The 2009 Grand Caravan with the 3.8L V6 is the most problematic variant, notorious for transmission cooler failures that cascade into catastrophic transmission damage. The 3.3L is slightly more durable but shares the same transmission weakness and suffers from intake manifold gasket leaks.
Symptoms: Milky pink fluid in transmission pan or radiator overflow, Transmission slipping or delayed engagement after cooler contamination, Complete transmission failure if coolant mixes with ATF, Overheating transmission after cooler blockage
Fix: The factory cooler built into the radiator fails internally, allowing coolant and ATF to cross-contaminate. Requires radiator replacement, external cooler addition, full transmission flush or rebuild if contamination occurred. If caught early (just cooler): 3-4 hrs labor. If transmission damaged: 8-12 hrs for rebuild/replacement.
Estimated cost: $800-1,200 if caught early; $2,800-4,500 for transmission rebuild
Lower Intake Manifold Gasket Leak (3.3L/3.8L)
Common · medium severity
Typical onset: 80,000-140,000 mi
Symptoms: Coolant puddles under the engine front, center, Sweet smell from engine bay, steam from intake area, Overheating or coolant loss with no external leaks visible, Rough idle or misfire if coolant enters cylinders
Fix: The composite gasket fails where the lower intake meets the block. Requires removal of upper plenum, fuel rail, and accessories. Book time is 4.5-6 hrs. Often triggers a head gasket failure if overheating occurs, so address immediately. Always replace upper gaskets and thermostat during this job.
Estimated cost: $650-1,100
3.8L Engine Oil Sludge and Internal Failure
Occasional · high severity
Typical onset: 90,000-150,000 mi
Symptoms: Rapid oil consumption (quart every 500-800 miles), Ticking/knocking from valve train or lower end, Check engine light with misfire codes, Catastrophic failure: rod knock, spun bearings, seized engine
Fix: The 3.8L is extremely sludge-prone with neglected oil changes. Sludge blocks oil passages, starving bearings and causing piston ring failure. Most end up needing short block or complete engine replacement. Used engine swap: 12-16 hrs. Rebuild: 18-24 hrs. The 3.3L has this issue less frequently but it still happens.
Estimated cost: $3,200-5,800 for used engine installed; $4,500-7,500 for rebuild
Rear Suspension Trailing Arm Bushings and Links
Common · medium severity
Typical onset: 60,000-110,000 mi
Symptoms: Clunking or knocking over bumps from rear, Wandering or loose feel at highway speeds, Uneven rear tire wear, especially inside edges, Visible rubber tears or metal-on-metal contact in trailing arm bushings
Fix: The rear trailing arm bushings deteriorate and the lateral links wear out. This van's load-bearing design accelerates wear. Trailing arms alone: 2.5-3.5 hrs per side. Full rear end refresh (both arms, lateral links, shocks): 5-7 hrs. Related to the rear axle recall but many fail outside recall criteria.
Estimated cost: $450-750 for trailing arm bushings; $900-1,400 for full rear suspension rebuild
TIPM (Totally Integrated Power Module) Failures
Occasional · high severity
Symptoms: Fuel pump won't prime, no-start condition, Wipers, windows, or locks operating on their own, ABS and traction control lights with no codes stored, Intermittent electrical gremlins across multiple systems
Fix: The TIPM is Chrysler's Achilles heel 2007-2016. Internal relays fail, most commonly the fuel pump relay. Sometimes fixable by resoldering relays (1.5 hrs), but Chrysler wants the whole module replaced (0.8 hrs labor but $400-900 for the part). Used TIPMs are risky. This is related to the wiring/fuse recall but many fail outside recall scope.
Estimated cost: $150-300 for relay repair; $500-1,100 for new TIPM installed
Power Sliding Door Mechanisms and Cables
Common · low severity
Typical onset: 70,000-120,000 mi
Symptoms: Door reverses or stops mid-cycle with warning chime, Door opens but won't close, or vice versa, Cable fraying visible at door hinge area, Motor runs but door doesn't move
Fix: The cables stretch and fray, and the plastic rollers in the track break. Per door: cable replacement 2-3 hrs, roller/track service 1.5-2 hrs. If motor fails: add 1 hr. Many owners just disable the power function and use manual mode. Not safety-critical but annoying and parts are expensive from Chrysler.
