2002 Dodge Grand Caravan Recalls, Problems & Maintenance

The 2002 Dodge Grand Caravan has no open NHTSA recalls. Owners report 8 recurring issue clusters, led by “Power steering pump, hose and rack failures.” Dodge uses Stellantis' Oil Change Indicator — it watches engine load and duty cycle and messages when to change oil, capped at 10,000 miles or 12 months. Know your engine: the 3.6L Pentastar V6 goes 100,000 miles on plugs, while HEMI V8s carry sixteen plugs (two per cylinder) on a roughly 30,000-mile interval — that's a real cost difference at the service counter. HEMI models with MDS cylinder deactivation are especially sensitive to overdue oil.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2002 Dodge Grand Caravan.

Reported to NHTSA

Power steering pump, hose and rack failures

STEERING

21 NHTSA complaints · 2004-07 → 2010-12

“THE RACK AND PINION IS LEAKING, CAUSING THE POWER STEERING FLUID TO LEAK ON OUR 2002 DODGE GRAND CARAVAN SPORT. WE HAD THE RACK AND PINION REPLACED IN FALL OF 2005 AFTER HAVING TROUBLE WITH STEERING”
— Owner report, NHTSA ODI #10186582
“TWICE EARLIER THIS YEAR I HAD TWO POWER STEERING HOSES BLOW OUT ON ME WHILE DRIVING. HAD TO MAKE AN EMERGENCY PULL-OVER AND HAVE VEHICLE TOWED. *TR”
— Owner report, NHTSA ODI #10244490
“PREMATURE FAILURE OF POWER STEERING PUMP ON 2002 DODGE GRAND CARAVAN. REPLACED UPPER POWER STEERING RETURN HOSE. *BF THE VEHICLE HAS BEEN RECALLED TWICE FOR THIS PROBLEM. *NM THE CONSUMER EXPERIENCED SIMILAR PROBLEMS WITH THE POWER STEERING HOSE PRIOR TO THE FIRST RECALL”
— Owner report, NHTSA ODI #10099387

Read all complaints on NHTSA →

Intermittent headlight and front module failures

EXTERIOR LIGHTING

18 NHTSA complaints · 2005-01 → 2011-12

“WHEN THE LOW BEAMS ARE ON ONE HEADLIGHT IS OUT AND WHEN THE HIGH BEAMS ARE ON THE OTHER HEADLIGHT IS OUT. I HAD IT FIXED TWICE BY TWO DIFFERENT SHOPS UNTIL I FOUND THAT THE PROBLEM IS THE FRONT COMPUTER MODULE”
— Owner report, NHTSA ODI #10430046
“THE CONTACT STATED THE DRIVER SIDE LOW-BEAM AND PASSENGER SIDE HIGH BEAM HEADLIGHTS WOULD NOT OPERATE. THE CONTACT REPLACED THE HEADLIGHT BULBS AND THE FAILURE CONTINUED TO OCCUR. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE MULTI-FUNCTION SWITCH WAS REPLACED”
— Owner report, NHTSA ODI #10365460
“WHEN THE IGNITION IS FIRST TURNED ON, THE DAYLIGHT LIGHTS COME ON THE DRIVER SIDE ONLY, THE PASSENGER LIGHT IS OFF. WHEN THE HEADLIGHTS ARE TURNED ON THE PASSENGER SIDE TURNS ON ONLY, THE DRIVER SIDE IS OFF”
— Owner report, NHTSA ODI #10292668

Read all complaints on NHTSA →

Transmission failure and abnormal shifting

POWER TRAIN

14 NHTSA complaints · 2004-07 → 2008-01

“DRIVING ON THE FREEWAY GOING 65 MPH THE VAN DOWN SHIFTED TO A LOWER GEAR WITH A JOLT. FOLLOWING THE OWNERS MANUAL I PULLED TO THE SIDE OF THE ROAD AND PUT THE MINI VAN IN PARK. RESTARTED THE VAN PUT IT IN GEAR AND STARTED TO MOVE AND HEARD AND FELT THE TRANSMISSION GRINDING”
— Owner report, NHTSA ODI #10149265
“2002 DODGE GRAND CARAVAN WITH 69,500 MILES. TRANSMISSION MADE A JERKING AND DID NOT WANT TO SEEM TO SHIFT. TOOK TO DODGE DEALER AND THEY COULD NOT DUPLICATE. THEY ALLOWED SERVICE MAN TO DRIVE HOME AND DROVE APPROX. 100 MILES. THEY CONCLUDED NO PROBLEM THEY COULD FIND”
— Owner report, NHTSA ODI #10146036
“AT 62,000 MILES THE CAR WOULD NOT SHIFT INTO GEAR. AFTER MOVING THE GEAR SHIFT ALL THE WAY UP AND DOWN IT ENGAGED, BUT BEGAN DOWNSHIFTING VERY HARD FROM 4TH TO 3RD. DEALER PERFORMED MAINTENANCE AND REPROGRAMMED THE MODULE WHICH RESOLVED THE PROBLEM FOR ABOUT 8,000 MILES”
— Owner report, NHTSA ODI #10201285

