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 1996 Dodge Grand Caravan owners, lightly cleaned up (personal details are redacted by NHTSA).
On 12/5/2002, my husband & I were sitting at a red light in our 1996 Dodge Grand Caravan when we were rear-ended by a Ford taurus. Being lower to the ground than the Caravan, the taurus hit the dealer installed tow bar causing the frame to buckle above both axles & minimal damage to the body of the van. The case for recovery of medical bills & wages lost is now coming up & we found out that they are claiming that we were hit between 8-10 MPH. I talked with someone in your legal department & she told me to see if Chrysler could give me info on the strength of that frame & if not, to file a complaint. We heard back from Chrysler this morning & they said that they couldn't help us.
Purchased tire "as new" from grave's tire in carthage, tx. Come to find it was 6 yrs old when purchased and dry rotted as it blew in 2 months time of being on the vehicle. Tire shop owner (leo graves) says he isn't honoring his 60,000 mile/1 yr warranty, this happened to another customer of his and as far as he is concerned, we both hit something in the road. ...updated 10/15/15 updated 11/30/2017
1996 Dodge Grand Caravan corrosion perforation condition at the top of the strut tower. The front driver side strut tower rusted. I am very concerned that the front end will collapse while driving. Driver's side strut tower completely rusted away. Making vehicle unsafe to be on the road. Someone is going to get hurt or killed if they don't recall these and fix them. Apparently Chrysler wants to be named after someone else once someone gets killed and then they sue Chrysler and win for Chrysler being careless and cheap when building a vehicle. …
My 1996 Dodge Grand Caravan has a left front strut tower that is cracked around the top where the spring sits. There isn't a spot of rust or structural damage on this vehicle except that strut tower. From my discussion with a Chrysler body shop manager, it appears that they had a problem with these strut towers. I think this is a safety risk because if one of these lets go at highway speed, it will immediately impact steering and driveability potentially leading to a crash. I know my way around a car so I was able to spot this problem and recognize the potential danger. I think with most drivers this problem will go unrecognized and that is why I am writing you today. Please get the word out. I called chryster and registered a complaint, but I don't expect them to inform anyone.
96 Grand Caravan strut mount rust couldn't pass inspection and they said my kids could have died if I had a accident. This should be a major recall. The government involves in every aspect of our lives to keep our children safe until it makes corporation pay money to fix a known problem let see what you guys do with this. Sorry im upset just seems extremely dangerous and as I read on the internet tons of people with this problem and Chrysler knows about it caused I called the to and said if I had a issue to write to you guys but most likely nothing will be done. That is a quote from a Chrysler customer service rep.
The strut mounts thoroughly rusted and separated from the body which then caused a driving hazard. Several mechanics have stated that this has been a most common occurrence among the chrsyler/Dodge Mini-vans of 1996. Chrysler will not extend good will or assistance even though the fault lies with them in its poor design that was soon after revamped. What is really distressing is that Chrysler raised the cost of the strut mounts recently, which are dealer parts only, by about 84% as they realize more and more consumers need to make this expensive repair.
We took our 1996 Grand Caravan in for recalls that Dodge sent us. They called my wife back and told her it was condemnable and unsafe to drive, because the strut tower was very badly rusted. By the time I had the chance to call them, because I was at work, the person she talked to had left, however I did talk to another person acquainted with the vehicle. He said because of the mileage and that I wasn't the original owner Dodge wouldn't do anything for us. He also said it would cost $2000.00 per side to fix and the van wasn't worth it. I said this is a serious thing and it should be fixed by Chrysler because they obviously used inferior materials on that part of the van. He said that they would not fix it, and the weather where we live had something to do with it. I said so I am just out of a vehicle to drive?, and he said you can drive it but it's not safe. …
Serpentine belt or tensioner clip has had to be repaired 4 times (towed every time) electrical problems since the beginning; turn the key and the windshield wipers start going, turn the key off and the wipers "keep" going, take the key totally out of the ignition and the wipers go and the "dinging" alarm that tells you the lights are on or the key is in, starts.(I seriously thought the car was possessed) or turn the key and "nothing" comes on except the engine. I've replaced the battery 5 times at least - it's usually better w/ a new battery for a little while. Have had to have the window motor and assembly replaced on drivers side twice and 5 times on the passenger side. Most recent was 4/04, which was replaced 7/04 again. The side sliding doors on both side do not lock, if you push the button down, you can't get it back up. …
The cup holder in some vehicles is located directly adjacent to the dashboard. When the vehicle stops, beverage splashes onto the dash, in this case into a computer board in the dash through slots in the dash for the heater controls. The result is total failure of the front and rear window defroster, windshield washer and wipers, front and rear heaters, and air conditioning. The lack of ability to clear the front and rear glass constitutes a safety hazard. This particular vehicle is a 1996 Dodge Grand Caravan se [redacted]. Possibly several brands of vehicle have this engineering design problem. The response that I got from Chrysler when I asked about replacement parts is that the warranty is for three years, and after that "tough." their e-mail response is attached. …
Service agent determined/confirmed anti-freeze coolant leak into the passenger side carpet and door sill area. The leak made an offensive odor, fermenting the carpet, and the residual smell/antifreeze fumes appears unhealthy to breath in. The leak was detected by visible substantial wetness of the carpet area about the sill area. Carpet became slightly discolored/stained by the anti-freeze leak. The actual location of the leak could not be detected without the complete disassembly of the rear interior trim. A quote of over $230 in materials and $430 in labor was given to repair the leaking core. This is an exorbitant amount of cost, and offers a potential unhealthy situation if left unrepaired. The owner cannot foresee expenditure of such magnitude of costs, and must try to seek a less expensive remedy. …
Body complaints in other Grand Caravan years
Frequently asked questions
How common are body problems on the 1996 Dodge Grand Caravan?
NHTSA has 59 complaints about the body & structure of the 1996 Dodge Grand Caravan, 5% of the model year's 1,157 complaints. The component named most often is body › door (48 mentions).
Is there a recall for 1996 Dodge Grand Caravan body problems?
No. NHTSA lists no body & structure 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 body problems start?
Half of the complaints with a recorded mileage happened before about 117,000 miles, and 22% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 4 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.