Dodge Caravan 1996 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Dodge Model: Caravan Year: 1996 Platform: NS Platform Codes Vehicle Codes: PG (Passenger Van), RG (Passenger Van Cargo) 👋 Introduction Market Position Segment: Minivan Target...

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标签: 1996 Car Cars Dodge Dodge Caravan Misc

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Description

🏷️ Basic Information

Identification

Make:

Dodge

Model:

Caravan

Year:

Platform:

NS Platform

Codes

Vehicle Codes:

PG (Passenger Van), RG (Passenger Van Cargo)

👋 Introduction

Market Position

Segment:

Minivan

Target Audience:

Families, commercial users requiring cargo capacity

Competitive Analysis

Key Competitors:

Ford Windstar, Chevrolet Lumina APV, Toyota Previa, Honda Odyssey (though Odyssey was a different concept initially)

Key Features

Design:

Front-wheel drive unibody construction, sliding rear doors (later models), flexible interior seating arrangements

Powertrain Options:

Versatile V6 engine options catering to different power and efficiency needs.

Utility:

Spacious interior, cargo hauling capability, family-friendly design

Manual Value

Benefit:

Enables DIY repairs, professional diagnostics, and in-depth understanding of vehicle systems, saving time and money.

📋 Manual Details

Coverage Areas

Engine Coverage:

3.0L V6 (Mitsubishi 6G72 SOHC), 3.3L V6 (Chrysler EBD OHV), 3.8L V6 (Chrysler EGT OHV)

Transmission Coverage:

3-speed Automatic (A500/42LE), 4-speed Automatic (A604/41TE, 42LE/42TE)

Drivetrain Coverage:

Front-Wheel Drive (FWD)

Body Coverage:

All body styles, interior, exterior, glass, doors, panels

Electrical Coverage:

Wiring diagrams, starter, alternator, lighting, body control modules, instrument cluster

Chassis Coverage:

Suspension (front and rear), steering, brakes, exhaust

Page Count

Total Pages:

Comprehensive (exact count not specified, but implied to be extensive)

Manual Type

Type:

Factory Service Repair Manual

Purpose:

Repair, maintenance, diagnostics, troubleshooting

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, pistons, crankshaft, timing, lubrication system, cooling system

Engine Performance:

Fuel injection system, ignition system, emission controls, turbocharger (if applicable, though not standard on '96)

Transmission Components:

Transmission disassembly, assembly, hydraulic system, torque converter, valve body

Drivetrain Components:

Axles, CV joints, differential (integral to transaxle)

Brake System:

Front disc brakes, rear drum brakes, ABS (if equipped), parking brake

Steering System:

Power steering pump, steering gear, steering column, tie rods

Suspension System:

Front struts, rear shocks, control arms, ball joints, bushings, springs

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, fuel lines

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes

HVAC System:

Air conditioning, heating, ventilation, blower motor, controls

Body And Interior:

Door mechanisms, power locks, power windows, seat mechanisms, dashboard removal

Lighting System:

Headlights, taillights, interior lighting, fog lights

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, electrical diagnostics

Repair:

Engine rebuilds, transmission overhaul, suspension component replacement, brake caliper replacement, starter motor replacement

Diagnostics:

OBD-I (On-Board Diagnostics) procedures, sensor testing, actuator testing

Calibration:

Wheel alignment procedures, ABS sensor calibration (if applicable)

Installation:

Component installation, accessory installation (e.g., towing components)

Technical Depth

Depth:

Comprehensive, covering all aspects from routine maintenance to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic procedures.

📊 Manual Specifications

File Format

Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing for quick navigation to specific topics.

Print Quality

Quality:

High-resolution scans/files suitable for printing pages or the entire manual.

Binding Type

Format:

Digital Download (Printable)

Paper Type

Intended Use:

For home printing and workshop use.