Read all complaints on NHTSA →

Fuel system leaks and gasoline odor in cabin

FUEL/PROPULSION SYSTEM

8 NHTSA complaints · 2004-11 → 2018-06

“LEAKING FUEL RAIL CAP 2002 DODGE CARAVAN IS LEAKING GAS ALL OVER THE SPARK PLUGS ENGINE AND ELECTRICAL PARTS WHEN 1ST TURNING THE VEHICLE ON IN THE MORNING”
— Owner report, NHTSA ODI #10971147
“STRONG FUEL SMELL ENTERING THE CABIN AT LOW SPEED OR IDLE COMING FROM VEHICLE WHEN RUNNING”
— Owner report, NHTSA ODI #11104678
“THE CONTACT STATED THAT THE VEHICLE'S FUEL TANK CONTROL VALVE WELD JOINT HAS BEEN LEAKING FOR THREE WEEKS. THE MECHANIC FOUND THE LEAK AFTER THE VEHICLE WAS TAKEN IN BECAUSE THE CHECK ENGINE LIGHT KEPT ILLUMINATING”
— Owner report, NHTSA ODI #10190660

Read all complaints on NHTSA →

Sliding door and power door lock failures

STRUCTURE, LATCHES/LOCKS/LINKAGES

8 NHTSA complaints · 2005-01 → 2011-09

“VAN WAS SITTING IN THE DRIVEWAY WHEN I TRIED TO OPEN THE PASSENGER SIDE SLIDING DOOR. DOOR WILL NOT UNLOCK BY PULLING UP ON THE ACTUAL LOCK OR VIA THE POWER DOOR SWITCH. IT'S NOT A POWER SLIDING DOOR”
— Owner report, NHTSA ODI #10423193
“2002 DODGE GRAND CARAVAN SLIDING DOOR LOCKS AND CAN'T BE OPENED MANUALLY OR REMOTELY. PASSENGERS MUST EXIT OPPOSITE SIDE OF CAR. STARTED 3 DAYS AGO, HAVEN'T HAD TIME TO BRING TO DEALER YET”
— Owner report, NHTSA ODI #10263301
“DT*: THE CONTACT STATED WHILE PARKED DOWN HILL THE MANUAL SLIDING DOORS SLAMMED SHUT. THE DOOR GOES INTO THE LOCK POSITION BUT, THE PLASTIC MECHANISM THAT HOLDS THE DOOR LOCKED HAS A CRACK WHICH CAUSES THE DOOR TO SLAM SHUT. THE DEALERSHIP HAS BEEN ALERTED”
— Owner report, NHTSA ODI #10153065

Read all complaints on NHTSA →

Air bag warning light and clockspring failures

AIR BAGS

30 NHTSA complaints · 2004-06 → 2019-06

“AIRBAG LIGHT HAS HAD TO BE RESET BY DEALER SEVERAL TIMES SINCE WE HAVE BOUGHT THE VEHICLE NEW IN 2002. TIRED OF PAYING $100 FOR THEM TO PROVIDE A TEMPORARY, UNEXPLAINED INEFFECTIVE REPAIR. *TR”
— Owner report, NHTSA ODI #10200517
“IN JUNE OF 2007, WHENEVER THE VEHICLE WAS STARTED, THE AIR BAG LIGHT CONTINUALLY REMAINED ILLUMINATED. THE CONTACT TOOK THE VEHICLE TO HIS LOCAL MECHANIC FOR REPAIR AND WAS INFORMED THAT THE CLOCK SPRING FAILED”
— Owner report, NHTSA ODI #10228435
“AIRBAG LIGHT TURNS ON AND OFF INTERMITTENTLY WHILE DRIVING THE VEHICLE. DRB III SCAN TOOL INDICATED DRIVER'S SQUIB CIRCUIT #2 FAILURE. CLOCK SPRING REPLACED, CORRECTING THE FAILURE. FAILED PART RETAINED BY DEALER.*AK”
— Owner report, NHTSA ODI #10100096

Read all complaints on NHTSA →

Brake wear, freezing and fluid loss

SERVICE BRAKES, HYDRAULIC

12 NHTSA complaints · 2004-06 → 2009-02

“TRAVELING AT APPROXIMATELY 40 MPH BRAKES WERE APPLIED AND QUICKLY FAILED. RESULTED IN ACCIDENT. NOTICED FLUID LEAK IN THE ROAD WHERE BRAKES WERE APPLIED. *TR”
— Owner report, NHTSA ODI #10257527
“BRAKE FAILURE EVERY 16000 MILES OR SO. I HAD TO REPLACE THE FRONT BRAKE PADS 4 TIMES SINCE I HAD THIS VEHICLE. I HAD TO REPLACE THE ROTORS TWICE SINCE PURCHASE BECAUSE THE ROTORS DELAMINATED. YESTERDAY THE VAN HAD A HARD TIME STOPPING”
— Owner report, NHTSA ODI #10100911
“THE CONTACT STATED THAT WHENEVER THE VEHICLE IS PARKED IN COLD WEATHER OR GETS WET, THE BRAKE SYSTEM LOCKS AND THE VEHICLE IS UNABLE TO MOVE. HE HAD TO REMOVE THE REAR BRAKE DRUM IN ORDER TO REPAIR THE VEHICLE”
— Owner report, NHTSA ODI #10212709

