The 1992 Dodge Caravan was revolutionary for families but notorious for transmission failures and 3.0L V6 head gasket issues. These vans nickel-and-dime you to death if you don't catch problems early.
A604 (41TE) Automatic Transmission Failure
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Harsh or delayed shifts between gears, especially 2nd to 3rd, Slipping under acceleration or won't move in any gear, Transmission fluid dark brown or burnt smell, Check engine light with transmission codes
Fix: The A604 4-speed auto is the Achilles heel. Internal clutch packs and solenoid pack fail. Rebuild takes 8-12 hours; many shops won't touch these anymore and recommend remanufactured unit swap. External oil cooler lines rust through and starve the trans—catch that early and you might avoid the big job.
Estimated cost: $1,800-3,200
3.0L Mitsubishi V6 Head Gasket Failure
Common · high severity
Typical onset: 90,000-130,000 mi
Symptoms: White smoke from exhaust on cold start, Coolant loss with no visible leaks, Overheating or fluctuating temp gauge, Milky oil on dipstick or oil cap
Fix: The 3.0L V6 blows head gaskets more than the other engines. Both heads usually need work. Job requires 10-14 hours labor, and you should resurface heads and replace timing belt/water pump while you're in there. If coolant contaminated the oil long enough, you're looking at bearing damage and full rebuild.
Estimated cost: $1,400-2,800
2.5L I4 Crankshaft and Main Bearing Wear
Occasional · high severity
Typical onset: 120,000-180,000 mi
Symptoms: Deep knocking noise from bottom of engine that increases with RPM, Low oil pressure warning at idle when warm, Metal shavings in oil during change, Vibration through whole vehicle
Fix: The 2.5L four-cylinder develops excessive crankshaft endplay and wears main bearings prematurely, especially if oil changes were skipped. This is a full engine teardown or short-block replacement job requiring 14-18 hours. Most owners junkyard-swap a low-mileage used engine instead of rebuilding.
Estimated cost: $2,200-4,000
Liftgate Strut and Latch Failure
Common · low severity
Symptoms: Liftgate drops suddenly when opened—head injury risk, Latch won't hold gate closed, pops open over bumps, Struts visibly leaking oil or collapsed
Fix: Struts wear out from constant cycling and desert heat accelerates it. Latch mechanisms rust and stick. Struts are 0.5 hour job, latches maybe 1-1.5 hours depending on rust. Multiple recalls on this—check if yours was done. Easy DIY but don't ignore it; falling liftgate has sent people to the ER.
Estimated cost: $120-350
Fuel Filter and Pump Restriction
Occasional · medium severity
Typical onset: 100,000+ mi
Symptoms: Engine stumbles or dies during acceleration, Hard starting when hot, Loss of power at highway speeds, Whining noise from fuel tank area
Fix: Inline fuel filter rarely gets changed and clogs up, starving the engine. Fuel pump in-tank assembly also fails. Filter is 0.5 hour, but if pump is dying you're at 2-3 hours to drop the tank. Do both at the same time if tank is already down.
Estimated cost: $250-650
Transmission Mount Collapse
Common · medium severity
Typical onset: 70,000-110,000 mi
Symptoms: Heavy clunk when shifting from Park to Drive or Reverse, Vibration through floor and steering wheel, Visible engine movement when revving in Park
Fix: Front and side transmission mounts crack and separate from the rubber. This puts extra stress on the already-weak A604 transmission and causes harsh shifting. Replacing both mounts takes 2-3 hours. Do this BEFORE the transmission starts acting up to extend its life.
Estimated cost: $200-400
Windshield Wiper Linkage Bushing Wear
Occasional · low severity
Symptoms: Wipers move slowly or unevenly, One wiper works, other doesn't move or flops around, Clunking noise from cowl area when wipers run
Fix: Plastic bushings in the wiper linkage wear out and fall apart. Takes 1-2 hours to remove cowl cover and access linkage. Not expensive but annoying in rain. Recall campaign addressed some of this—verify it was completed.
Estimated cost: $150-300
Owner tips
Change transmission fluid every 30,000 miles with ATF+3 or compatible—this extends A604 life significantly
Inspect transmission cooler lines for rust annually; $40 in lines beats $2,500 transmission
Run quality oil and change at 3,000 miles if you have the 2.5L I4—it's sensitive to oil quality
Check all recall campaigns were completed, especially liftgate latch and wiper linkage
Budget $500-800/year for unexpected repairs after 100,000 miles—these nickel-and-dime you
Only buy if under 100k miles with documented transmission services and you can wrench yourself—otherwise the repair costs will exceed the vehicle's value within a year.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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VEHICLE DESCRIPTION: MINIVANS. THE LEFT HAND WINDSHIELD WIPER PIVOT DRIVE ARM WAS NOT MECHANICALLY STAKED TO THE PIVOT SHAFT.
