The 1996 Dodge Grand Caravan with the 41TE/A604 four-speed automatic is a spacious family hauler undermined by catastrophic transmission failures and 3.0L/3.3L engine oil-sludge issues that often lead to complete rebuilds.
41TE/A604 Transmission Failure
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Harsh 2-3 shift or complete loss of second gear, Slipping on acceleration, especially when warm, Red fluid leaking from bell housing area or oil cooler lines, Governor pressure solenoid codes (P0740, P0750)
Fix: Rebuild or replace transmission (8-12 labor hours). Must also replace external oil cooler and flush lines to prevent repeat failure from contaminated ATF. OE governor pressure solenoid pack and overdrive/underdrive solenoids typically replaced during rebuild.
Estimated cost: $2,200-3,800
3.0L/3.3L Oil Sludge and Engine Failure
Common · high severity
Typical onset: 90,000-150,000 mi
Symptoms: Knocking or ticking noise from crankcase, especially cold start, Blue smoke from exhaust under load, Loss of oil pressure at idle when hot, Severe oil consumption (1 qt per 500-800 miles)
Fix: These engines sludge badly with extended drain intervals. Rod bearings and piston rings fail first, often requiring short-block replacement or full rebuild (18-24 labor hours). Head gaskets also common on 3.3L. Machine work, parts, and reassembly is extensive.
Estimated cost: $3,500-5,500
Transmission Oil Cooler Line Corrosion
Common · medium severity
Typical onset: 70,000-120,000 mi
Symptoms: ATF pooling under vehicle after parked, Transmission overheating and slipping, Visible rust perforation on steel cooler lines at frame rail bends
Fix: Replace both cooler lines from transmission to radiator-mounted cooler (2.5-3.5 hours). Road salt accelerates corrosion on these poorly-protected steel lines. Failure causes rapid fluid loss and transmission damage if not caught early.
Estimated cost: $350-550
Fuel Pump Failure
Occasional · high severity
Typical onset: 100,000-160,000 mi
Symptoms: No-start condition with crank but no fire, Stalling when fuel tank below 1/4 full, Whining noise from rear when key turned to 'on', Intermittent loss of power climbing hills
Fix: Drop fuel tank and replace pump module assembly (2.5-3 hours). Tank must come down completely on this generation. Strainer and sock filter should be replaced simultaneously. Related recall addressed external fuel line quick-connects but not pump itself.
Estimated cost: $450-750
Front Engine/Transmission Mount Collapse
Common · medium severity
Typical onset: 80,000-130,000 mi
Symptoms: Severe clunking when shifting from park to drive or reverse, Vibration through steering wheel and floor at idle, Visible engine sag when viewed from side with hood open
Fix: Replace front torque strut mount and main transmission mount (2-3 hours combined). Hydraulic mounts deteriorate and allow excessive engine movement that accelerates CV axle and exhaust failures. Common on all 3.0/3.3/3.8 V6 models.
Estimated cost: $300-500
Integrated Child Seat Belt Mechanism Failure
Occasional · medium severity
Symptoms: Child seat belts won't retract or lock properly, Warning light illuminated on dash, Belt webbing frayed at retractor mechanism
Fix: Multiple recalls issued for integrated child seat assemblies in second-row bench. Replacement requires complete seat removal and belt mechanism swap (1.5-2 hours per seat). Check recall status before purchasing; many were never remedied.
Estimated cost: $0 if recall applies, $400-650 otherwise
Owner tips
Change ATF every 30,000 miles with Mopar ATF+4 only—aftermarket fluid kills these transmissions faster
Use 5W-30 synthetic oil and change every 4,000 miles maximum to combat sludge on 3.0L/3.3L engines
Inspect transmission cooler lines annually for rust bubbling—catch leaks before pump runs dry
Check engine mounts every 50,000 miles and replace at first sign of cracking or sagging
Only buy if you find documented evidence of transmission rebuild and religious oil changes—budget $4,000-6,000 for inevitable drivetrain work otherwise.
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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ON CERTAIN MINI VANS, THE CLOCKSPRING ASSEMBLY MAY HAVE BEEN WOUND INCORRECTLY DURING THE VEHICLE ASSEMBLY PROCESS.
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 VEHICLES WITH 70,000 MILES OR LESS. AN EXTENDED LIFETIME WARRANTY WILL ALSO BE PLACED ON THIS COMPONENT FOR ALL AFFECTED VEHICLES, REGARDLESS OF MILEAGE. DAIMLERCHRYSLER WILL ALSO REIMBURSE OWNERS WHO HAVE PAID TO HAVE THE CLOCKSPRING REPLACED ON THEIR VEHICLES. OWNER NOTIFICATION BEGAN NOVEMBER 18, 2002. 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.
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.
VEHICLE DESCRIPTION: MINIVANS. FUEL CAN LEAK FROM THE FUEL TANK AT THE INTERFACE OF THE FUEL PUMP MODULE ATTACHMENT.
Consequence: IF A FUEL LEAK OCCURS IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Remedy: DEALERS WILL REPLACE THE FUEL PUMP MODULE ATTACHING NUT WITH A NUT THAT INCLUDES TIGHTER DESIGN TOLERANCES. THE SEALING O-RING WILL ALSO BE REPLACED.
CHILD SEAT · 98V185000
1998-08-06 · EA97003
VEHICLE DESCRIPTION: MINI VANS EQUIPPED WITH INTEGRATED CHILD SEATS. THE SHOULDER HARNESS RESTRAINT ON THE INTEGRATED CHILD SEAT CAN BECOME DIFFICULT TO EXTRACT WHEN THE SAFETY BELT LATCH PLATE BECOMES CONTAMINATED.
Consequence: THIS CAN CAUSE DIFFICULTY IN RELEASING A CHILD FROM THE RESTRAINT.
