Fuel leaks and fuel pump failures
FUEL/PROPULSION SYSTEM
6 NHTSA complaints · 2005-04 → 2017-08
“THE CONTACT STATED THAT THE VEHICLE WAS LEAKING FUEL”
“MY FAMILY BEGAN NOTICING A GAS SMELL SEVERAL MONTHS AGO”
“FUEL LEAKING FROM TOP OF FUEL TANK”
2004 Dodge Caravan Recalls, Problems & Maintenance
The 2004 Dodge Caravan has no open NHTSA recalls. Owners report 6 recurring issue clusters, led by “Fuel leaks and fuel pump 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.
Save this car as:
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 2004 Dodge Caravan.
Reported to NHTSA
Brake overheating and lock-up
SERVICE BRAKES, HYDRAULIC
5 NHTSA complaints · 2005-11 → 2013-09
“BRAKES LOCKED, PADS AND ROTORS BURNT, MASTER CYLINDER NOT ALLOWING FLUID TO RETURN”
“THE PEDAL TRAVEL GOES TO ZERO AND THE BRAKE IS LOCKED”
“I PROCEEDED TO CONTINUE DOWN THE HWY, AND WITHIN MINUTES, IT HAPPENED AGAIN”
Power steering leakage and noise
STEERING
3 NHTSA complaints · 2004-10 → 2011-03
“POWER STEERING PRESSURE HOSE LEAKING - REPLACED TWO TIMES IN THREE YEARS - NO RECALL ON THIS ITEM, ADVISED BY DEALER THAT THIS IS A FREQUENT REPAIR AND IS SERIOUS”
“CONSUMER WAS REFUSED SERVICE AFTER RECEIVING A RECALL LETTER FOR THE POWER STEERING LEAKAGE, NHTSA RECALL 04V386000”
Seat frame and latch failures
SEATS
3 NHTSA complaints · 2004-06 → 2019-05
“THE BROKEN PART IS ACTUALLY THE FRAME OF THE SEAT, NOT THE TILT MECHANISM”
“WHILE DRIVING AT 25 MPH LATCH MECHANISM WAS NOT LOCKED PROPERLY”
Stalling after refueling
FUEL/PROPULSION SYSTEM
12 NHTSA complaints · 2010-12 → 2017-01
“EVERY TIME VEHICLE IS FUELED UP, THE VEHICLE PUTTERS AND SHUTS OFF, CAUSING ALL POWER STEERING TO LOCK UP WHILE DRIVING”
“WHEN ONE DRIVES AWAY AFTER REFUELING THE GAS TANK THE VEHICLE QUITS RUNNING. IT WILL RESTART”
“IT WILL STALL OUT WITHIN A FEW MINUTES OF DRIVING AFTER LEAVING THE GAS STATION”
Airbag clockspring malfunction
AIR BAGS
3 NHTSA complaints · 2008-10 → 2016-01
“THE AIRBAG WARNING LIGHT IS ILLUMINATED DUE TO A MALFUNCTIONING CLOCKSPRING”
“THE DEALER DIAGNOSED THE PROBLEM AS A BROKEN AIRBAG CLOCKSPRING WHICH IS HOUSED INSIDE THE STEERING COLUMN AND ALSO NOT COVERED UNDER THE EXTENDED WARRANTY THAT I PURCHASED AT TIME I BOUGHT THE CAR NEW AT THE DEALER”
Issues on other model years
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.
Essential maintenance
Critical for safety and preventing major damage
Engine Oil & Filter (Oil Change Indicator)
Every 10,000 miChange 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 miRotate 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 miInspect 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 miHEMI 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 miGrand 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 miRWD 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 miReplace 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 miInspect 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 miReplace 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 miStellantis 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 miTest 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)
117 crashes 1990–2024
How the 117 occupant deaths break down
85
driver deaths
32
passenger deaths
117
occupant deaths
Crash years covered: 1990–2024 This model year first appears in 2004 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.
2
complaints mentioning a crash
3
complaints mentioning a fire
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 2004 Dodge 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.