Read all complaints on NHTSA →

Fire and smoke from wiring and components

ELECTRICAL SYSTEM

10 NHTSA complaints · 2004-09 → 2023-09

“DODGE GRAND CARAVAN JUST WENT UP IN FLAMES WHILE DRIVING WITHIN MAYBE 5 MINUTES FIRE FIGHTERS CONTROL THE SITUATION BUT THE MOTOR ,BATTERY, EVERYTHING IN FRONT INSIDE HOOD JUST MELTED I REALLY NEED HELP I HAD JUST FINISHED PAYING IT WHEN THIS HAPPENED”
— Owner report, NHTSA ODI #10451654
“DT*: THE CONTACT STATED WHILE PARKED AT A STOP LIGHT WHITE SMOKE CAME FROM THE HEATING VENT ON THE PASSENGER SIDE OF THE DASH BOARD. THE SMOKE BEGAN TO TURN BLACK AND FLAMES ERUPTED FROM THE DASHBOARD VENT. THE CONTACT PULLED OFF OF THE ROAD”
— Owner report, NHTSA ODI #10157559
“WHILE DRIVING I SMELLED SMOKE. I COULDN'T SEE WHERE IT WAS COMING FROM SO I CONTINUED DRIVING. THEN I SAW SMOKE COMING OUT FROM BEHIND THE PANEL ON THE PASSENGER SIDE REAR SLIDING DOOR. I THEN PULLED OVER TO SEE WHAT WAS GOING ON”
— Owner report, NHTSA ODI #10222249

Read all complaints on NHTSA →

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter (Oil Change Indicator)

Every 10,000 mi

Change when the indicator says so — never beyond 10,000 miles or 12 months. Pentastar 3.6L: 0W-20. HEMI 5.7L: 5W-20 (0W-40 for 6.4L SRT). MDS-equipped HEMIs punish stretched oil intervals with lifter and cam wear.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 8,000 mi

Rotate every 8,000 miles. Charger/Challenger R/T and Scat Pack: staggered-width setups can't rotate front-to-rear — budget rear tires accordingly.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect pads and rotors at every oil change. Heavy Durangos used for towing and hard-driven Chargers both run through rear pads faster than the front-pad-first rule of thumb suggests.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Spark Plugs

Every 30,000 mi

HEMI 5.7L: sixteen plugs roughly every 30,000 miles — check your year's manual. Pentastar 3.6L (Charger/Challenger V6, Durango V6, Journey, Grand Caravan): 100,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Automatic Transmission Fluid

Every 60,000 mi

Grand Caravan/Journey (62TE): ATF+4 service every 60,000 miles in family duty. Charger/Challenger/Durango with the TorqueFlite 8-speed: no published normal interval, but specialists recommend service around 60,000-100,000 miles — sooner with towing.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Rear Differential Fluid

Every 60,000 mi

RWD Charger/Challenger and AWD Durango: replace rear diff fluid around 60,000 miles, sooner with towing or drag-strip duty. Limited-slip units need the friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Engine Air Filter

Every 30,000 mi

Replace every 30,000 miles. HEMIs pull serious airflow — a clogged filter costs measurable power before it throws a code.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Serpentine Belt

Every 60,000 mi

Inspect from 60,000 miles, replace on cracking or glazing. On the HEMI, a shredded belt can take the cooling drive with it mid-drive.

Estimated cost — typical U.S. ranges

Dealer

~$195–$235

Shop

~$135–$165

DIY

~$20–$50

DIY-friendly if you can reach the tensioner. Inspect for cracks rather than swap on a strict mileage interval.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace every 20,000 miles where equipped (behind the glovebox on most models). Some earlier Journeys and Avengers shipped without one — check before buying a filter.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Coolant Replacement (OAT)

Every 100,000 mi

Stellantis OAT coolant is scheduled for 10 years / 150,000 miles; shops commonly refresh by 100,000. OAT-compatible coolant only — mixing chemistries gels the system.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Battery Test & Service

Every 25,000 mi

Test annually after year 3. Big-audio Chargers and tow-package Durangos lean on the battery hard; weak batteries surface as gremlins in the electronics before they fail to crank.

Estimated cost — typical U.S. ranges

Dealer

~$225–$390

Shop

~$160–$280

DIY

~$130–$250

Most auto-parts stores test and install batteries free with purchase. Skip the dealer markup.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

346 crashes 1990–2024

How the 346 occupant deaths break down

229

driver deaths

117

passenger deaths

346

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2001 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

15

complaints mentioning a crash

14

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2002 Dodge Grand Caravan reflects Dodge's published service intervals and the Oil Change Indicator System system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.