Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Dodge Grand Caravan owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owns a 2004 Dodge Grand Caravan. While driving 45 MPH, the temperature gauge on the instrument panel started going to the red side; indicating that the vehicle was having trouble regulating the engine cooling system. The contact also stated that there was a strong odor of fuel entering the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel pump and carbon filter needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 100,000.
Tl* the contact owns a 2004 Dodge Grand Caravan. The contact stated while driving, the vehicle overheated without warning. The failure occurred several times. The contact stated as precaution the vehicle was stopped to allow the engine to cool down. The vehicle was not taken to a dealer nor was the manufactured notified of the failure. The vehicle was not repaired. The failure mileage was 213,000. Consumer stated after changing the thermostat pieces of plastic came out of the motor. Problem with overheating has occured for 4 years.
Tl* the contact owns a 2004 Dodge Grand Caravan. The contact was driving 15 MPH when the smell of burned rubber emitted inside of the vehicle and flames were visible from under the hood. In addition, the head lights failed to illuminate intermittently. The vehicle was destroyed and the fire was extinguished. The vehicle was taken to the dealer but not repaired. The cause of the failure was unknown. The manufacturer was not contacted. The vehicle was not repaired and the VIN was unavailable. The failure and the current mileages were 121,000.
In January 2011, I had to replace the catalytic converter in my vehicle and it has been running fine until now. Last week, my check engine light came on and I made a service appt. With mckinney Dodge in easley sc to get it checked out. I was called today (04/02/2013) and was advised the same part needed to be replaced again. The service department advised the part only had a 12 month warranty. I told him this was unacceptable for a part that was very expensive to only have a 12 month warranty. He provided the Chrysler customer service # ([phone]). I called them and the lady reviewed the record, and restated they could not assist, as it only had a 12 month warranty. The vehicle mileage is now a little over 156,000. I have put around 45,000 miles on the car since January 2011. …
Periodically, the engine of our 2004 Grand Caravan sputters and dies without warning. Typically this happens right after filling the gas tank. Upon leaving the gas station, the van runs normally for a minute or two, then cuts out all together. Usually this happens just as we are pulling out of the station into traffic. Once the van is re-started, it runs roughly for a minute, then quite normally. This first occurred in late 2009 and happened infrequently for a time. The older the van becomes, the more frequently it happens - now on almost every fill-up. Related to this issue, periodically after starting the van at home, with a nearly full tank of gas, it runs fine for a minute or two, then the engine seems to go into idle and completely fails to respond to the gas pedal. Typically this happens after stopping at a stop sign near home. The engine runs, but there is no acceleration. …
Since this date, after every fill up, the car will hesitate, backfire, and in many cases die. The car can be restarted, and then will operate with no difficulty. On one occurrance the backfire was so pronounced that it blew the air cleaner off, breaking all of the mounting clips. The car must be driven very carefully after a fill up due to this condition. You cannot rely on getting into heavy traffic due to the hesitation and frequency of the engine die out. I have taken this car in to the Dodge dealer on more than one occassion and they claim no knowkledge of the issue. I write this because there was an article in the kenosha news, dated Wednesday May 15th, 2013 which detailed 3 Chrysler, Dodge brand cars probed for this same issue. They mentioned only v8 engines, but I want to let someone know that this issue includes others such as my 3.3l v6. …
After taking on gas, engine will sometimes stumble and most of the time quit running. Tried not over filling it and it still will just die sometime after taking on gas. On two occasions, it did this after hitting highway speeds. It would suddenly lose power and you had to pull off the road. It would normally start back up and have no more problems until next fill up. Because of this, we don't fill up and hit the road. We drive around before driving at highway speeds. Once, it died in front of several cars and a big truck had to brake hard and swerve off the road. So far, there has not been any known accidents but feel it is a matter of time before someone gets hurt. The mechanic said it was something wrong with a valve in gas tank and that you can't buy the part. …
For the past four years or so, almost every time after filling up the gas tank, the 2004 Dodge Grand Caravan anniversary edition stalls. I can be just pulling away from the pump when it happens, or stopped at a stop light within a few minutes from leaving the gas station. You can feel the car 'jump' like someone is pressing the gas pedal quickly and it jerks the van a bit forward. Then it stalls. It takes a few turns of the key and pressing the gas pedal very quickly and forcefully to get it started again. I have gotten into the habit of driving the van around a parking lot for a few minutes until it feels back to normal before pulling out into traffic, as I'm concerned it will stall out in the middle of traffic. This only happens right after filling up the gas tank. It concerns me now more than ever since my son is learning how to drive and I want him to be safe.
Dt: consumer's wife was driving near home and lost power steering and power brakes. She was able to stop the vehicle by standing on the brakes. The dealership was called and they pick up the vehicle. They replaced the serpentine belt and pulley. A year later while driving on the interstate the serpentine belt fell off again in the middle of heavy traffic. The consumer had to pull to the side of road. The dealer was called and they determined that the serpentine belt and pulley had broken again. It was repaired. Called the manufacturer to report the problem. The manufacturer said that there was nothing they could do about it. No more problems as of yet.
1. Metal coolant lines going to rear heater failed ,massive corrosion where the heater hose attaches to the pipe completely rotted/rusted out, the vehicle had 75K miles on it. 2. If the coolant level gets too low of course my engine will overheat and seize. 3. The steel pipes need to be replaced for aluminum pipes or corrosion protection from the factory that's needed to withstand harsh climes, especially ones where salt is used to deice roadways.
Engine complaints in other Grand Caravan years
Frequently asked questions
How common are engine problems on the 2004 Dodge Grand Caravan?
NHTSA has 20 complaints about the engine & cooling of the 2004 Dodge Grand Caravan, 17% of the model year's 116 complaints. The component named most often is engine (3 mentions).
Is there a recall for 2004 Dodge Grand Caravan engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 Dodge Grand Caravan, though it has 1 recall 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 Dodge Grand Caravan engine problems start?
Half of the complaints with a recorded mileage happened before about 85,000 miles, and 14% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to engine & cooling 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.