Estimated cost: $350-650 per door for cable; $180-320 for rollers
Owner tips
Install an external transmission cooler immediately on any 3.8L or 3.3L—it's $150 in prevention vs. $3,500 in transmission work
Change oil every 3,500 miles maximum on the 3.8L; this engine cannot tolerate extended intervals
Check for coolant/ATF cross-contamination every oil change—pull trans dipstick and radiator cap, look for milkshake fluid
The 4.0L V6 is rare but more durable than the 3.8L—seek it out if buying used, though parts availability is worse
Avoid the 3.8L entirely; the 3.3L is marginal with religious maintenance and an added cooler, but expect $2,000-4,000 in deferred issues on any high-mileage example.
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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Fitment notes: Standard top post battery; located under hood
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Every control module on the 2008-2020 Dodge Grand Caravan — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
📍 Rear cargo area, driver side or behind rear bumper
🔧 wiTECH or Autel/Launch
⚠️ Optional equipment; controls trailer lighting and integrated brake controller
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE · 20V396000
2020-07-07
Chrysler (FCA US LLC) is recalling certain 2008-2010 Chrysler Town and Country and Dodge Grand Caravan and 2007-2011 Dodge Nitro vehicles. These vehicles may have a loose or missing brand emblem in the center of the steering wheel. The loose emblem or the securing nuts for the emblem within the driver air bag module may become projectiles in the event of a driver air bag deployment.
Consequence: Projectiles as a result of driver air bag deployment in the event of a crash can increase the risk of injury.
Remedy: Chrysler will notify owners, and dealers will replace the driver's air bag cover with a redesigned cover, free of charge. The recall began February 11, 2021. Owners may contact FCA US LLC customer service at 1-800-853-1403. Chrysler's number for this recall is W09.
AIR BAGS:FRONTAL · 16V047000
2016-01-29
FCA US LLC (Chrysler) is recalling certain model year 2009 Dodge Journey vehicles manufactured December 31, 2007, to August 31, 2008, 2008-2009 Dodge Grand Caravan and Chrysler Town and Country vehicles manufactured June 18, 2007, to August 31, 2008. In the affected vehicles, the air bag control units may corrode and fail.
Consequence: If the air bag control unit fails, the air bags may not deploy in the event of a crash, increasing the risk of occupant injury. Additionally, the air bags may inadvertently deploy, increasing the risk of a crash.
Remedy: Chrysler will notify owners, and dealers will replace the air bag control unit, free of charge. The recall began on December 6, 2016. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is S07.
ELECTRICAL SYSTEM:IGNITION:SWITCH · 14V373000
2014-06-26 · RQ14002
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring.
Chrysler Group LLC (Chrysler) is recalling certain model year 2009-2010 Dodge Journey vehicles manufactured June 29, 2007, to June 17, 2010, and 2008-2010 Dodge Grand Caravan and Chrysler Town and Country vehicles manufactured January 26, 2007, to June 17, 2010. Road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine.
Consequence: If the ignition key inadvertently moves into the OFF or ACCESSORY position, the engine will turn off, which will then depower various key safety systems including but not limited to air bags, power steering, and power braking. Loss of functionality of these systems may increase the risk of crash and/or increase the risk of injury in the event of a crash.
Remedy: Chrysler will notify owners, and dealers will replace the ignition switch and key FOBs, free of charge. The recall began on May 26, 2015. Owners may contact Chrysler customer service at 1-800-853-1403. Chrysler's number for this recall is R03. Note: This is an expansion of recall 11V-139.
Freedom Motors Inc., (Freedom Motors) of Savaria Vehicle Group (formerly The Liberty Motor Company) is recalling one model year 2009 Volkswagen Routan and certain model year 2008-2010 Dodge Grand Caravan and Chrysler Town & Country wheelchair accessible vehicles modified by The Liberty Motor Company from February 2008 through January 2011. Over time and with use, the vehicle's rear axle may develop cracks which could lead to axle failure.
Consequence: Failure of the rear axle may increase the risk of a crash.
