The 1990 Dodge Caravan pioneered the minivan segment but suffers from transmission fragility and 2.5L engine bearing failures that define ownership experience. Good bones otherwise, but these two systems will determine whether you drive it or tow it.
A604 (41TE) Automatic Transmission Failure
Common · high severityTypical onset: 80,000-130,000 mi
Symptoms: Harsh 2-3 shift or slipping between gears, No movement in Drive or Reverse after warm-up, Transmission overheating, burnt ATF smell, Check Engine light with speed sensor codes
Fix: The Ultradrive 4-speed auto is notorious for solenoid pack, clutch pack, and governor pressure sensor failures. Rebuild runs 12-16 hours; used replacements are gambles. External oil cooler supplementation helps survivors. Most shops recommend full rebuild over band-aid fixes.
Estimated cost: $1,800-3,200
2.5L Turbo I (Naturally Aspirated) Crankshaft and Rod Bearing Failure
Common · high severityTypical onset: 100,000-150,000 mi
Symptoms: Deep knocking sound on cold start that worsens with RPM, Metal shavings in oil, dropping oil pressure, Catastrophic engine seizure if ignored
Fix: The 2.5L four-cylinder inherits Chrysler's under-oiled crankshaft design from the K-car era. Rod bearings spin, crank journals score. Requires full teardown: crank grinding/replacement, new bearings, often pistons if debris circulated. Engine rebuild 18-24 hours, short block swap 14-18 hours.
Estimated cost: $2,200-4,000
Transmission Mount Collapse
Common · medium severityTypical onset: 60,000-100,000 mi
Symptoms: Heavy clunk when shifting Drive-Reverse, Vibration through floor at idle in gear, Visible sagging of transmission bell housing
Fix: The hydraulic transmission mount deteriorates, allowing excessive drivetrain movement. Strains CV axles and shift linkage. Replacement requires supporting the transmission, 2.5-3.5 hours. Cheap part, labor-intensive access on AWD models.
Estimated cost: $250-450
Fuel Pump and Sending Unit Failure
Occasional · high severityTypical onset: 90,000-140,000 mi
Symptoms: No-start with key on/pump not priming, Stalling in hot weather or low fuel conditions, Erratic or non-functional fuel gauge
Fix: In-tank pump fails from wear and heat cycling. Requires fuel tank drop, 3-4 hours labor. Sending unit often corrodes simultaneously. Replace both together to avoid repeating the job.
Estimated cost: $400-650
3.0L Mitsubishi V6 Head Gasket Leaks
Occasional · medium severityTypical onset: 110,000-160,000 mi
Symptoms: External coolant seepage at head/block mating surface, White smoke at cold start, sweet smell, Gradual coolant loss without visible leaks
Fix: The 3.0L Mitsubishi engine develops head gasket seepage, especially rear bank. Both heads typically done together: 10-14 hours labor, includes resurfacing heads if warped. Less catastrophic than 2.5L bearing issues but still requires major disassembly.
Estimated cost: $1,400-2,200
Liftgate Latch and Lock Mechanism Seizure
Common · low severitySymptoms: Liftgate won't open from exterior handle, Must crawl inside to release from interior, Latch stuck partially engaged
Fix: Chrysler recalled this twice but many weren't fixed. Latch mechanism corrodes and binds. Disassemble, clean, lubricate, or replace latch assembly. 1.5-2 hours. More annoyance than safety issue unless it fails open on highway.
Estimated cost: $150-280
Buy only with documented transmission rebuild and if it has the 3.0L or 3.3L V6 — the 2.5L is a ticking time bomb and the A604 will break your heart twice.
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.