1996 Dodge Caravan Service and Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 1996 Codes Platform Code: NS Generation Generation Designation: Second Generation (NS) 👋 Introduction Market Position Vehicle Segment: Compact Minivan Target Audience:...

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Type: Caravan

Vendor:

Sku: 456313

Tags: 1996 Caravan Cars Dodge Misc

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Codes

Platform Code:

Generation

Generation Designation:

Second Generation (NS)

👋 Introduction

Market Position

Vehicle Segment:

Compact Minivan

Target Audience:

Families, businesses requiring versatile cargo and passenger transport.

Competitive Analysis

Key Competitors:

Toyota Previa, Honda Odyssey, Ford Windstar, Chevrolet Venture.

Key Features

Vehicle Selling Points:

Spacious interior, flexible seating configurations, practicality, and affordability.

Manual Value Proposition

Manual Advantage:

Provides factory-level repair and maintenance information, crucial for accurate and efficient servicing, saving on dealership costs.

📋 Manual Details

Coverage Areas

Coverage Scope:

All Models & All Repairs A-Z

Page Count

Estimated Page Count:

Over 1000 (typical for comprehensive factory manuals)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Printed

📖 Manual Coverage

Systems Covered

Engine Service:

Detailed diagnosis, repair, and overhaul procedures for all gasoline engines offered.

Transmission Service:

Coverage for automatic transmissions, including diagnostic charts, removal, installation, and internal component repair.

Drivetrain Service:

Front-wheel drive axle and differential service, including CV joints and boots.

Suspension Service:

Front and rear suspension component diagnosis, replacement (struts, shocks, ball joints, control arms), and alignment specifications.

Steering Service:

Power steering system diagnosis, pump, rack and pinion repair, and steering column service.

Brake Service:

Front and rear disc brake systems, including caliper, rotor, pad replacement, parking brake, and ABS system diagnosis and repair.

Electrical System Service:

Comprehensive wiring diagrams, component locations, diagnostic procedures for starting and charging systems, lighting, accessories, and power distribution.

HVAC Service:

Air conditioning and heating system diagnosis, refrigerant handling, component replacement (compressor, evaporator, heater core).

Body And Interior Service:

Door mechanisms, interior trim, seating systems, glass replacement, and exterior body panel repair and alignment.

Fuel System Service:

Fuel injection system diagnosis, fuel pump, injectors, and fuel tank service.

Exhaust System Service:

Exhaust manifold, catalytic converter, muffler, and pipe replacement.

Cooling System Service:

Radiator, water pump, thermostat, and cooling fan diagnosis and replacement.

Procedures Included

Maintenance Procedures:

Routine checks, fluid changes, filter replacements, lubrication, and belt adjustments.

Troubleshooting Guides:

Systematic diagnostic flowcharts and symptom-based troubleshooting for common and complex issues.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for all major vehicle systems.

Diagnostic Information:

Detailed diagnostic codes (DTCs), sensor readings, and electrical testing procedures.

Technical Specifications:

Torque values, clearances, fluid capacities, and alignment settings.

Wiring Diagrams:

Complete and detailed electrical schematics for all vehicle systems.

Technical Depth

Depth Of Coverage:

Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls.

Diagnostic Capability:

Advanced diagnostics for electronic control modules (ECMs), sensors, and actuators.

Rebuild Procedures:

Detailed instructions for rebuilding major components like engines and transmissions.

📊 Manual Specifications

File Format

Digital Format Quality:

N/A (Printed Manual)

Print Quality

Print Clarity:

High-quality printing with clear diagrams and text.

Binding Type

Binding:

Durable binding (e.g., spiral-bound or sewn) suitable for workshop use.

Paper Type

Paper Quality:

Durable, possibly laminated or heavyweight paper to withstand shop conditions.