Consequence: THIS COULD ALLOW THE DRIVE ARM TO DISENGAGE FROM THE SHAFT LEADING TO A LOSS OF WIPER FUNCTION. THE DRIVER'S VISIBILITY WOULD BE IMPAIRED, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL REPLACE THE LEFT HAND SIDE WINDSHIELD WIPER PIVOT ASSEMBLY.
SEAT BELTS:FRONT:BUCKLE ASSEMBLY · 97V148000
1997-09-09 · EA96016
VEHICLE DESCRIPTION: PASSENGER MINI-VANS. COVERS ON THE SOLID STALK MOUNTED SEAT BELT BUCKLES CAN BECOME DISLODGED CAUSING THE RELEASE BUTTON TO STICK INSIDE THE COVER. THE BUCKLE WOULD THEN BE ONLY PARTIALLY LATCHED.
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.
Remedy: DEALERS WILL INSTALL A COVER RETAINING CLIP TO THE STALK MOUNTED BUCKLE COVER TO PREVENT DISLOCATION OF THE BUCKLE COVER.
SEAT BELTS:FRONT:ANCHORAGE · 97V149000
1997-09-09 · EA97005
VEHICLE DESCRIPTION: PASSENGER MINI-VANS. THE CENTER REAR SEAT, RIGHT OUTBOARD SIDE, SAFETY BELT ANCHOR HOOK CAN BECOME UNATTACHED FROM THE BODY ANCHOR POSITION.
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED INCREASING THE RISK OF PERSONAL INJURY.
Remedy: DEALERS WILL REPLACE THE ANCHOR HOOK RETAINING CLIP WITH A REVISED PROFILE CLIP AND A COVER PLATE.
THE BOLTS USED TO ATTACH THE STRUT TO THE BODY AND THE REAR LIFTGATE CAN ACCUMULATE FATIGUE DAMAGE IF THREE FACTORS COMBINE. IF THE BOLT IS LOOSE, THE GAS STRUT IS OVER-PRESSURIZED, AND THE FREQUENCY OF OPENING AND CLOSING CYCLES IS HIGHER THAN FOR THE AVERAGE CUSTOMER, THE BOLT CAN FAIL.
Consequence: PERSONAL INJURY COULD OCCUR IF THE BOLTS BREAK ALLOWING THE LIFTGATE TO FALL SUDDENLY.
Remedy: DEALERS WILL INSPECT FOR LOOSE FASTENERS, IF THE FASTENERS ARE LOOSE, THE STRUT (AND INTEGRAL BOLTS) WILL BE REPLACED. IF THE BOLT SHOWS EVIDENCE OF TORQUE, THE BOLT WILL BE REMOVED, LARGER WASHERS WILL REPLACE THE EXISTING WASHER AND THE BOLT WILL BE REINSTALLED AND HAND TIGHTENED TO THE TARGET TORQUED.
STEERING: STEERING WHEEL/HANDLE BAR · 96V229000
1996-11-18 · RQ00011
THE STEERING WHEEL ARMATURE STAMPING CAN CRACK AND SEPARATE FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN.
Consequence: IF THE STEERING WHEEL SEPARATES FROM THE CENTER HUB ATTACHMENT TO THE STEERING COLUMN, LOSS OF CONTROL CAN OCCUR INCREASING THE RISK OF AN ACCIDENT.
Remedy: DEALERS WILL INSPECT THE STEERING WHEEL FOR ARMATURE CRACKS IN THE CENTER HUB ATTACHMENT AREA. ANY STEERING WHEELS SHOWING CRACKS WILL BE REPLACED. ALL OTHER VEHICLES WILL HAVE A REINFORCEMENT PLATE INSTALLED TO PREVENT STEERING WHEEL SEPARATION IN THE EVENT CRACKING OCCURS.
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP · 96V099000
1996-06-13 · EA95016
THE ABS HYDRAULIC CONTROL UNIT CAN EXPERIENCE EXCESSIVE BRAKE ACTUATOR PISTON SEAL WEAR CAUSING PUMP-MOTOR DETERIORATION.
Consequence: IF THIS CONDITION OCCURS, THE ABS FUNCTION COULD BE LOST AND REDUCED POWER ASSIST WOULD BE EXPERIENCED DURING VEHICLE BRAKING INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.
Remedy: DEALERS WILL TEST THE VEHICLE'S ANTI-LOCK BRAKE SYSTEM AND REPAIR THE VEHICLES IF NECESSARY. ALSO THE WARRANTY ON ALL ABS COMPONENTS WILL BE EXTENDED TO 10 YEARS OR 100,000 MILES (EXCEPT FOR THE BRAKE ACTUATOR PISTON ASSEMBLY AND THE PUMP-MOTOR ASSEMBLY WHICH WILL HAVE A LIFETIME COVERAGE). OWNERS WILL ALSO BE REIMBURSED FOR PREVIOUS ABS COMPONENT REPAIR COSTS.
