329, reference number 25794408, and they state not covered,that my car was apparently built on August 2, 2004 per Chrysler email response? …
I took my vehicle in for inspection and it failed due to the engine cradle being rusted out, the cost of repair is $2500-$4000. I googled "engine cradle rusted out" and the articles that were listed first all pertain to Chrysler Pacifica 2005. I proceeded to call Chrysler about my problem and was told they are not extending warranties to cover the problem but that they would "document" my call. I was also told that if I made any repairs to my vehicle pertaining to this problem that I should keep my receipts. I am a single mother trying to raise 3 teenagers and do not have this kind of money to put into repairing a vehicle that isn't even worth the cost to repair it. Furthermore, Chrysler knows about this problem and has not issued a recall to all Pacifica owners to fix it. They are allowing their customers to drive a vehicle that is extremely unsafe. …
Typical rust through of engine cradle sub frame (k frame) of a Pacifica SUV almost causing the engine to drop through to the ground. Discovered the rust through, and subsequent engine shift, in mid October 2015 @ approximately 144,000 miles, while car was up on a lift. Car was no longer drivable due to this condition. Had a local Chrysler dealership's repair shop to replace the cradle frame and motor mounts shortly thereafter. They disavowed any help or their involvement in getting Chrysler to cover the repair of a known defect. Called Chrysler's customer service and was told my Pacifica was not part of the extended warranty issued for a small number of and short production run of pacificas. Am attempting to again contact Chrysler customer service via letter and ask for help with the cost of repairs. Also trying to join the class action group that is suing Chrysler over this issue. …
During a mechanical evaluation for a clunking noise and possible wheel bearing problem in the front end, the vehicle was raised on a lift for inspection. The engine sub-frame was found to be badly rusted with holes completely through the metal. The clunking noise was suspected to be the rotting sub-frame flexing while steering and acceleration/deceleration. The mechanic declined to make any repairs and I was advised to park the vehicle until the sub-frame could be replaced. I was also advised to call Chrysler since a recall was issued on a portion of these vehicles. My VIN number was not included in the recall, even though it had been manufactured at about the same time, was purchased in western pa and operated in the "salt belt". We've enjoyed owning this car and my wife wanted to retire the car to our home in florida. …
Official Chrysler service repair shop has been doing my oil changes every 3 months - 4 times a year since 2005 when I purchased the car. Not once has their mechanic mentioned the rust of the cross member. I only found out and took pictures this week when I had a local shop change my breaks and do transmission service and they showed me the rust, could not believe that no one ever mentioned this as it was extreme with cracks and holes and that Chrysler is aware of this issue regarding rust on cross member due to them not properly coating the engine cradle. Chrysler has had certain VIN #'s recalled, but claim not mine though build in 2004, I am in a snow belt state ( ny). They don't want to take responsibility. I am afraid to drive car, dangerous and engine can fall out - could cost $4000-5000 to repair front and back - and unfortunately I don't have finances to purchase a new car. …
At the service dealer today I was told that my engine carriage frame is so rusted that it is not safe to drive. The sides are also severely rusted. I bought this car new and have serviced it every 3000 miles. I go through the car wash in the winter alot. I learned that Chrysler was aware of this problem early on. Why was I not notified of this, so my car could have been under coated ( which should have been done as soon as the problem was noticed) and I could still be driving it. I am 71 and on ss, and planned on this being my last car. Now, it can't be fixed and I couldn't with a clear conscience trade or sell it. Wouldn't want a family with kids in the car, going down the road and have the engine fall out. This is a safety issue that needs to be addressed before someone is killed. My car looks like brand new inside and out. I meticulously took care of it. …
Our 2005 Chrysler Pacifica (156,595 miles) passed our annual state inspection, but we needed to travel 1000 miles, so we asked our mechanic to give it a more thorough look just to make sure it could handle a long distance trip. The underside of the engine cradle looked fine, but he happened to feel it move, so he used a camera to inspect the hidden upper side. Good thing he did! The engine cradle was practically rusted through, and the engine could have dropped out if we hit a significant bump. I was shocked to discover that this is a problem that Chrysler knows about, but only recalled a hand-full of cars. This is a disgrace. My family could have died, and many others are at risk for a known problem that is not easily spotted on a routine inspection. Not to mention, we had to pay nearly $3000 for repairs. …
Body complaints in other Pacifica years
Frequently asked questions
How common are body problems on the 2005 Chrysler Pacifica?
NHTSA has 413 complaints about the body & structure of the 2005 Chrysler Pacifica, 33% of the model year's 1,244 complaints. The component named most often is body (219 mentions).
Is there a recall for 2005 Chrysler Pacifica body problems?
No. NHTSA lists no body & structure recall for the 2005 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 2005 Chrysler Pacifica body problems start?
Half of the complaints with a recorded mileage happened before about 116,000 miles, and 2% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 0 fires and 0 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.