The 2000 Dodge Caravan is a workhorse minivan plagued by catastrophic transmission failures and serious engine oiling defects, particularly in the 3.3L/3.8L V6 models. Budget heavily for powertrain replacement or rebuild if buying used.
41TE Transmission Failure (Complete Rebuild or Replacement)
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Harsh or delayed 2-3 upshift, especially when cold, Slipping on acceleration or uphill grades, Whining or buzzing noise from transmission area, Limp mode (stuck in 2nd gear) with check engine light, Complete loss of forward gears
Fix: The 41TE 4-speed automatic is the Achilles heel. Solenoid pack failures mask deeper clutch pack and valve body wear. Most need full rebuild (12-16 hours) or remanufactured unit swap (8-10 hours). Transmission oil cooler contamination often damages fresh rebuilds—cooler and lines must be replaced simultaneously.
Estimated cost: $2,200-3,800
3.3L/3.8L V6 Sludge and Oil Consumption Leading to Engine Failure
Common · high severity
Typical onset: 90,000-150,000 mi
Symptoms: Excessive oil consumption (1 qt per 500-1,000 mi), Valve train noise (ticking or tapping) on cold start, Blue smoke from exhaust on startup or acceleration, Loss of power and rough idle as rings fail, Seized engine if oil starvation occurs
Fix: The 3.3L and 3.8L V6 engines develop oil sludge in the valve covers and oil galleys, starving the top end. Worn piston rings follow, then spun bearings. PCV system neglect accelerates this. Proper fix is short block replacement or full rebuild (18-24 hours). Head gaskets often blown by overheating from this cascade.
Symptoms: Coolant loss with no visible external leaks, White smoke from exhaust (coolant burning), Rough idle or misfire codes on multiple cylinders, Milky oil on dipstick if severe, Overheating in advanced cases
Fix: The paper-thin lower intake gaskets leak coolant into the crankcase or cylinders. Must remove upper plenum and intake to replace (6-8 hours). Gasket kit runs $50-80, but labor dominates. Use updated Fel-Pro gaskets, not OEM. Flush cooling system and change oil immediately after repair.
Estimated cost: $600-1,100
Transmission Oil Cooler Line Corrosion and Failure
Common · medium severity
Typical onset: 70,000-120,000 mi
Symptoms: Transmission fluid puddles under vehicle (red or brown fluid), Rapid fluid loss leading to slipping or no engagement, Rust perforation visible on steel cooler lines near radiator, Low fluid level on dipstick without obvious leak source
Fix: Steel cooler lines rust through at bends and mounting points, especially in salt-belt states. Lines leak or burst, dumping fluid. Replace both lines as a set (2-3 hours), flush cooler, and replace all fluid. If lines failed and trans ran low, expect internal damage within 5,000 miles.
Estimated cost: $300-550
ABS Pump and Module Failure
Occasional · medium severity
Typical onset: 100,000-150,000 mi
Symptoms: ABS warning light illuminated constantly, Grinding or groaning noise from ABS pump under hood, Loss of ABS function (normal braking still works), Brake pedal pulsation during normal stops (rare)
Fix: The Bendix 10 ABS unit develops internal pump motor failures or corroded valve block. Remanufactured unit replacement is standard (2-3 hours), requires brake bleed. Some shops program used units, but reliability is hit-or-miss. Regular braking unaffected, but no ABS assist.
Estimated cost: $800-1,400
Fuel Pump Failure and Fuel Gauge Sender Issues
Occasional · medium severity
Typical onset: 80,000-130,000 mi
Symptoms: No-start condition with crank but no fire, Stalling at idle or under load after running fine, Fuel gauge reading empty when tank is full, or stuck at half, Whining noise from rear of vehicle before failure
Fix: In-tank fuel pump module includes pump, strainer, and sending unit—all fail. Tank must be dropped (2-3 hours). Use OEM-quality pump (Delphi or Bosch), not economy units that fail in 6 months. Address this with tank below half-full to ease removal. Recall 00V226000 covered some early pumps.
Estimated cost: $450-750
Front Suspension Lower Control Arm Bushing and Ball Joint Wear
Occasional · low severity
Typical onset: 90,000-140,000 mi
Symptoms: Clunking noise over bumps from front end, Wandering or vague steering feel, Uneven tire wear on inside edges, Play in wheel when lifted and pushed/pulled
Fix: Lower control arm bushings collapse and ball joints wear, especially on pre-2001 models without revised arms. Replace entire control arms with ball joints pressed in (2.5-3.5 hours both sides). Alignment mandatory after. Worn tie rod ends often accompany this.
