Target Audience:
DIY Mechanics, Professional Technicians, Fleet Maintenance
Key Competitors:
Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture, Pontiac Montana, Buick Terraza
Utility:
Family hauling, cargo transport, versatile seating configurations
Versatility:
Available Stow 'n Go seating (later models) significantly enhanced cargo flexibility
Value Proposition:
Affordable family vehicle with a strong emphasis on practicality and passenger comfort
Model Years:
2001, 2002, 2003, 2004, 2005, 2006, 2007
Regions Covered:
North America (USA, Canada, Mexico)
Type:
Service and Repair Manual
Powertrain:
Engine (3.3L V6 OHV, 3.8L V6 OHV, 4.0L V6 SOHC), Transmission (41TE/42LE Automatic)
Chassis:
Suspension (Front & Rear), Steering, Brakes (Front & Rear Disc, ABS), Driveline (FWD)
Electrical:
Wiring Diagrams, Powertrain Control Modules (PCM), Body Control Modules (BCM), Lighting, Audio System, HVAC Controls, Power Accessories (Windows, Locks, Seats)
Body:
Body Repair, Exterior & Interior Trim, Doors, Glass, Seats, HVAC System Components, Safety Restraint System (SRS)
Maintenance:
Oil Change, Filter Replacements, Spark Plug Replacement, Fluid Checks & Changes, Belt Inspection & Replacement, Tire Rotation
Diagnostics:
Troubleshooting Flowcharts, Diagnostic Trouble Codes (DTCs), Component Testing, Sensor Readings, PCM Relearn Procedures
Repair:
Engine Overhaul, Transmission Repair/Overhaul, Brake System Repair, Suspension Component Replacement, Steering Rack Replacement, Electrical Component Diagnosis & Replacement, HVAC Component Repair
Technical Specifications:
Torque Specifications, Fluid Capacities, Electrical Schematics, Component Locations, Diagnostic Procedures
Depth:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds and advanced electrical diagnostics)
Engine 1 Displacement:
3.3 Liters (3301 cc)
Engine 1 Configuration:
3.3L V6 OHV (12 Valve)
Engine 1 Power Hp:
Approx. 180 hp @ 5000 RPM
Engine 1 Torque Lb Ft:
Approx. 205 lb-ft @ 3600 RPM
Engine 2 Displacement:
3.8 Liters (3778 cc)
Engine 2 Configuration:
3.8L V6 OHV (12 Valve)
Engine 2 Power Hp:
Approx. 200-215 hp @ 5000 RPM (depending on year/tune)
Engine 2 Torque Lb Ft:
Approx. 230-235 lb-ft @ 3600 RPM (depending on year/tune)
Engine 3 Displacement:
4.0 Liters (3952 cc)
Engine 3 Configuration:
4.0L V6 SOHC (24 Valve)
Engine 3 Power Hp:
Approx. 230 hp @ 5200 RPM
Engine 3 Torque Lb Ft:
Approx. 245 lb-ft @ 4000 RPM
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Coolant Type:
Chrysler/Dodge HOAT (Hybrid Organic Acid Technology) Antifreeze/Coolant, Extended Life (typically Mopar OAT or equivalent)
Spark Plugs:
Platinum or Iridium type (e.g., Champion, NGK, Bosch - consult manual for exact OE spec and replacement intervals)
System:
On-Board Diagnostics (OBD-II), Catalytic Converter, EGR (Exhaust Gas Recirculation)
Transmission Type:
4-Speed Automatic (41TE / 42LE)
Optional Transmission:
N/A (FWD models exclusively used the 4-speed automatic)
Control Mode:
Electronic Control with Torque Converter Lock-up
Fluid Type:
ATF+4 (Automatic Transmission Fluid, Type 9602 or equivalent)
Fluid Capacity Quarts:
Approx. 4.5-5.0 quarts (dry fill) / 3.5-4.0 quarts (drain and fill)
Drive Type:
Front-Wheel Drive (FWD)
Length In:
Approx. 175-181 inches (depending on wheelbase configuration)
Width In:
Approx. 72 inches
Height In:
Approx. 68 inches
Wheelbase In:
Approx. 112-119 inches (depending on wheelbase)
Passenger Capacity:
7-8 Passengers (depending on seating configuration)
Cargo Volume Cu Ft:
Approx. 140-150 cu. ft. (with rear seats folded/removed)
Curb Weight Lbs:
Approx. 3900-4400 lbs (depending on engine and trim)
Gross Vehicle Weight Rating Gvwr Lbs:
Approx. 5600-5900 lbs
Towing Capacity Lbs:
Approx. 2000-3800 lbs (depending on configuration and factory tow package)
NHTSA Frontal Driver Rating:
Good (for applicable years/tests)
NHTSA Frontal Passenger Rating:
Good (for applicable years/tests)
IIHS Frontal Offset Rating:
Acceptable (for applicable years/tests)
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Traction Control System (TCS) on some models/trims
Airbags Front:
Standard Driver and Front Passenger Airbags
Airbags Side:
Optional Front Side-Impact Airbags
Seatbelts:
3-Point Seatbelts with Pretensioners and Load Limiters (Front), 3-Point Seatbelts (Rear)
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) System on rear seats
Audio System:
Standard AM/FM stereo with CD player or cassette. Optional Infinity audio systems and rear-seat entertainment systems were available on higher trims.
