Vehicle Segment:
Minivan / Passenger Van
Target Audience:
Families, fleet operators, tradespeople seeking versatile and practical transportation.
Key Competitors:
Dodge Grand Caravan, Toyota Sienna, Honda Odyssey, Ford Windstar, Chevrolet Venture.
Market Differentiation:
Known for its practicality, spacious interior, comfortable ride, and often competitive pricing. The Caravan platform offered a good balance of features and functionality for its class.
Body Styles:
Long-wheelbase (ES) and short-wheelbase (SE, SXT) variants available.
Seating Configurations:
Flexible seating options, including Stow 'n Go (introduced later, but the platform was designed for evolving configurations) allowing for multiple passenger and cargo arrangements.
Powertrain Options:
V6 engine options were prevalent, offering a good balance of power and refinement for a vehicle of its size.
Engine Mechanical:
Complete diagnosis, repair, overhaul, and specifications for all engine variants. Includes cylinder head, block, pistons, crankshaft, camshafts, valvetrain, timing systems, lubrication, cooling.
Engine Performance:
Fuel injection system diagnosis and repair (MPI), ignition system, emissions control systems (catalytic converter, EGR, EVAP), engine control module (ECM) diagnosis.
Transmission Automatic:
Diagnosis, repair, overhaul, and specifications for the automatic transmission. Includes torque converter, valve body, planetary gear sets, clutch packs, seals, and fluid.
Transmission Manual:
Diagnosis, repair, and specifications for manual transmission variants if applicable.
Drivetrain:
Front-wheel drive axle shafts, CV joints, differential, rear axle service (if applicable).
Suspension:
Front and rear suspension components, struts, shock absorbers, springs, control arms, ball joints, bushings, wheel alignment specifications.
Steering:
Power steering system diagnosis and repair, steering gear, tie rods, power steering pump, fluid specifications.
Brakes:
Front and rear disc brake systems, caliper, rotor, pad replacement, brake fluid specifications, ABS system diagnosis and repair, parking brake.
Electrical System:
Complete wiring diagrams, charging system (alternator, battery, starter), lighting system, horn, wipers, power windows, door locks, interior and exterior electrical components.
Body And Frame:
Body panel repair, door mechanisms, tailgate/liftgate, bumpers, interior trim, chassis lubrication, corrosion protection.
Heating Ventilation Air Conditioning HVAC:
HVAC system diagnosis, refrigerant handling, compressor, condenser, evaporator, heater core, climate control panel, blower motor, airflow controls.
Routine Maintenance:
Oil changes, filter replacements, fluid level checks and top-offs, tire rotation and pressure checks, spark plug replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon faults across all systems, including symptom-based troubleshooting charts and fault code interpretation.
Major Repairs:
Engine overhaul, transmission rebuild, suspension component replacement, brake system overhauls, steering system repairs.
Component Replacement:
Step-by-step instructions for replacing virtually all serviceable components, from sensors and actuators to major assemblies.
Electrical Diagnostics:
Pinpoint testing, circuit continuity checks, voltage drop testing, diagnostic connector usage, relay and fuse testing.
Diagnostic Charts:
Extensive diagnostic flowcharts and symptom-to-cause tables.
Torque Specifications:
Precise torque values for all fasteners and critical components.
Alignment Specifications:
Detailed wheel alignment angles (camber, caster, toe) for front and rear axles.
Schematics:
Comprehensive electrical wiring diagrams for all circuits and options.
Rebuild Procedures:
Detailed instructions for disassembling, inspecting, cleaning, and reassembling major components like engines and transmissions.
NHTSA Frontal Impact Driver:
4-star (2004 model year specific rating may vary slightly)
NHTSA Frontal Impact Passenger:
4-star (2004 model year specific rating may vary slightly)
NHTSA Side Impact Front Seat:
5-star (2004 model year specific rating may vary slightly)
NHTSA Side Impact Rear Seat:
4-star (2004 model year specific rating may vary slightly)
ABS:
Standard Anti-lock Braking System (ABS) on all four wheels.
Traction Control:
Available Traction Control System (TCS) on some models.
Airbags Front:
Dual front airbags (driver and passenger).
Airbags Side:
Optional side-curtain airbags or side-impact airbags (availability varies by trim).
Seatbelts:
Three-point seatbelts for all seating positions, pretensioners for front seats.
Oil Change Interval:
Every 3,000 miles or 3 months if using conventional oil; 6,000 miles or 6 months if using synthetic oil and severe driving conditions are not met. Refer to manual for exact intervals based on driving habits.
Engine Air Filter Replacement:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Spark Plug Replacement:
Approx. 60,000 - 100,000 miles depending on plug type (e.g., platinum or iridium). Manual will specify exact type and interval.
Transmission Fluid Change:
Inspect every 30,000 miles, recommended change every 60,000 miles, or sooner under severe service. ATF+4 is designed for longer intervals but regular inspection is key.
Coolant Flush:
Initial change at 100,000 miles, then every 50,000 miles thereafter. Mopar OAT (Olds Antifreeze Type) or equivalent is typically required.
Engine Oil Viscosity 3.3L:
SAE 5W-30 (API Certified)
Engine Oil Viscosity 3.8L:
SAE 5W-30 (API Certified)
Engine Coolant:
Mopar OAT (Orange Antifreeze) or equivalent 50/50 mix.
Brake Fluid:
DOT 3 (or DOT 4, consult manual for specific application)
Power Steering Fluid:
ATF+3 or ATF+4 (check manual for confirmation on 2004 models).
Transmission Hard Shifting:
Can be caused by worn solenoids, fluid degradation, or internal wear in the 41TE/42LE transmission. Manual provides diagnostic steps.
Power Steering Pump Noise:
Whining or groaning noise from the power steering pump can indicate low fluid, air in the system, or a failing pump.
Cv Joint Failure:
Clicking noise when turning can indicate worn front CV joints. Manual covers replacement procedure.
Rear Hatch Strut Failure:
Common wear item, struts may lose pressure and fail to hold the liftgate open.
Blower Motor Failure:
HVAC blower motor can fail, resulting in no airflow from vents. The blower resistor can also fail, causing fan speed issues.
Chrysler Minivan Legacy:
Chrysler pioneered the minivan segment with the original Dodge Caravan and Plymouth Voyager in 1983. The Chrysler Caravan is a direct descendant of this groundbreaking vehicle.
Third Generation Start:
The third generation (RS body style) was introduced for the 1996 model year, representing a significant redesign with improved aerodynamics, interior space, and available all-wheel drive.
2004 Updates:
The 2004 model year is part of the latter half of the third generation's lifecycle. Minor updates may have included feature packaging changes, new exterior/interior color options, and potential refinement of existing systems.
Production Location:
Primarily Windsor, Ontario, Canada, and St. Louis, Missouri, USA.
Production Years Third Gen:
1996-2007