Estimated cost: $400-700
Owner tips
Change transmission fluid and filter every 30,000 miles religiously—this transmission cannot tolerate neglect
Use 5W-30 synthetic oil and change every 3,000-4,000 miles on 3.3L/3.8L engines to fight sludge buildup; clean PCV valve annually
Inspect transmission cooler lines for rust every oil change—catch leaks before catastrophic fluid loss
Flush cooling system every 24 months with OEM-spec coolant to prevent intake gasket corrosion
If buying used, avoid any vehicle with history of overheating or unknown transmission service—walk away
Only buy one if it has documented transmission rebuild within 30,000 miles and immaculate oil change records—otherwise, you're buying someone else's $4,000 repair bill waiting to happen.
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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CURT MFG IS RECALLING CERTAIN CLASS 3 RECEIVER HITCHES, P/N 13347, SOLD AS AFTERMARKET EQUIPMENT FOR USE ON 1997-2007 CHRYSLER TOWN AND COUNTRY VANS, 1996-2007 DODGE CARAVANS, AND 1996-2004 PLYMOUTH VOYAGER VANS. WHEN THE HITCH IS LOADED TO THE MAXIMUM RATING, THE HITCH MAY FRACTURE OR BREAK AT THE BEND LOCATION WHERE THE MAIN BODY OF THE HITCH MEETS THE HITCH MUFFLER STRAP.
Consequence: IF THE AREA IN QUESTION FRACTURES OR BREAKS, THIS COULD CAUSE AN UNSTABLE DRIVING CONDITION, POSSIBLY RESULTING IN A CRASH.
Remedy: CURT MFG WILL NOTIFY OWNERS OF RECORD AND WILL REPLACE THE HITCH FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN DURING AUGUST 2010. OWNERS MAY CONTACT CURT MFG AT 1-715-831-8713.
EXTERIOR LIGHTING:HEADLIGHTS · 09E025000
2009-05-11
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
EXTERIOR LIGHTING · 09E012000
2009-04-07
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
VISIBILITY:GLASS, SIDE/REAR · 07E104000
2007-12-11
CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.
Remedy: SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS WHOLESALE CUSTOMERS AND REIMBURSE WHOLESALE CUSTOMERS FOR CURRENT INVENTORY AND AT A SPECIFIED RATE FOR REPLACING THEIR CUSTOMER'S GLASS. WHOLESALE CUSTOMERS CAN CONTACT SAFELITE'S WHOLESALE DIVISION, SERVICE AUTOGLASS TOLL FREE AT 1-888-246-6298. THE RECALL BEGAN ON JANUARY 15, 2008.
CERTAIN AIRTEX FUEL PUMP MODULES, P/NOS. E7089M, E7094M, E7113M, AND E7129M, MANUFACTURED BETWEEN JUNE 1 AND SEPTEMBER 24, 2006. THESE FUEL PUMP MODULES WERE SOLD AS AFTERMARKET FOR USE IN CERTAIN DAIMLERCHRYSLER VEHICLES LISTED ABOVE. SILICONE MATERIAL USED IN MANUFACTURE OF THE FLAPPER VALVE WAS OUT-OF-SPECIFICATION, LEADING TO EXCESS SWELL OF THE FLAPPER VALVE RESTRICTING THE FLOW OF FUEL TO THE FUEL PUMP MODULE.
Consequence: FUEL RESTRICTION COULD RESULT IN LOSS OF POWER AND/OR ENGINE STALL, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: AIRTEX WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE FUEL PUMP MODULES FREE OF CHARGE. THE RECALL BEGAN ON OCTOBER 18, 2006. OWNERS MAY CONTACT AIRTEX TOLL-FREE AT 1-866-867-3759.
SERVICE BRAKES, HYDRAULIC · 06E022000
2006-03-13
CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAND NAMES OF NAPA, RAYBESTOS, AIMCO, AC DELCO, CARQUEST, BENDIX, AND WAGNER. ONLY PRODUCTS THAT WERE MANUFACTURED FROM JULY 27, 2005 THROUGH JANUARY 17, 2006 (DATE CODES 0529 THROUGH 0602) ARE SUBJECT TO THIS RECALL. WHEN SUBJECT TO VERY COLD TEMPERATURES, AN INTERNAL SEAL IN THE MASTER CYLINDER COULD LOSE FLEXIBILITY AND MAY CAUSE BRAKE FLUID TO LEAK.
