Which parts fail
Components named in complaints (air conditioning, heater, defroster, HVAC controls).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1996 Dodge Grand Caravan owners, lightly cleaned up (personal details are redacted by NHTSA).
Body module for 96 Grand Caravan part # 04686930 failed. This module controls body elements: power windows, power locks, A/C, interior features, instruments (odometer specifically) and windshield wipers. Windshield wipers cease to operate upon failure of this module. This can occur at any time, at any place (parked or driving) under any driving conditions (sunshine or hurricane). I see this as a critical design flaw. Functionality of a vital safety component, windshield wipers,is tied to a part that cannot be repaired easily. Accoding to Chrysler customer assistance, the part is not produced any more, it is not stocked. The order will not be filled. The part is not readily repairable. The module must be programmed with vehicle information (features, odometer readings) so the part is not stocked by dealers or distributors. Customers must wait for old part to come in and be reconditioned. …
Since the first week that I owned this car. Whenever I run the air conditioner, the car will stall out. At first, I could restart the car readily. Later, it took several tries to restart it. Now I know that I have to wait several minutes in order to restart it. I must leave the air conditioner off, if I want the car to continue running. I have reported this to the dealer more times than I can count, and they did some engine adjustments which never solved the problem. Apparently there was a TSB on this problem, but no solution has been found. When the air conditioner is running, it doesn't matter whether I'm driving in stop and go traffic or whether I'm at speed. It will happen. So, the way to avoid the problem is not to use the air conditioner. But I bought the car with air conditioning, and I'm entitled to have what I paid for. …
The evaporator coil is prone to premature failure. I work for a company that owns 25 to 30 Dodge caravans af various years and this is a common problem on models built between 1993 and 1999. Also the dealership has admitted to me that they have repaired 100's of vehicles (Chrysler/Dodge/Plymouth) with this type of problem. Daimler Chrysler's customer assistance hot line offered no help what so ever. When the refrigerant (r134a) leaks, it enters the passenger compartment and can be toxic if combusted, not to mention not a good thing to breath non-combusted.
Air conditioning-dealer replaced compresser,condensor and evaporator, we purchased van in March and A/C never worked when the weather warmed up. Fuel pump failed and had to be replaced at a cost of $450. Tires went next at a cost of $350 for two front tires. Transmission is slipping and won't shift consistantly. Will cost $1500-$1800 to replace on a two year old van with 45000 miles.( dot number: m30d tire size: 21565r16 )
Replacement of ac compressor & evaporator cost $1450; engine head was replaced free even though warranty had expired(spent $870 on maint and repairs of which $300 was to replace spark plug wires and resistor pack that was said to cause check engine light. Head was actually casuing problem); fan relay repaired under warranty; Firestone said water pump frozed and caused belt to break ($300 repair).
Air conditionercondenser/driver side window regulator/tie rod, transmission shift cable, and o2 sensor were replaced. Also, there was a noise coming from front of vehicle, and from the exhaust area. Engine check light appeared. In addition, serpentine belt and water pump were replaced.
Air conditioner blows out hot air. Consumer purchased vehicle in March and there was no reason to turn it on. On inspection list air conditioner was checked as working. Consumer lives in a hot climate, and air conditioner is very much needed. Dealer couldn't determine the problem.
Intermittently windshield wipers become inoperable and sometimes come on by themselves, obstructing view of driver. Vehicle at dealer's for repair. O2 sensor, ignition switch, key cylinder, and A/C blower resistor and wiring kit all replaced.
We had to replace the A/C compressor, high pressure switch, expansion valve and receiver/driver to repair leaks due to premature wearout. This cost us $1240.00. Chrysler has had problems with this A/C system breaking down prematurely.
At the start up of the van, the compressor pulley was locked up to the point that it would not turn and the belt was rubbing on the pulley causing large amount or smoke. Cost to repair was more than $3,000.00.
AC & Heater complaints in other Grand Caravan years
Frequently asked questions
How common are ac & heater problems on the 1996 Dodge Grand Caravan?
NHTSA has 26 complaints about the a/c & heater of the 1996 Dodge Grand Caravan, 2% of the model year's 1,157 complaints. The component named most often is appliance › air conditioner (24 mentions).
Is there a recall for 1996 Dodge Grand Caravan ac & heater problems?
No. NHTSA lists no a/c & heater recall for the 1996 Dodge Grand Caravan, though it has 9 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 1996 Dodge Grand Caravan ac & heater problems start?
Half of the complaints with a recorded mileage happened before about 109,000 miles, and 50% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to a/c & heater 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.