⚙️ Engine Specifications

Primary Engine

Engine 1:

3.0L V6 (Mitsubishi 6G72)

Engine 1 Displacement:

182 cu in (2972 cc)

Engine 1 Configuration:

SOHC, 12 Valves

Engine 1 Horsepower Est:

141 hp @ 4800 RPM

Engine 1 Torque Est:

171 lb-ft @ 3100 RPM

Engine 2

Engine 2:

3.3L V6 (Chrysler EBD)

Engine 2 Displacement

Engine 2 Displacement:

203 cu in (3301 cc)

Engine 2 Configuration

Engine 2 Configuration:

OHV, 12 Valves

Engine 2 Horsepower Est

Engine 2 Horsepower Est:

150 hp @ 4400 RPM

Engine 2 Torque Est

Engine 2 Torque Est:

185 lb-ft @ 3200 RPM

Engine 3

Engine 3:

3.8L V6 (Chrysler EGT)

Engine 3 Displacement

Engine 3 Displacement:

230 cu in (3778 cc)

Engine 3 Configuration

Engine 3 Configuration:

OHV, 12 Valves

Engine 3 Horsepower Est

Engine 3 Horsepower Est:

166 hp @ 4400 RPM

Engine 3 Torque Est

Engine 3 Torque Est:

207 lb-ft @ 3200 RPM

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

🔧 Transmission

Standard

Transmission 1:

3-speed Automatic (A500 / 42LE)

Optional

Transmission 2:

4-speed Automatic (A604 / 41TE)

Transmission 3:

4-speed Automatic (42LE, updated version of A500)

Features

Type:

Transaxle (engine and transmission integrated unit)

Fluid Type Spec:

ATF+4 (often specified as equivalent or Mopar ATF+3 for this era, check manual for exact specification)

Fluid Capacity Est:

Approx. 9-11 quarts (8.5-10.5 liters) for a complete drain and fill, higher for torque converter refill.

📐 Dimensions

Exterior

Length Est:

Approx. 175-180 inches (4445-4572 mm)

Width Est:

Approx. 72 inches (1829 mm)

Height Est:

Approx. 68-70 inches (1727-1778 mm)

Interior

Seating Capacity:

5-7 passengers depending on configuration

Cargo

Cargo Volume Est Max:

Over 100 cubic feet (2832 liters) with rear seats removed.

Weights

Curb Weight Est:

Approx. 3500-4000 lbs (1588-1814 kg) depending on engine and trim.

🛡️ Safety Features

Ratings

NHTSA Driver Front Impact Est:

Likely 3 or 4 star rating (typical for era, specific data may vary)

NHTSA Passenger Front Impact Est:

Likely 3 or 4 star rating (typical for era, specific data may vary)

Active Features

Anti-lock Braking System (Optional on some trims)

Passive Features

Airbags:

Driver and passenger front airbags standard

Seatbelts:

3-point front and rear seatbelts

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with cassette player, optional CD player, optional premium sound systems.

Display:

Basic analog gauges, digital odometer, climate control displays.

Driver Assistance

Cruise Control:

Standard on most trims, electronic speed control.

Connectivity

Auxiliary Inputs:

None standard; aftermarket solutions exist.

Comfort Features

Power Options:

Power windows, power door locks, power mirrors (available).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles or 6 months, whichever comes first (under normal driving conditions).

Air Filter Replacement:

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

Spark Plug Replacement:

Copper plugs: 30,000 miles; Platinum plugs: 60,000-100,000 miles (check manual for specific type).

Transmission Fluid Change:

Every 30,000-60,000 miles, depending on driving conditions (severe service may require more frequent changes).

Coolant Change:

Every 30,000 miles or 2 years.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (check manual for specific viscosity based on temperature/engine)

Coolant Type:

Mopar Antifreeze/Coolant (Ethylene Glycol based) or equivalent.

Brake Fluid Type:

DOT 3

Known Issues

Common Problem 1:

Transmission solenoid issues (especially on 4-speed units), leading to shifting problems.

Common Problem 2:

Head gasket failures (particularly on the 3.3L and 3.8L engines, though less common on the 3.0L Mitsubishi).

Common Problem 3:

Water pump leaks or bearing failure.

Common Problem 4:

Front suspension wear (ball joints, tie rods, struts).

Common Problem 5:

CV axle boots cracking and tearing, leading to joint damage.

📚 Vehicle History

Brand Heritage

Parent Company:

Chrysler Corporation

Model Evolution

Generation:

NS Platform (1996-2000)

Predecessor:

1991-1995 Dodge Caravan (SH Platform)

Key Updates For 1996:

Major redesign, new exterior styling, improved safety features, updated interior, introduction of more powerful engines.

Production

Assembly Locations Est:

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

🏆 Awards & Recognition

Recognitions

Minivan Segment Impact:

The Caravan, along with its Plymouth Voyager and Chrysler Town & Country siblings, defined and dominated the minivan segment for years, offering unparalleled practicality and versatility.

Ratings

Initial Reception:

The 1996 redesign was well-received for its improved styling and safety, solidifying its market leadership.