🏷️ Basic Information

Make:

Dodge

Model:

Caravan

Years Covered:

2004, 2005, 2006, 2007

Platform:

NS (Third Generation)

👋 Introduction

Vehicle Segment:

Minivan, a segment known for practicality, family hauling, and versatility. The Dodge Caravan was a dominant player in this market.

Competitors:

Primary competitors included the Honda Odyssey, Toyota Sienna, Ford Windstar, Chevrolet Venture/Uplander, and the Kia Sedona. The Caravan often competed on price and feature packaging.

Versatility:

Known for its flexible interior seating arrangements (e.g., Stow 'n Go from 2005 onwards), ample cargo space, and comfortable ride.

Value Proposition:

Often positioned as a more affordable alternative to some Japanese competitors while offering robust functionality.

📋 Manual Details

All Models And Trims:

Yes, covers all variations including standard, long wheelbase (Grand Caravan), and potential special editions within the specified years.

Estimated Pages:

Over 2000 pages (typical for comprehensive service manuals of this era).

Type:

Factory Service Manual / Repair Manual

Accuracy:

Vehicle-specific, derived from OEM factory service data, not generic DIY guides.

Language:

English

Format:

Digital (e.g., PDF, CD-ROM) or Printed Bound Book (depending on specific product offering).

📖 Manual Coverage

Engine:

All gasoline engines, including major repairs, diagnostics, and specifications. Covers timing belt/chain replacement, cylinder head removal/installation, piston/ring service, crankshaft and bearing service, lubrication system, cooling system.

Transmission:

Automatic Transmissions (e.g., 40TE/41TE, 42LE, 45RFE). Covers diagnostics, fluid service, seal replacement, valve body service, torque converter replacement, complete overhaul procedures.

Brakes:

Hydraulic brake system, Anti-lock Braking System (ABS). Covers brake fluid replacement, caliper/wheel cylinder service, brake line inspection/replacement, ABS sensor diagnostics, rotor/pad replacement.

Steering Suspension:

Power steering system, front and rear suspension components, steering linkage. Covers Strut replacement, ball joint service, tie rod end replacement, power steering pump/rack and pinion service, wheel alignment specifications.

Electrical System:

Battery, charging system (alternator), starting system (starter), ignition system, lighting, instruments, power accessories, body control module (BCM), fuse box diagrams, wiring diagrams.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system. Covers refrigerant handling, compressor service, condenser/evaporator service, blower motor replacement, temperature control system diagnostics.

Body And Interior:

Body panel removal/installation, door hardware, glass replacement, interior trim, seat mechanisms, headliner, body sealant and corrosion protection, chassis electrical.

Diagnostics Troubleshooting:

Extensive troubleshooting charts and diagnostic procedures for all major systems, including drivability issues, electrical faults, and mechanical failures, often referencing OBD-II diagnostic trouble codes (DTCs).

Maintenance:

Scheduled maintenance tasks, fluid checks and changes, filter replacements, lubrication points, tire rotation, brake inspection.

Repair:

Step-by-step repair procedures for virtually every component and system, including detailed instructions for disassembly, component replacement, and reassembly.

Diagnostics:

Systematic diagnostic approaches, symptom-based troubleshooting, wiring diagram interpretation, using diagnostic tools.

Specifications:

Torque specifications for fasteners, engine data (bore, stroke, compression ratio), electrical specifications, fluid capacities, tire pressures, alignment angles, diagnostic data.

Depth:

Comprehensive, covering everything from basic fluid changes to complete engine and transmission overhauls, including intricate electrical system diagnostics and body repair.

📊 Manual Specifications

Searchability:

Typically fully searchable text if digital format (PDF), allowing quick access to specific topics.

Illustrations:

High-quality diagrams, exploded views, and illustrations to guide complex procedures.

Binding:

If printed: Perfect bound or spiral bound for durability and ease of use in a workshop environment.

Durability:

If printed: High-quality, durable paper designed to withstand workshop conditions.

⚙️ Engine Specifications

Engine Options:

2.4L DOHC I4 (less common in later years of this generation), 3.3L OHV V6, 3.8L OHV V6, 4.0L SOHC V6 (introduced later in the generation for some models).

3.3L V6 Horsepower:

Approximately 170-180 hp

3.3L V6 Torque:

Approximately 200-210 lb-ft

3.8L V6 Horsepower:

Approximately 200-215 hp

3.8L V6 Torque:

Approximately 230-240 lb-ft

Injection Type:

Electronic Fuel Injection (EFI) / Multi-point Fuel Injection (MPI).

