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 Dodge Grand Caravan owners, lightly cleaned up (personal details are redacted by NHTSA).
Significant rusting has spread on the driver side rear wheel corner panel and beneath the sliding door rocker panel, leaving large areas of visible rust and missing paint, as well as revealing eroded/chipped chunks of metal of the undercarriage. Multiple body shop exams have shown that this problem has originated from the inside out, leaving little to no easy fix. There is also minor rusting of the same sort on the passenger side of the van as well. Expert consultants have determined that this damage May result in serious hazard if/when the rocker or panel portions of the affected areas drop from the vehicle and damage either of the rear tires. This also poses a risk to any traffic that May be trailing the vehicle at the time parts separating due to rust. …
I activated the passenger side automatic sliding door. There was a pop and a flash indicative of an electrical short and the door no longer opened or closed automatically. I inspected the wires and found that two wires were broken and possibly made contact with each other, causing an electrical short. The vehicle was inside my garage at the time and no one was inside. However, this is a dangerous situation should the vehicle catch fire because of the flimsy wiring on the doors. The driver side door stopped working two days later, but with no pop or flash. I noticed several other vehicles had the same problem, and there are several documented cases of the same problem throughout the web.
Tl* the contact owns a 2005 Dodge Grand Caravan. While driving 25 MPH, the passenger side sliding door opened without warning. The contact pulled the vehicle over to the side of the road and attempted to close the door automatically by depressing the sliding door button; however, it failed to close the door. The contact had to close the door manually. The vehicle was taken to titusville Chrysler Jeep Dodge (5600 U.S. 1, titusville, fl 32780, [phone]) where it was diagnosed that the motor switch needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 163,000. The VIN was not available.
Tl* the contact owns a 2005 Dodge Grand Caravan. When the contact attempted to unlock the driver and passenger side doors with the key fob, they would not unlock. The only way to unlock the doors was manually with the key. The contact replaced the batteries in the fob, but that did not work. The contact also stated that the rear sliding door did not open, even manually with a key. The vehicle was driven to the dealer but there was a fee for the diagnostic test. The manufacturer was notified of the failures. The vehicle was not repaired. The approximate failure mileage was 205,000.
Tl* the contact owns a 2005 Dodge Grand Caravan. While driving various speeds, all the doors remained opened without warning. The contact's daughter diagnosed that the fuse needed to be cleaned. The vehicle was repaired. The manufacturer was not made aware of the failure. The failure mileage was 154,000. The VIN was not available.
Multiple electrical failures. Backup lights, door locks, interior lights, right side power window, and sliding side doors. The items do not function on our van. Upon pulling the battery terminal these items will work for a short period of time and then cease to function again. After extensive research on the internet and several hundred dollar in dealer "repairs" I have discovered that this is due to a software problem with the body control module on the 2005 Dodge Grand caravans. The fix is supposed to be a firmware update to the BCM provided by Dodge. The issue I have is that if this is a software/firmware update to the van's computer why should the dealer expect me to pay $70 so my vehicle will function properly the same as it did when purchased. No modifications have been made to the van and it currently has just over 60K mileage. …
Driving down a highway, and the right rear window of our 2005 Dodge Grand Caravan (63K miles) just fell out at ~60 miles per hour. There was no warning, the car has never been in an accident, the window was not vented, and nothing was up against the window. We are fortunate that this happened while we were in the right lane, and it was the right side of the car, so the window probably fell to the side of the road. We are also fortunate that we did not have anything fall out the window that could have caused an accident. We reported the incident (informally) to the police so that they could drive by the area where it occurred to ensure there were no road hazards. We have nothing to explain why the window fell out. We contacted Chrysler and they concluded it was not a defect. …
I am concerned with overall quality control on this vehicle. I purchased this vehicle new to provide safety and comfort for my growing family. I was disappointed in the vehicles performance and gas mileage during the first several weeks of ownership. I returned the vehicle to the dealership and they replaced the oxygen sensor units that they said where defective. Several months later the heater/air conditioning blower went out. Next with less than 20,000 miles on the vehicle I had to replace the brakes. Now with less than 28.000 miles on the vehicle I noticed that the passenger side floor was soaked, the vehicle was making unusual sounds when turning and the passenger side door would not close automatically. At the dealership I found out that the rack and pinion steering unit had failed along with the the cable on the passenger side door. …
I pushed the button to open the sliding doors and there have been so many times when the door will close without having been told to. Typically, the sensor will catch when there is a hand or a child pushing it back open, but there have been occasions, like today that it started to open, then about 18 inches after it had begun opening that it reverses and closes and does not have the sensor kick in. Today the door slammed into my left shoulder. I had to use all my strength to push it off my shoulder and to override the motor to get it to open. I am so grateful my 2 year old was still on the shipping cart because that would have crushed his hand if he wasn't able to get out of the way. Most times it is the passenger side siding door that does this. …
Dodge 2005 Grand Caravan. Driver side door would refuse to open with inside button by door. Would open if pushed console button. The door would decide that it was not closed properly and fully open while driving. (very dangerous). The passenger side would open only if you used the key bob and had a jerky motion that would trip a sensor and close the door(usually on a passenger getting in or out of the vehicle. The door was adjusted and door motor replaced. Still had a problem with the door occasionally bumping the side of the vehicle. Verified that the vehicle had not been in an accident and resolved by leaving the plastic interior door cover off. The problem with the doors opening and closing by themselves was found in both cases to be linked to the door wiring harness. …
Body complaints in other Grand Caravan years
Frequently asked questions
How common are body problems on the 2005 Dodge Grand Caravan?
NHTSA has 70 complaints about the body & structure of the 2005 Dodge Grand Caravan, 7% of the model year's 996 complaints. The component named most often is body › door (36 mentions).
Is there a recall for 2005 Dodge Grand Caravan body problems?
No. NHTSA lists no body & structure recall for the 2005 Dodge Grand Caravan, though it has 5 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 Dodge Grand Caravan body problems start?
Half of the complaints with a recorded mileage happened before about 75,000 miles, and 11% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 1 injury 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.