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2004 Dodge Grand Caravan Recalls, Problems & Maintenance

The 2004 Dodge Grand Caravan has no open NHTSA recalls. Owners report 6 recurring issue clusters, led by “Sliding door latch and power door 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 Grand Caravan.

Reported to NHTSA

Sliding door latch and power door failures

LATCHES/LOCKS/LINKAGES

8 NHTSA complaints · 2004-12 → 2021-03

“WE HAVE A DODGE GRAND CARAVAN WITH ELECTRIC SIDE DOORS. THE MOTORS MECHANISM HAS STOPPED THE ABILITY FOR MY DAUGHTERS TO BE ABLE TO OPEN THEM MANUALLY”
— Owner report, NHTSA ODI #10394064
“BOTH OF THE SLIDER DOORS ARE IMPOSSIBLE TO OPEN FROM THE INSIDE THE VEHICLE. I HAVE TO PHYSICALLY GET OUT OF THE VEHICLE AND OPEN THEM FROM THE OUTSIDE”
— Owner report, NHTSA ODI #10184065
“THE SLIDING RT SIDE DOOR HAS OPENED ELECTRONICALLY NUMEROUS TIMES AS THE VEHICLE IS MOVING DOWN THE ROAD. MOTOR WAS REPLACED, STILL CONTINUED TO MALFUNCTION”
— Owner report, NHTSA ODI #10104555

Read all complaints on NHTSA →

Front brake wear and rotor warping

SERVICE BRAKES, HYDRAULIC

7 NHTSA complaints · 2004-08 → 2008-02

“REPLACED FRONT BRAKES ON 2004 DODGE GRAND CARAVAN FOR THE FIRST TIME ON 8/31/05 WHEN MILEAGE WAS AT 39,320. ROTORS WERE ALSO RESURFACED AT THIS SAME TIME”
— Owner report, NHTSA ODI #10175943
“DURING INSPECTION DEALERSHIP INFORMED THE CONSUMER THAT FRONT BRAKES WORE OUT PREMATURELY. THE BRAKES WERE REPLACED”
— Owner report, NHTSA ODI #10103743
“SUDDEN NEED FOR FRONT BRAKES”
— Owner report, NHTSA ODI #10214631

Read all complaints on NHTSA →

Engine stall after refueling

FUEL/PROPULSION SYSTEM

29 NHTSA complaints · 2007-10 → 2016-11

“ENGINE STALLS OUT 10 OR 15 SECONDS AFTER FILLING THE GAS TANK”
— Owner report, NHTSA ODI #10819667
“CAR SHUTS OFF AFTER FILLING THE GAS TANK. THIS HAS HAPPENED SEVERAL TIMES. ALWAYS ON THE ROAD AND IN TRAFFIC”
— Owner report, NHTSA ODI #10702901
“AFTER FILLING MY '04 GRAND CARAVAN WITH FUEL AND ATTEMPTING TO LEAVE THE PUMP MY CARAVAN SHUTS OFF”
— Owner report, NHTSA ODI #10683697

Read all complaints on NHTSA →

Fuel leak and fuel odor at pump housing or tank

FUEL/PROPULSION SYSTEM

8 NHTSA complaints · 2005-06 → 2019-09

“HAIRLINE CRACKS IN FUEL PUMP OUTLET JUST BEFORE CONNECTING TO FUEL LINE LEADS TO STRONG FUEL SMELL AND FUEL VAPORS ALL AROUND VEHICLE”
— Owner report, NHTSA ODI #11253106
“NOTICED FUEL SMELL AND VEHICLE STALLING OR HESITATING AFTER FUELING, FOUND FUEL LEAK COMING FROM VERY SMALL CRACKS ON FUEL PUMP HOUSING TOP LOCATED ON THE PASSENGER SIDE OF THE VAN CLOSE TO THE EXHAUST SYSTEM”
— Owner report, NHTSA ODI #10593944
“FUEL LEAK FROM FUEL TANK AT THE FUEL PUMP VERY CLOSE TO THE EXHAUST!!!!”
— Owner report, NHTSA ODI #10477214

Read all complaints on NHTSA →

Steering rack and power steering failures

STEERING

8 NHTSA complaints · 2004-08 → 2010-09

“RACK AND PINION BINDING IN TURNS. CORRECTIVE ACTION HAD TO REPLACE RACK AND PINION”
— Owner report, NHTSA ODI #10355292
“VEHICLE HAS 55,000 MILES ON IT AND RACK AND PINION ASSEMBLY IS LEAKING”
— Owner report, NHTSA ODI #10235822
“POWER STEERING RESERVOIR FILTER CLOGS CAUSING POWER STEERING FAILURE. IT IS MORE SEVERE IN COLD WEATHER”
— Owner report, NHTSA ODI #10213332

Read all complaints on NHTSA →

Air bag warning light and deployment reports

AIR BAGS

5 NHTSA complaints · 2009-08 → 2021-11

“AIR BAG LIGHT COMES ON INTERMITTENTLY AND GOES OFF WITHIN 5 SECONDS. HAPPENS MOSTLY WHEN I TURN”
— Owner report, NHTSA ODI #10279406
“I WAS DRIVING AND THE PASSENGER SIDE AIRBAG DEPLOYED. THERE WAS NO ONE IN THE PASSENGER SEAT AND NO ACCIDENT TO CAUSE THE AIRBAG TO BLOW”
— Owner report, NHTSA ODI #10667399
“THE AIR BAGS FAILED TO DEPLOY WITH THE IMPACT INVOLVED”
— Owner report, NHTSA ODI #10353307

Read all complaints on NHTSA →

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.

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)

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.

4

complaints mentioning a crash

1

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 2004 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.

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