Remedy: Freedom Motors will notify owners, and dealers will replace the affected axles, free of charge. The recall began on April 1, 2014. Owners can contact Freedom Motors at 1-800-561-9600. Freedom Motors' number for this recall is ENGF0216-3.
ELECTRICAL SYSTEM:WIRING · 10V235000
2010-06-03
CHRYSLER IS RECALLING CERTAIN MODEL YEAR 2008 AND 2009 DODGE GRAND CARAVAN AND CHRYSLER TOWN & COUNTRY PASSENGER VEHICLES MANUFACTURED FROM FEBRUARY 2007 THROUGH SEPTEMBER 2009. SOME OF THE VEHICLES MAY HAVE BEEN BUILT WITH AN IMPROPERLY ROUTED WIRE HARNESS THAT MAY HAVE A CONDITION WHERE THE LOWER SLIDING DOOR HINGE BRACKET CAN MAKE CONTACT AND WEAR THROUGH THE WIRE INSULATION.
Consequence: A SHORT CIRCUIT COULD OCCUR INSIDE THE SLIDING DOOR, OVERHEATING THE LATCH, POSSIBLY RESULTING IN A FIRE.
Remedy: CHRYSLER WILL NOTIFY OWNERS AND DEALERS WILL REPAIR THE VEHICLES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 15, 2010. OWNERS MAY CONTACT CHRYSLER TOLL-FREE AT 1-800-853-1403.
SERVICE BRAKES, HYDRAULIC · 09V351000
2009-09-11
ELDORADO NATIONAL IS RECALLING MODEL YEAR 2008-2009 AMERIVAN MOBILITY VEHICLES BUILT ON CHRYSLER TOWN & COUNTRY AND DODGE GRAND CARAVAN PLATFORMS VEHICLES. THE REAR BRAKE LINES MAY HAVE BEEN IMPROPERLY ROUTED AND NOT SECURED PROPERLY DURING THE ALTERATION. IF NOT ROUTED AND SECURED PROPERLY, THE BRAKE LINES COULD RUB AGAINST THE VEHICLE CAUSING A BRAKE FLUID LEAK.
Consequence: A BRAKE FLUID LEAK COULD RESULT IN A LOSS OF BRAKING ABILITY, POSSIBLY CAUSING A CRASH.
Remedy: ELDORADO NATIONAL AMERIVAN DEALERS WILL INSPECT THE VEHICLES AND IF THE BRAKE LINES WERE IMPROPERLY ROUTED THEY WILL BE CORRECTLY REINSTALLED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 13, 2009. OWNERS MAY CONTACT ELDORADO NATIONAL AT 1-800-955-9086. THESE MINIVANS HAVE BEEN ALTERED INTO WHEELCHAIR ACCESSIBLE VEHICLES BY ELDORADO. THIS RECALL IS NOT BEING CONDUCTED BY CHRYSLER GROUP LLC AND WILL NOT BE PERFORMED AT NO COST BY DODGE OR CHRYSLER DEALERS UNLESS THEY ARE ALSO AN ELDORADO NATIONAL DEALER.
ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS · 09V046000
2009-02-05
CHRYSLER IS RECALLING 6,138 MY 2009 TOWN AND COUNTRY AND DODGE GRAND CARAVAN VEHICLES. UNUSED ELECTRICAL CONNECTORS FOR THE BLIND SPOT DETECTION SYSTEM MAY BECOME CORRODED AND COULD SHORT CIRCUIT, WHICH CAN CAUSE A VARIETY OF CONDITIONS.
Consequence: IF THE FUSE FOR THIS CIRCUIT DOES NOT BLOW, THE CONNECTORS COULD OVERHEAT AND POTENTIALLY CATCH FIRE.
Remedy: DEALERS WILL SEAL THE POWER CIRCUIT AT THE SUBJECT CONNECTOR AND REPLACE THE FUSE FOR THIS CIRCUIT IF NECESSARY FREE OF CHARGE. THE RECALL BEGAN ON MARCH 9, 2009. OWNERS MAY CONTACT CHRYSLER AT 1-800-853-1403.
Wiper blades
Fifth generation (RT platform). Both front wipers are same length.
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2009 Dodge Grand Caravan 4.0L V6 and can vary by trim.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.