Remedy: DEALERS WILL CLEAN THE LATCH MECHANISM. AN EXTENDER WILL BE ADDED TO THE EMERGENCY RELEASE ANCHOR FOR THE CHILD SEAT SAFETY BELTS SO THAT THE RELEASE CLIPS ARE MORE VISIBLE AND ACCESSIBLE TO THE OPERATOR IN THE EVENT THAT THE RETRACTOR MECHANISM CAN NOT BE UNLOCKED. IN ADDITION, AN INSTRUCTIONAL OWNER'S MANUAL SUPPLEMENT CARD WILL BE PROVIDED.
SEAT BELTS:INTEGRATED CHILD SEAT · 97I001000
1996-10-24 · EA97003
VEHICLE DESCRIPTION: MULTIPURPOSE PASSENGER VEHICLES EQUIPPED WITH INTEGRAL CHILD SEATS. THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH FEDERAL REGULATION 573. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. ON THE INTEGRAL CHILD SEAT, THE SHOULDER BELTS RESTRAINING THE CHILD RETRACT AND LOCK IN PLACE AFTER THE BELT BUCKLE IS CONNECTED TO THE LATCH PLATE. THE LATCH PLATE MOVEMENT LOCKS THE BELTS TO MAKE SURE THE CHILD IS RESTRAINED IN THE CASE OF A VEHICLE CRASH.
Consequence: THE LATCH PLATE LOCATED IN THE SEAT CUSHION AREA MUST BE FREE TO MOVE BACK AGAINST ITS STOP AFTER THE BUCKLE IS REMOVED TO ALLOW THE SHOULDER BELTS TO BE PULLED OUT. ALWAYS BE SURE THE AREA AROUND THE LATCH PLATE IS FREE OF FOOD OR OTHER ITEMS THAT MIGHT PREVENT THE LATCH PLATE FROM MOVING BACK.
Remedy: OWNERS ARE BEING PROVIDED WITH A VIDEO TAPE AND 2 HARNESS CLIPS. THE VIDEO TAPE INSTRUCTS OWNERS ON THE PROPER USE AND MAINTENANCE OF THE CHILD SEATS.
SEAT BELTS:INTEGRATED CHILD SEAT · 96V136000
1996-07-18
THE BOLTS WHICH SECURE THE INTEGRATED CHILD SEAT MODULES TO THE SEAT FRAME CAN BREAK.
Consequence: IN THE EVENT OF A VEHICLE ACCIDENT, THE CHILD SEAT MAY NOT PROVIDE ADEQUATE PROTECTION TO THE OCCUPANT.
Remedy: DEALERS WILL REPLACE THE INTEGRATED CHILD SEAT MODULE BOLTS.
FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP · 96V002000
1996-01-16
A STATIC ELECTRIC CHARGE CAN BUILD UP ON THE UNGROUNDED METAL SECTION OF THE FUEL FILLER TUBE.
Consequence: THIS CONDITION COULD CAUSE A SPARK TO OCCUR WHEN FUELING THE VEHICLE AND POSSIBLY IGNITE THE FUEL VAPORS.
Remedy: DEALERS WILL INSTALL A GROUND STRAP FOR THE FUEL FILLER TUBE.
ENGINE AND ENGINE COOLING:ENGINE:GASOLINE · 96V006000
1996-01-11
IN CERTAIN VEHICLES, THE ENGINE CYLINDER HEAD OIL GALLEY PLUG DOES NOT SEAL PROPERLY AND ENGINE CYLINDER HEAD OIL IS NOT ADEQUATELY RETAINED.
Consequence: INADEQUATE SEALING AND RETENTION OF THE PLUG CAN RESULT IN OIL LEAKAGE WHICH COULD CAUSE A FIRE IN THE ENGINE COMPARTMENT.
Remedy: DEALERS WILL INSTALL AN EXPANSION PLUG AND RETAINING BRACKET OVER THE CYLINDER HEAD OIL GALLEY PLUG.
FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS · 95V236000
1995-12-08 · PE95053
THE FUEL TANK ROLLOVER VALVE CAN ALLOW FUEL TO PASS INTO THE VAPOR CANISTER RESULTING IN THE POTENTIAL FOR FUEL LEAKAGE.
Consequence: FUEL LEAKAGE INCREASES THE POTENTIAL FOR A VEHICLE FIRE.
Remedy: DEALERS WILL REPLACE THE FUEL TANK FILLER TUBE WITH A FILLER TUBE THAT HAS AN ADDITIONAL ROLLOVER VALVE. THE ASSOCIATED ROLLOVER VALVE VAPOR HOSES WILL BE REROUTED.
SEATS · 95V225000
1995-11-28
THE BOLTS WHICH SECURE THE REAR BENCH SEATS TO THE SEAT RISERS MAY BE EMBRITTLED AND FRACTURE.
Consequence: IN CASE OF AN ACCIDENT, THE BOLT MAY FAIL AND CAN CAUSE THE SEAT TO BREAK AWAY FROM THE SEAT RISERS, WHICH INCREASES THE POTENTIALOF INJURY TO ITS OCCUPANTS.
Remedy: DEALERS WILL REPLACE THE REAR BENCH SEAT TO RISER BOLTS.
SEAT BELTS:INTEGRATED CHILD SEAT · 95I004000
1995-09-25
Remedy: CHRYSLER DEALERS WILL REPLACE BOTH CHILD SEAT ASSEMBLIES WITH REVISED SEATS CONTAINING RETRACTOR IMPROVEMENTS. THE REVISED SEATS WILL ALSO INCREASE CHILD COMFORT BY INCORPORATING PROTECTIVE SEAT BELT WRAPS TO PREVENT BELT CHAFE.
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