VEHICLE DESCRIPTION: LIGHT DUTY PASSENGER MINIVANS WITHOUT REMOTE RELEASE. THIS IS NOT A SAFETY RECALL. THERE HAS BEEN NO DETERMINATION THAT A SAFETY DEFECT EXISTS WITH THE MINIVAN LATCHES. CHRYSLER IS CONDUCTING A SERVICE CAMPAIGN TO REPLACE THE LIFTGATE LATCH ASSEMBLY OF THE AFFECTED MINIVANS. IN A COLLISION, THE REAR LIFTGATE LATCH ASSEMBLY COULD OPEN.
Consequence: IF THE LIFTGATE LATCH OPENS, OCCUPANTS CAN BE EJECTED RESULTING IN SIGNIFICANTLY INCREASED RISK OF INJURY OR DEATH.
Remedy: CHRYSLER DEALERS WILL REPLACE THE LIFTGATE LATCH WITH A NEW STRONGER LATCH ASSEMBLY WITHOUT CHARGE. CHRYSLER BEGAN NOTIFYING OWNERS OF THESE VEHICLES IN OCTOBER 1995.
VEHICLE DESCRIPTION: LIGHT DUTY PASSENGER MINIVANS WITH REMOTE RELEASE. THIS IS NOT A SAFETY RECALL. THERE HAS BEEN NO DETERMINATION THAT A SAFETY DEFECT EXISTS WITH THE MINIVAN LATCHES. CHRYSLER IS CONDUCTING A SERVICE CAMPAIGN TO REPLACE THE LIFTGATE LATCH ASSEMBLY OF THE AFFECTED MINIVANS. IN A COLLISION, THE REAR LIFTGATE LATCH ASSEMBLY COULD OPEN.
Consequence: IF THE LIFTGATE LATCH OPENS, OCCUPANTS CAN BE EJECTED RESULTING IN SIGNIFICANTLY INCREASED RISK OF INJURY OR DEATH.
Remedy: CHRYSLER DEALERS WILL REPLACE THE LIFTGATE LATCH WITH A NEW STRONGER LATCH ASSEMBLY WITHOUT CHARGE. CHRYSLER BEGAN NOTIFYING OWNERS OF THESE VEHICLES IN MARCH 1996.
FUEL SYSTEM, GASOLINE · 92V147000
1992-10-14
FUEL TANK FLANGES WERE NOT BENT AS REQUIRED TO ALLOW THE SPECIFIED CLEARANCE FOR THE FUEL TANK MOUNTING STRAPS AND FUEL LINES AT THE TANK.
Consequence: THE UNBENT FLANGES TO THE FUEL TANK WILL DAMAGE THEMOUNTING STRAPS AND/OR FUEL LINES. THE DAMAGED MOUNTING STRAPS MAY BREAK CAUSINGTHE TANK TO DROP AND THE DAMAGED FUEL LINE WILL LEAK FUEL. IN EITHER CASE A FIRECOULD RESULT IF THE SPILLED FUEL IS EXPOSED TO AN IGNITION SOURCE.
Remedy: REPAIR THE FLANGE BY BENDING TO THE CORRECT ANGLE; REPLACE DAMAGED FUEL LINES AND MOUNTING STRAPS.
STEERING: STEERING WHEEL/HANDLE BAR · 92V015000
1992-02-14 · PE92004
THE ZINC PLATING OPERATION PERFORMED ON THE UPPER STEERING COLUMN SHAFT COUPLING BOLT CAUSED HYDROGEN EMBRITTLEMENT AND BREAKAGE OF THE BOLT.
Consequence: FRACTURES OF THE UPPER STEERING COLUMN SHAFT COUPLINGBOLT RESULT IN A LACK OF COUPLING LOAD ON THE SHAFT AND LOSS OF STEERINGCONTROL.
Remedy: REPLACE THE ZINC PLATED BOLT WITH A PHOSPHATE PLATED BOLT.
SERVICE BRAKES, HYDRAULIC:PEDALS AND LINKAGES · 91V170000
1991-10-04
THE BRAKE PEDAL PAD ATTACHMENT TO THE PEDAL ARM MAY NOT HAVE ADEQUATE STRENGTH DUE TO MISLOCATION OF WELDS, AND COULD BREAK.
Consequence: FAILURE OF THE PEDAL PAD TO PEDAL ARM ATTACHMENT RESULTSIN LOSS OF BRAKING ABILITY, AND COULD RESULT IN AN ACCIDENT.
Remedy: REPLACE INADEQUATE BRAKE PEDALS WITH PROPERLY MANUFACTURED PEDALS.
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