The 1991 Dodge Caravan pioneered the minivan segment but suffers from notorious A-604 automatic transmission failures and 3.0L Mitsubishi V6 head gasket issues. The 2.5L four-cylinder with TorqueFlite 3-speed is the most durable powertrain, but even those see oil consumption and bearing wear past 100k.
A-604 (41TE) 4-Speed Automatic Transmission Failure
Common · high severityTypical onset: 80,000-130,000 mi
Symptoms: Harsh shifts or delayed engagement from Park to Drive, Slipping between gears, especially 2nd-3rd upshift, No forward movement but reverse works (or vice versa), Burnt transmission fluid smell, dark/metallic fluid on dipstick
Fix: Internal clutch pack and solenoid failures plague this Ultradrive unit. Rebuilds often last only 30-50k miles due to poor valve body design. Most shops recommend remanufactured unit with updates. 8-12 hours labor for R&R, plus fluid/filter, plus transmission cooler line inspection (recall item—replace any rusty lines).
Estimated cost: $1,800-3,200
3.0L Mitsubishi V6 Head Gasket Failure
Common · high severityTypical onset: 70,000-110,000 mi
Symptoms: White smoke from exhaust on cold start, Coolant loss with no visible leaks, Overheating or erratic temperature gauge, Milky oil on dipstick or under oil cap, External coolant seepage at head/block junction
Fix: Head gaskets blow between cylinders or into coolant jackets. Must resurface heads (often warped), replace all gaskets, timing belt, water pump while apart. If overheated badly, heads may crack. 14-18 hours labor for both sides. Do not ignore early symptoms—head damage triples the bill.
Estimated cost: $1,400-2,800
2.5L Four-Cylinder Oil Consumption and Bearing Wear
Common · medium severityTypical onset: 100,000-150,000 mi
Symptoms: Burning one quart or more per 800-1,000 miles, Blue smoke on deceleration or startup, Rod knock or main bearing rumble at idle when hot, Low oil pressure warning light at idle when warm
Fix: Piston ring wear and bearing clearance issues. Oil consumption alone can be lived with if you check weekly. Rod/main bearing noise requires full lower-end rebuild or short block replacement. 18-22 hours labor for in-chassis rebuild, 12-16 for short block swap. Overhead rebuild (head gasket, valve seals) adds 6-8 hours.
Estimated cost: $2,200-4,500
Power Steering Rack Leaks and Wandering
Common · medium severityTypical onset: 90,000-140,000 mi
Symptoms: Power steering fluid puddle under driver side, Groaning noise on full lock turns, Excessive play in steering wheel (more than one inch), Vehicle wanders in lane, requires constant correction
Fix: Rack seals leak, inner tie rod sockets wear sloppy. Most shops replace entire rack assembly (remanufactured) rather than rebuild. 4-6 hours labor, includes alignment. Check steering coupler for looseness at firewall—recall item for coupler bolt failure on some units.
Estimated cost: $600-1,100
Rear Liftgate Hinge Cracking and Latch Failure
Occasional · low severitySymptoms: Liftgate sags on one side when open, Latch will not catch or releases while driving, Visible cracks in sheet metal around hinge mounting points, Rear wiper/washer fluid leaks into cargo area
Fix: Sheet metal fatigue at hinge mounts, latch mechanisms corrode. NHTSA recalls cover some latch and hinge issues—check VIN. Hinge repair may require welding reinforcement plates. Latch replacement is 1-2 hours, hinge work 3-5 hours if welding needed.
Estimated cost: $200-700
Fuel Pump and Tank Sending Unit Failure
Occasional · medium severityTypical onset: 100,000-150,000 mi
Symptoms: No-start condition, engine cranks but won't fire, Stalling at highway speed or after 20+ minutes driving, Fuel gauge reads empty when tank is full, or stuck on full, Whining noise from rear of vehicle at idle
Fix: In-tank pump wears out, sending unit float arms corrode. Must drop fuel tank (2-3 hours labor). Replace pump and filter as assembly. Fuel filter is inline under vehicle—service every 30k to extend pump life.
Estimated cost: $400-750
ABS Pump and Controller Failure (if equipped)
Occasional · medium severityTypical onset: 80,000-120,000 mi
Symptoms: ABS warning light stays on after startup, Pulsing brake pedal during normal stops (false ABS activation), Extended stopping distance, mushy pedal feel, Pump motor runs continuously or cycles randomly
Fix: Bendix 10 ABS system—pump motor and accumulator fail, controller corrosion. Remanufactured units available. 3-5 hours labor, requires brake bleed and sometimes DRBII scan tool reset. Recall for brake line corrosion—inspect all hard lines while diagnosing ABS.
Estimated cost: $800-1,500
Buy only the 2.5L with 3-speed auto if you need cheap utility transport and can accept oil consumption; avoid 3.0L V6 and all 4-speed automatics unless freshly rebuilt with receipts.
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.