Ignition System:

Distributorless Ignition System (DIS) with coil-on-plug (COP) or coil pack configurations depending on the specific engine.

🔧 Transmission

Standard Transmission:

4-speed Automatic Transmission (e.g., 40TE/41TE, 42LE variants).

Optional Transmission:

In later years, the 45RFE 4-speed automatic (and later 6-speed automatics for related models) became available, particularly with larger V6 engines.

Transmission Control:

Electronic controls with adaptive shift strategies.

📐 Dimensions

Wheelbase:

Standard: ~113 inches; Long Wheelbase (Grand Caravan): ~119 inches.

Length:

Varies by wheelbase, typically 189 inches (standard) to 201 inches (long).

Curb Weight:

Approximately 4000-4500 lbs, depending on engine and configuration.

Towing Capacity:

Typically rated up to 3,800 lbs with optional towing package.

🛡️ Safety Features

NHTSA Front Impact:

Generally performed well, often receiving 4 or 5 stars for front driver and passenger impacts in NHTSA testing.

IIHS Ratings:

Good to Acceptable ratings in IIHS frontal and side impact tests for the era.

ABS:

Standard Anti-lock Braking System (ABS) on most models.

Traction Control:

Available Traction Control System (TCS) on some trims/models.

Airbags:

Frontal airbags for driver and passenger, available front side-impact airbags, and overhead airbag curtains on some later models.

Seat Belts:

3-point seat belts with pretensioners for front occupants, integrated child seats available.

💡 Technology Features

Entertainment Options:

Optional rear-seat entertainment systems (DVD players), premium audio systems, and Sirius satellite radio were available.

Parking Sensors:

Rear parking assist sensors were an optional feature on some trims.

Power Accessories:

Power windows, power door locks, power liftgate (on some models), and power adjustable pedals were common features.

OBD Ii:

Compliant with OBD-II standards for emissions monitoring and diagnostic trouble code retrieval. The manual details how to access and interpret these codes.

🔧 Maintenance

Oil Change:

Typically every 5,000 to 7,500 miles with synthetic oil, or 3,000 to 5,000 miles with conventional oil, depending on driving conditions and oil type recommended in the manual.

Timing Belt:

For 3.3L and 3.8L V6 engines (OHV design), these typically use a timing chain. The 4.0L V6 (SOHC) uses a timing chain. Early 2.4L engines might have had belts, but chains became more prevalent. The manual will specify based on engine variant.

Spark Plugs:

Recommended replacement interval generally between 60,000 and 100,000 miles, depending on the type of spark plug (e.g., platinum or iridium) specified.

Engine Oil:

SAE 5W-30 is common for most V6 engines. Verify with the manual for specific engine and temperature range requirements. API SN or newer service classification recommended.

Transmission Fluid:

ATF+4 (or equivalent Mopar specification) for automatic transmissions. Crucial to use the correct fluid type to prevent transmission damage.

Coolant:

Mopar OAT (Organic Additive Technology) coolant (typically pink or orange). A 50/50 mix with distilled water is standard.

Brake Fluid:

DOT 3 or DOT 4 brake fluid, depending on the system specification. The manual will specify the exact type and bleeding procedure.

Transmission Reliability:

Some earlier transmissions in this generation could be prone to overheating or solenoid issues if not properly maintained. The manual addresses diagnostic and repair procedures.

Power Sliding Doors:

Mechanisms for power sliding doors could sometimes experience issues with motors, cables, or switches. Detailed troubleshooting is available.

Cv Axles:

Front CV axle boots can wear out and tear, leading to axle failure. Regular inspection is recommended.

Suspension Components:

Wear on tie rod ends, ball joints, and struts is common with mileage, impacting steering and ride quality. The manual provides replacement procedures and alignment specs.

📚 Vehicle History

Dodge Minivan Legacy:

Dodge is a pioneer in the minivan segment, having introduced the original Dodge Caravan and Plymouth Voyager in 1984, revolutionizing family transportation.

Third Generation:

This generation (NS) represented a significant update, offering improved aerodynamics, a more refined interior, and enhanced safety features over its predecessors.

Manufacturing Location:

Primarily Windsor, Ontario, Canada, and Saltillo, Mexico.

Production Period:

The NS platform ran from 2001-2007, with this manual covering the latter half of this generation's lifecycle.

🏆 Awards & Recognition

Popularity:

The Dodge Caravan was consistently one of the best-selling minivans in North America for many years, indicating market acceptance and perceived value.

Safety Awards History:

While specific awards vary year by year, models in this generation often received good marks in safety assessments from organizations like IIHS and NHTSA for their segment.