Navigation:
Optional factory navigation system available on some higher-trim models from mid-2000s onwards.
Cruise Control:
Standard cruise control
Parking Assistance:
Optional rear park assist sensors available on later models.
Auxiliary Input:
Generally not available on most models; aftermarket solutions are common.
Oil Change Interval Miles:
Every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (consult owner's manual/manual for specifics).
Transmission Fluid Change Interval Miles:
Every 30,000-100,000 miles, depending on usage and fluid type (ATF+4 often rated for longer intervals, but regular inspection and partial changes recommended).
Coolant Change Interval Miles:
Initial change at ~100,000 miles, then every ~50,000-75,000 miles for HOAT/OAT coolant.
Spark Plug Replacement Interval Miles:
Platinum plugs: ~100,000 miles; Iridium plugs: ~100,000 miles (consult manual for exact type and interval).
Engine Oil Type And Viscosity:
SAE 5W-30 (preferred for most conditions, check manual for exceptions).
Engine Oil Capacity Quarts:
Approx. 4.5 quarts (3.3L) / 5.0 quarts (3.8L, 4.0L) with filter change.
Power Steering Fluid:
ATF+4 or specific Mopar power steering fluid.
Brake Fluid:
DOT 3 or DOT 4 (check cap/manual for precise specification).
Transmission Problems:
Potential issues include torque converter shudder, valve body issues, and solenoid failures. Early models of the 41TE were more prone to issues. Regular fluid changes are critical.
Engine Issues:
3.3L and 3.8L are generally robust but can suffer from intake manifold gasket leaks, oil cooler line leaks, and occasional head gasket issues. The 4.0L SOHC can experience timing chain wear and oil leaks.
Suspension Wear:
Common wear items include ball joints, tie rod ends, struts/shocks, and control arm bushings due to vehicle weight and family usage.
Electrical Issues:
Can include issues with power window motors, door lock actuators, HVAC blower motors, and intermittent issues with the BCM or PCM.
Exhaust System:
Corrosion of exhaust components, including catalytic converters and mufflers, is common in areas with road salt.
Body Rust:
Rust can form on rocker panels, wheel arches, and the rear quarter panels, especially in northern climates.
Dodge Legacy:
Dodge has a long history of producing robust and practical vehicles, often targeting value-conscious buyers.
Fourth Generation Introduction:
Introduced for the 1996 model year, the RS platform (which this manual covers) was a significant redesign, offering improved aerodynamics, safety, and interior space.
Mid-Cycle Refresh:
The 2001 model year marked a significant refresh for the fourth generation, with updated styling, interior amenities, and powertrain enhancements. This manual specifically covers this refreshed period.
Manufacturing Locations:
Primarily Windsor, Ontario, Canada; Saltillo, Mexico
Platform Sharing:
Shared platform with Plymouth Grand Voyager and Chrysler Voyager/Town & Country (NS platform originally, RS platform for this era).
Car And Driver 10 Best:
The Dodge Caravan (and its Plymouth/Chrysler siblings) frequently appeared on Car and Driver's 10 Best lists in earlier generations, establishing its minivan credentials.
Consumer Reports:
Received varied ratings from Consumer Reports over the years, often praised for practicality but sometimes criticized for reliability in specific areas.
Safety Certifications:
Met or exceeded all applicable Federal Motor Vehicle Safety Standards (FMVSS) for its model years.
