2004 DODGE CARAVAN

Typical onset: 80,000-150,000 mi

Symptoms: Harsh or delayed 2-3 upshift, especially when cold, Slipping between gears under load, Complete loss of forward gears, stuck in limp mode, Burnt transmission fluid smell, dark brown or black fluid

Fix: Transmission rebuild or replacement required. Often the solenoid pack fails first (4-6 hours labor), but internal clutch pack damage follows quickly. Full rebuild: 12-16 hours. Remanufactured unit swap: 8-10 hours. Input/output speed sensor codes are early warning signs—address immediately.

Estimated cost: $2,200-3,800

Typical onset: 120,000-180,000 mi

Symptoms: Deep knocking noise from bottom of engine, worse under load, Low oil pressure warning light, especially at idle when hot, Metal shavings or glitter in oil during changes, Sudden catastrophic failure with rod through block

Fix: Requires complete engine teardown. Rod bearings wear prematurely due to marginal oiling system design. If caught early with just bearing noise, in-chassis crank polish and bearing replacement: 18-22 hours. Most times we see spun bearings or damaged journals requiring short-block or full replacement: 20-28 hours.

Estimated cost: $3,500-6,500

Typical onset: 90,000-140,000 mi

Symptoms: Coolant leak visible below intake plenum, dripping onto starter area, Coolant smell from engine bay, no visible external leak, Gradual coolant loss, needs topping off every few weeks, White smoke at startup after overnight sit (coolant seeping into cylinders)

Fix: Upper and lower intake manifold gaskets deteriorate. Replace both plenum and lower gaskets as a set with updated composite gaskets. Must remove upper plenum, fuel rail, throttle body. 5-7 hours labor. Always inspect for coolant contamination in oil—if present, plan for head gasket job instead.

Estimated cost: $650-1,100

Typical onset: 100,000-160,000 mi

Symptoms: Overheating with no obvious coolant leak, Milky tan oil on dipstick or oil cap, White exhaust smoke that smells sweet, Bubbles in coolant overflow tank at idle, pressurized cooling system

Fix: Typically starts at rear cylinder (closest to firewall) on one bank. Requires cylinder head removal, resurfacing, and gasket replacement. If caught before severe overheating, heads usually don't crack. Both heads: 14-18 hours. Single head: 10-12 hours. Always check for warpage—these heads can twist if overheated severely.

Estimated cost: $1,800-3,200

Typical onset: 70,000-120,000 mi

Symptoms: Power steering fluid spraying onto engine or ground, visible under vehicle, Sudden loss of power assist while driving, Groaning noise from pump when turning, Fluid puddle under vehicle after parking, reddish color

Fix: High-pressure hose from pump to rack develops leaks at crimp fittings or splits from age/heat exposure. This is a recall item (06V-263) but many weren't fixed. Replace pressure hose and return hose as preventive maintenance. 2-3 hours labor. Flush system to remove any metal debris from worn pump.

Estimated cost: $350-550

Typical onset: 90,000-150,000 mi

Symptoms: ABS and brake warning lights illuminated together, Pump motor runs continuously after key-off, drains battery, Loss of ABS function, pedal feels normal but no modulation, Codes for pump motor circuit or pressure switch

Fix: Internal motor brushes wear or solenoid valves stick. Entire HCU (hydraulic control unit) assembly typically needs replacement—no reliable rebuild kits. Must be bled with scan tool for proper calibration. 3-4 hours labor including programming.

Estimated cost: $900-1,400

Symptoms: Blower only works on highest speed setting, No lower speed settings (1-3) for fan, Intermittent fan operation on medium speeds, Burning smell from HVAC vents

Fix: Resistor block located behind glove box fails from heat and vibration. Takes out speeds 1-3, high speed bypasses resistor so still works. Simple replacement, accessible from passenger footwell. 0.5-1.0 hour labor. Check blower motor for excessive current draw before replacing—worn motor causes repeat resistor failures.

Estimated cost: $120-220