⚙️ Engine Specifications

Primary Engine

Engine Options:

2.4L Inline-4 (2.4L Chrysler I4), 3.0L V6 (3.0L Mitsubishi 6G72 V6)

Performance

2.4L Horsepower:

Approx. 150 hp @ 5600 rpm

2.4L Torque:

Approx. 167 lb-ft @ 4000 rpm

3.0L V6 Horsepower:

Approx. 158 hp @ 5000 rpm

3.0L V6 Torque:

Approx. 181 lb-ft @ 3750 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Engine Codes

2.4L Engine Code:

3.0L V6 Engine Code:

🔧 Transmission

Standard Transmission

Transmission Type:

4-speed Automatic Transaxle

Optional Transmission

Transmission Options:

Manual transmission was available on some earlier models, but less common for 1996. Primarily automatic.

Features

Transmission Fluid Type:

ATF+4 (or equivalent compatible fluid, refer to manual for exact spec)

Transmission Details

Transmission Model Automatic:

A604 (4-speed electronically controlled automatic transaxle)

📐 Dimensions

Exterior

Wheelbase:

Approx. 112.1 inches

Length:

Approx. 177.6 inches

Width:

Approx. 72.1 inches

Height:

Approx. 67.6 inches

Cargo

Max Cargo Volume:

Approx. 143.1 cubic feet (with rear seats removed)

Weights

Curb Weight:

Approx. 3500 - 3800 lbs (depending on engine and configuration)

Gross Vehicle Weight Rating:

Varies by configuration, typically around 5000-5300 lbs

🛡️ Safety Features

Ratings

NHTSA Driver Side Front Impact:

4/5 Stars (for 1996 models)

NHTSA Passenger Side Front Impact:

4/5 Stars (for 1996 models)

Active Features

Anti-lock Braking System (ABS) available on certain trims/options.

Passive Features

Airbags:

Driver's side airbag standard. Passenger airbag optional or standard on higher trims.

Seat Belts:

All seating positions equipped with three-point seat belts; front seat belts with pretensioners.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM cassette stereo; optional CD player and premium sound systems available.

Driver Assistance

Cruise Control:

Standard or optional depending on trim level.

Anti Theft System:

Factory immobilizer system optional on some models.

Connectivity

Connectivity Options:

Limited by 1996 standards; no integrated Bluetooth or USB connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-7,500 miles or 3-6 months, depending on oil type and driving conditions (refer to manual for exact recommendation).

Air Filter Replacement:

Every 15,000-30,000 miles or as needed based on driving environment.

Spark Plug Replacement:

Varies by plug type, generally 30,000-100,000 miles (refer to manual for specific recommendations).

Fluid Specifications

Engine Oil Type And Viscosity:

Refer to manual; typically 5W-30 or 10W-30 for gasoline engines, API service SG or higher.

Coolant Type:

Ethylene Glycol based coolant, typically Mopar HOAT or equivalent.

Brake Fluid Type:

DOT 3

Known Issues

Common Wear Items:

Struts, ball joints, CV axles, brake components, and exhaust systems are common wear items.

Transmission Issues:

Early A604 transmissions can be prone to solenoid issues and torque converter shudder if not properly maintained.

Engine Issues:

Intake manifold gasket leaks on V6 engines, occasional head gasket issues, and oil leaks can occur.

Electrical Gremlins:

Faulty power window regulators, door lock actuators, and dashboard warning lights can be common.

Fluid Capacities

Engine Oil Capacity:

Approx. 4.5 quarts (with filter) for 2.4L I4; approx. 4.7 quarts (with filter) for 3.0L V6.

Coolant Capacity:

Approx. 11 quarts

📚 Vehicle History

Brand Heritage

Dodge Minivan Legacy:

Dodge pioneered the modern minivan segment with the original Caravan/Voyager in 1984, establishing a strong market presence.

Model Evolution

Second Generation Ns:

The 1996 Caravan represents the second generation (NS), introduced for the 1996 model year, featuring a redesigned exterior and interior, and improved safety features.

Production

Manufacturing Location:

Windsor, Ontario, Canada and St. Louis, Missouri, USA

Production Period:

Second generation (NS) ran from 1996 to 2000.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

Dodge Caravan (and its Plymouth Voyager sibling) were frequent recipients of Car and Driver's '10Best' list in their earlier generations, setting benchmarks for the segment.

Ratings

Consumer Reports Reliability:

Reliability ratings varied by model year and engine choice; specific details would be in contemporary consumer reports.