Summary
The Dodge Caravan has 61 recalls spanning 1990 through 2017, with the most serious recent issue affecting 2017 models where a faulty brake switch can allow the shifter to move out of Park without the brake pedal being pressed, risking unintended vehicle movement.
The 2017 model year also has the related problem that rear lights can stay illuminated in this condition, masking braking intent from drivers behind. Stepping back to the mid-2000s, 2005 models have a front seat belt retractor on the right side that may not properly restrain the occupant in certain crashes, a front airbag sensor that can corrode in salt-belt states and fail to deploy as designed, and a windshield wiper motor shaft that can break and leave the driver without front wipers in wet conditions. A 2003 model power liftgate latch can fail to engage the striker and swing open while driving, creating an ejection risk in a crash.
The 2002 model year has a power steering cooler hose on 3.3L and 3.8L engines that can split and spray fluid onto hot engine components, starting an underhood fire, and a radio that can short-circuit from air conditioning condensation and ignite a rear speaker. Wheelchair-accessible conversions of 2008-2010 vehicles, altered by the Braun Corporation, have two separate issues: the fuel fill pipe can contact a tire and wear through either component over time, and a suspension spring hat can rub through a tire and cause sudden pressure loss.
The 2001 model year has a lower front control arm pivot bolt that can fracture and cause the control arm to separate from the crossmember, resulting in sudden loss of steering and handling. On 1997 models, the brake master cylinder can allow fluid to migrate into the power brake booster, reducing braking force and extending stopping distances, and Goodyear Conquest tires mounted on steel wheels on those same vehicles can lose air pressure suddenly without warning.
The 1996 model year carries the densest cluster of recalls in the production run. Fuel system fire risks appear across multiple components: fuel injector O-ring seals on 3.3L and 3.8L engines can degrade and leak near ignition sources, the fuel pump module connection at the tank can leak, the rollover valve can pass liquid fuel into the vapor canister, and a static charge can build on the fuel filler tube and spark during fueling. An engine cylinder head oil plug can unseat and leak oil onto hot components. Rear bench seat bolts can become brittle and fracture in a crash, and integrated child seat bolts can break as well. The airbag clockspring can be wound incorrectly, disabling the driver's airbag.
Going further back, 1993 models have a steering wheel armature that can crack and separate from the column hub, causing loss of steering, and lug nut seating problems on 15-inch wheels that can lead to wheel loss. The 1992 model year has fuel tank mounting flanges that can damage fuel lines and cause the tank to drop, and brake pedal pad welds that can fail and leave the driver without a functional pedal. The 1991 model year has anti-lock brake pump porosity that can cause fluid loss, eventually eliminating both ABS and hydraulic brake assist, along with rear liftgate latch and seat belt buckle issues. The 1990 model year has front seat belt buckle straps that can fatigue and fail in a crash.
