Summary
The Dodge Grand Caravan has 46 recalls spanning 1993 through 2020, with the most serious recent issue being a fuel pump gasket defect on 2016–2019 vehicles modified by Vantage Mobility International where the gasket can deteriorate, allowing fuel to leak and raising the risk of fire.
Several other serious issues affect the later production years. On 2019 models, seat striker welds on the second and third row seats can fail in a crash, allowing seats to shift and seatbelts to lose their anchor point. A 2017 powertrain controller defect can cause the engine to stall without warning while driving. On 2016 models, hood striker bolts can loosen and allow the hood to fly open while driving, blocking the driver's view. The driver's door vent window switch on 2010–2014 vehicles can overheat and start a fire in the door armrest. The 2014 model year has a tire pressure monitoring system that can fail to detect an actually underinflated tire.
The 2008–2012 era carries a heavy concentration of recalls. On 2011–2012 models, the airbag wiring harness inside the steering wheel can chafe and short circuit, causing the driver's frontal airbag to fire without a crash. The 2013 model has two separate airbag concerns: the wrong software in the restraint control module can cause incorrect airbag behavior in a collision, and a side-impact crash can cause the airbag on the opposite side to deploy unexpectedly. On 2008–2010 models, the ignition switch can slip from the ON position to accessory while driving, cutting engine power, disabling power steering and brakes, and shutting off the airbags. The 2008–2009 power sliding door wiring harness can chafe against the lower hinge bracket, short circuit, and start a fire inside the door. The airbag control unit on 2008–2009 models can corrode and fail, preventing airbag deployment in a crash. Water from the HVAC drain on 2008 models can reach the restraint control module and trigger unintended airbag deployment. Unused blind spot detection wiring connectors on 2009 models can corrode, short circuit, and potentially catch fire if the fuse does not blow.
Going further back, the 2005–2006 model years have front crash sensors that can fail, disabling airbag deployment. The 2002 model year has a fuel tank control valve weld that can separate and leak fuel, creating a fire risk underneath the vehicle. The 1996 model year has a fuel pump module connection that can leak fuel with the same fire potential. The 1993 model year has a steering wheel armature that can crack and separate from the hub on high-mileage vehicles, causing loss of steering, and a wheel lug nut seating defect that can lead to wheel loss. The 1994 model year shares the lug nut seating issue.
Several recalls apply specifically to third-party modified vehicles. Wheelchair-accessible conversions by Liberty Motor Company on 2008–2010 models have a rear axle that can fail. Amerivan conversions on 2008 models may have improperly routed rear brake lines that can chafe, leak fluid, and reduce braking. Amerivan conversions on 2016 models may have a misrouted underbody fuel line that can contact other components and leak.