Consequence: LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTANCE, WHICH CAN RESULT IN A VEHICLE CRASH.
Remedy: AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE. THE RECALL BEGAN ON MARCH 20, 2006. OWNERS CAN CONTACT AFFINA GROUP CUSTOMER SERVICE AT 1-800-323-0354.
EXTERIOR LIGHTING:HEADLIGHTS · 06E023000
2006-03-13
CERTAIN ANZO COMBINATION HEADLAMP ASSEMBLIES SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS WHICH FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy: ANZO WILL NOTIFY OWNERS AND REPLACE THE HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN MAY 9, 2006. OWNERS MAY CONTACT ANZO USA AT 909-468-3688.
AIR BAGS · 04V480000
2004-10-06 · EA04013
ON CERTAIN MINIVANS, THE DRIVER'S AIR BAG MAY BECOME DISABLED DUE TO A FAILURE OF THE CLOCKSPRING, WHICH IS LOCATED IN THE HUB OF THE STEERING WHEEL.
Consequence: THIS CONDITION WILL MANIFEST ITSELF THROUGH ILLUMINATION OF THE AIR BAG WARNING LAMP, AND COULD EVENTUALLY RESULT IN A DRIVER'S AIR BAG OPEN CIRCUIT, IF THE PART IS NOT REPLACED IN A REASONABLE AMOUNT OF TIME.
Remedy: DEALERS WILL REPLACE THE CLOCKSPRING ASSEMBLY ON ALL COVERED VEHICLES WITH 70,000 MILES OR LESS. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DAIMLERCHRYSLER WILL OFFER AN EXTENDED LIFETIME WARRANTY UNDER WHICH IT WILL REPLACE THE CLOCKSPRING AT NO CHARGE IF IT FAILS. DAIMLERCHRYSLER WILL ALSO REIMBURSE OWNERS WHO HAVE PAID TO HAVE THE CLOCKSPRING REPLACED ON THEIR VEHICLES. THE RECALL BEGAN ON OCTOBER 12, 2004. OWNERS SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
EQUIPMENT:OTHER:LABELS · 03V505000
2003-12-10
ON CERTAIN MINIVANS AND 4X2 PICKUP TRUCKS, THE VEHICLE CERTIFICATION LABEL MAY HAVE GROSS AXLE WEIGHT RATINGS (GAWR) THAT EXCEED THE MAXIMUM TIRE LOAD CAPACITY AS DEFINED IN FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS."
Consequence: IMPROPERLY LOADING YOUR VEHICLE CAN CAUSE TIRE FAILURE AND RESULT IN A CRASH.
Remedy: OWNERS WILL BE PROVIDED WITH VEHICLE CERTIFICATION LABEL OVERLAYS CONTAINING CORRECTED INFORMATION RELATIVE TO VEHICLE GAWR AND TIRE SIZE. OWNER NOTIFICATION BEGAN MARCH 1, 2004. OWNERS SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-992-1997.
FUEL SYSTEM, GASOLINE · 03E053000
2003-10-24
CERTAIN AFTERMARKET REPLACEMENT FUEL FILTERS, MODELS WIX FILTER PART NUMBERS 33576, 33577, 33734; NAPA FILTER PART NUMBERS 3576, 3577, 3734; AND CARQUEST FILTER PART NUMBERS 86576, 86577, 86734 USED ON 1996-2000 DAIMLERCHRYSLER TOWN & COUNTRY, DODGE CARAVAN, AND PLYMOUTH VOYAGER VEHICLES, CAN CAUSE THE FUEL LINES TO LEAK.
Consequence: A POSSIBLE FIRE CAN OCCUR IN THE PRESENCE OF AN IGNITION SOURCE.
Remedy: WIX WILL NOTIFY ITS CUSTOMERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE.
NOTE: THIS DOES NOT INVOLVE ANY PRODUCTS MANUFACTURED BY THE DAIMLERCHRYSLER CORP. NOR ANY DAILMERCHRYSLER DEALERS.
OWNER NOTIFICATION IS EXPECTED TO BEGIN DURING NOVEMBER 2003. OWNERS WHO DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT WIX AT 704-864-6711.
EQUIPMENT · 03E045000
2003-09-26
AFTERMARKET REPLACEMENT FUEL FILTERS MANUFACTURED BETWEEN SEPTEMBER 17, 2002, AND JANUARY 20, 2003, SOLD UNDER THE BRAND NAMES LISTED ABOVE. THE FILTER MAY EXPERIENCE MALFUNCTION OF THE QUICK CONNECTOR EITHER BLOCKING FUEL FLOW TO THE ENGINE OR CAUSING A FUEL LEAK. THIS DOES NOT INVOLVE ANY PRODUCTS MANUFACTURED BY THE DAIMLERCHRYSLER CORP. NOR ANY DAILMERCHRYSLER DEALERS.
