2002 DODGE CARAVAN

Typical onset: 80,000-140,000 mi

Symptoms: Slipping between gears, especially 2nd-3rd shift, Delayed engagement when shifting to Drive or Reverse, Whining or grinding noise from bellhousing area, Check engine light with transmission codes (P0700, P0731-P0734)

Fix: The 41TE four-speed auto is notorious for solenoid pack failures, clutch pack burnout, and output shaft bearing disintegration. Fluid changes delay but don't prevent failure. Rebuild takes 8-12 hours; many shops recommend remanufactured units due to internal design flaws. Includes R&R, fluid, filter, converter inspection.

Estimated cost: $2,200-3,800

Typical onset: 90,000-150,000 mi

Symptoms: White smoke from exhaust on cold start, Coolant loss with no visible leaks, Overheating or erratic temperature gauge, Oil milkshake (chocolate milk appearance) on dipstick or under oil cap, Rough idle or misfires after sitting overnight

Fix: Both V6 engines have poor head bolt torque retention and thin head gasket design. External leaks are common at rear corners. Internal failures dump coolant into cylinders. Job requires 10-14 hours: heads off, resurface, new gaskets, timing components, coolant flush. Often find cracked heads during disassembly, adding $400-800 to bill.

Estimated cost: $1,800-3,200

Typical onset: 120,000-180,000 mi

Symptoms: Deep knocking from engine block that increases with RPM, Low oil pressure warning at idle when warm, Metallic shavings in oil during changes, Sudden catastrophic engine seizure in advanced cases

Fix: The 3.3L/3.8L V6 engines have inadequate oil delivery to rod bearings #2 and #5 under sustained load. Sludge buildup accelerates failure. Repair requires complete teardown: 18-24 hours for crank polishing, bearing replacement, rod inspection. Most techs recommend short-block or salvage engine instead due to labor costs exceeding engine value.

Estimated cost: $3,500-5,500

Typical onset: 70,000-120,000 mi

Symptoms: Rough idle or stalling when coming to a stop, P0171/P0174 lean codes (both banks), Whistling or hissing sound from intake area, Poor acceleration and fuel economy drop

Fix: The upper intake plenum uses a thin cork-rubber gasket that hardens and cracks, causing massive vacuum leaks. Common failure point between throttle body and manifold. Repair takes 3-4 hours: remove upper plenum, scrape old gasket, replace with upgraded material, new PCV valve recommended. Straightforward job but labor-intensive due to access.

Estimated cost: $400-700

Typical onset: 100,000-160,000 mi

Symptoms: Power steering fluid puddle under vehicle (passenger side front), Sudden loss of power steering assist, Squealing from pump during turns, Visible fluid spray on inner fender and frame rail

Fix: High-pressure hose from pump to rack degrades from engine heat and ozone exposure. Recall 03V-088 addressed some units but didn't cover all production. Hose assembly runs $80-150, labor 1.5-2 hours including fluid refill and system bleed. Check pump for damage from running dry—adds $250-400 if replacement needed.

Estimated cost: $220-450

Typical onset: 60,000-100,000 mi

Symptoms: Clunking noise over bumps (front end), Rattling during slow turns or parking lot speeds, Steering feels loose or imprecise, Visible play in sway bar end links when prying with bar

Fix: Ball joints in sway bar end links wear rapidly due to soft bushings. Strut mounts develop clunks from bearing degradation. Replace links in pairs (1 hour), strut mounts require strut removal (3-4 hours for both sides with alignment). Budget alignment after strut work.

Estimated cost: $180-320 (links only), $550-850 (with strut mounts)

Symptoms: Door won't latch closed or pops open while driving, Power sliding door opens partially then reverses, Manual door requires excessive force to close, Door ajar warning stays illuminated

Fix: Latch mechanisms corrode internally; cables stretch or fray. Manual doors need latch assembly and cable set (2-3 hours per side). Power doors add motor/module complexity (4-5 hours). Common to replace both sides preventively. TSB addresses calibration for power units.

Estimated cost: $350-600 (manual), $800-1,400 (power door)