The 2002 Dodge Caravan is known for catastrophic automatic transmission failures and chronic 3.3L/3.8L V6 engine problems, particularly head gasket and lower-end bearing issues. These aren't wear items—they're design weaknesses that make ownership risky beyond 100,000 miles.
41TE Automatic Transmission Failure
Common · high severity
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
3.3L/3.8L V6 Head Gasket Failure
Common · high severity
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
Lower End Bearing Failure (Rod/Main Bearings)
Occasional · high severity
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
Intake Manifold Plenum Gasket Leak (3.3L/3.8L)
Common · medium severity
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
Power Steering Hose Rupture
Occasional · medium severity
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
Sway Bar Links and Front Strut Mount Failure
Common · low severity
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.
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.
Change transmission fluid every 30,000 miles with Mopar ATF+4 only—third-party fluids accelerate 41TE failure
Monitor coolant level weekly on V6 engines; head gasket leaks start small and escalate fast
Use synthetic oil and 5,000-mile intervals to combat sludge buildup in lower end—these engines are not tolerant of extended drains
Inspect power steering hoses annually for seepage; a $25 hose replacement beats a $400 pump failure
Budget $1,000-1,500 annually for deferred maintenance after 100,000 miles—this platform nickel-and-dimes you to death
Hard pass unless free—transmission and engine failures are when-not-if propositions that often exceed vehicle value, making this a money pit past 100k miles.
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 · 08E048000
2008-08-08
EAGLE EYES IS RECALLING 11,534 HEADLAMP ASSEMBLIES, P/NOS. CS090-B001L AND CS090-B001R, SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR THE ABOVE LISTED PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE LOWER BEAM PHOTOMETRY REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: EAGLE EYES WILL NOTIFY OWNERS AND OFFER REPLACEMENT HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 30, 2008. OWNERS MAY CONTACT EAGLE EYES AT 1-800-568-1098.
EXTERIOR LIGHTING:HEADLIGHTS · 08E039000
2008-06-10
MAXZONE IS RECALLING 2,520 HEADLIGHT ASSEMBLIES, DEPO BRAND, P/NOS. 3341103L-AS AND 334-1103R-AS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR 2001-2007 DODGE CARAVAN PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: MAXZONE WILL NOTIFY OWNERS AND OFFER REIMBURSEMENT FOR ANY NONCOMPLIANT HEADLIGHTS. THE RECALL BEGAN ON JUNE 16, 2008. OWNERS MAY CONTACT MAXZONE AT THE FOLLOWING LOCATIONS: 1-888-286-1188 (WA, OR, CA, ID, NV, AZ, MT, WY, UT, CO, KS, NM, OK, TX, AR, LA, AK, HI) 1-877-253-8930 (ME, NH, VT, MA, CT, RI, NY, NJ, PA, MD, DE, WV, VA) 1-800-859-4755 (NC, SC, GA, FL, TN, AL, MS) 1-866-783-6858 (ND, SD, NE, MN, IA, MO, WI, IL, MI, IN, OH, KY).
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.
EQUIPMENT:ELECTRICAL:RADIO/TAPE DECK/CD ETC. · 04V531000
2004-11-02 · PE04049
ON CERTAIN MINI VANS, CONDENSATION FROM THE INSTRUMENT PANEL AIR CONDITIONING DUCTS MAY DROP THROUGH VENT HOLES IN THE TOP OF THE RADIO AND RESULT IN A SHORT CIRCUIT THAT SUBSEQUENTLY SENDS DIRECT CURRENT TO THE REAR SPEAKERS.
Consequence: THIS COULD RESULT IN A SPEAKER FIRE.
Remedy: DEALERS WILL ADD A SPECIAL TAPE TO THE TOP OF THE RADIO TO PREVENT THE POTENTIAL OF WATER INTRUSION. THE RECALL BEGAN ON JANUARY 31, 2005. OWNERS SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
STEERING:HYDRAULIC POWER ASSIST:HOSE, PIPING, AND CONNECTIONS · 04V386000
2004-08-05 · PE03012
ON CERTAIN MINIVANS EQUIPPED WITH 3.3 OR 3.8L V-6 ENGINE, THE UPPER POWER STEERING COOLER HOSE MAY SPLIT AND CAUSE A FLUID LEAK.
Consequence: POWER STEERING FLUID LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN AN UNDER HOOD FIRE.
Remedy: DEALERS WILL REPLACE THE UPPER POWER STEERING COOLER HOSE. THIS RECALL BEGAN ON SEPTEMBER 27, 2004. OWNERS SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
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.
CHILD SEAT · 01V310000
2001-10-04
VEHICLE DESCRIPTION: CERTAIN MINI VANS FAIL TO COMPLY WITH REQUIREMENTS OF FMVSS NO. 225, "CHILD RESTRAINT ANCHORAGE SYSTEMS." THE OWNER MANUALS SUPPLIED WITH THESE VEHICLES DO NOT INDICATE WHICH SEATING POSITIONS ARE EQUIPPED WITH TETHER ANCHORAGES AND CHILD RESTRAINT ANCHORAGE SYSTEMS AS REQUIRED BY THE STANDARD.
Consequence: IN THE EVENT OF A CRASH, THE CHILD SEAT MAY NOT BE PROPERLY ATTACHED INCREASING THE RISK OF INJURY TO THE CHILD.
Remedy: OWNERS WILL BE PROVIDED WITH THE NECESSARY CHILD RESTRAINT SYSTEM INFORMATION. OWNER NOTIFICATION IS EXPECTED TO BEGIN OCTOBER 8, 2001. OWNERS WHO DO NOT RECEIVE THE FREE INFORMATION WITHIN A REASONABLE TIME SHOULD CONTACT DAIMLERCHRYSLER AT 1-800-853-1403.
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