Consequence: IF THIS CONDITION OCCURRED WHILE THE VEHICLE IS IN MOTION, THE ENGINE COULD STALL. ALSO, IN THE PRESENCE OF AN IGNITION SOURCE, THE FUEL LEAK COULD RESULT IN A VEHICLE FIRE.
Remedy: AFTERMARKET REPLACEMENT FUEL FILTERS FOR 1995-2000 SHORT WHEELBASE CHRYSLER TOWN & COUNTRY, PLYMOUTH VOYAGER AND DODGE CARAVAN MINIVANS PART NO. 18232 AND DATE CODE 0237, 0249, OR 0252.
REPLACEMENT FUEL FILTERS FOR 1995-2000 LONG WHEELBASE CHRYSLER TOWN & COUNTRY, PLYMOUTH VOYAGER AND DODGE CARAVAN MINIVANS PART NO. 18230 AND DATE CODE 0237, 0249, 0251, OR 0304.
REPLACEMENT FUEL FILTERS FOR 2001-2004 CHRYSLER TOWN & COUNTRY, PLYMOUTH VOYAGER AND DODGE CARAVAN MINIVANS PART NO. 28871 AND DATE CODE 0249. THESE PART NUMBERS AND DATE CODES APPEAR ON THE GOLD-TONE FILTER.
DISTRIBUTORS AND RETAILERS WILL BE NOTIFIED TO ISOLATE AND RETURN AFFECTED INVENTORY. OWNERS WHO HAVE HAD THE FUEL FILTER SERVICED ON ONE OF THE APPLICABLE VEHICLES AFTER SEPTEMBER 17, 2002 SHOULD RETURN THEIR VEHICLE TO THE SERVICE FACILITY TO BE INSPECTED TO SEE IF THE FUEL FILTER THAT WAS INSTALLED IS ONE THAT IS INVOLVED IN THE RECALL. IF SO, THE OWNERS SHOULD HAVE THE FILTER REPLACED. TO RECEIVE A FULL REFUND PLUS THE COST OF POSTAGE, OWNERS SHOULD CUT THE CONNECTORS FROM THE HOSES, RINSE THE CONNECTORS AND RETURN THEM TOGETHER WITH PROOF OF THE AMOUNT PAID FOR THE REPLACEMENT PART AND LABOR, TO INTERCONTINENTAL AT INTERCONTINENTAL AUTO PARTS, INC., P.O. BOX 861, MAHWAH, NJ 07430, ATTN: FUEL FILTER RECALL. INTERCONTINENTAL WILL MAIL A FULL REFUND TO THE OWNER.
STRUCTURE · 03V094000
2003-03-07
CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EXCESSIVE MOISTURE AND ROAD SALT.
Consequence: THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.
Remedy: DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN MARCH 7, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT SOUTHERN COMFORT AT 1-800-745-6096.
FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM · 00V268000
2000-09-13 · RQ00008
VEHICLE DESCRIPTION: MINI VANS BUILT WITH 3.3L AND 3.8L ENGINES HAVE FUEL RAILS WITH NITROLE RUBBER O-RING SEALS THAT CAN DEGRADE OVER TIME. FUEL LEAKAGE FROM THE UNDERHOOD FUEL INJECTION FUEL RAIL COULD RESULT, INCREASING THE LIKELIHOOD OF A VEHICLE FIRE.
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE.
Remedy: DEALERS WILL INSTALL A SEAL ON THE VEHICLE FUEL RAILS TO PREVENT EXTERNAL LEAKAGE OF FUEL FROM THE FUEL RAIL CROSSOVER TUBE, SHOULD THE EXISTING O-RINGS CONTINUE TO DEGRADE. OWNER NOTIFICATION BEGAN ON JANUARY 25, 2002. DUE TO THE LARGE QUANTITY OF VEHICLES INVOLVED IN THIS CAMPAIGN, THE OWNER NOTIFICATION WILL BE PHASED OVER THE NEXT SEVERAL MONTHS. HOWEVER, IF A VEHICLE IS LEAKING FUEL FROM THE O-RINGS, THE VEHICLE SHOULD BE TAKEN INTO A DEALER TO HAVE THIS REPAIRED AS SOON AS POSSIBLE. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
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