DodgeCaravan20043.8L/dodge/caravan/2004/3-8l/
RS platform

2004 Dodge Caravan — 3.8L

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 Caravan 3.8L.

Body VANEngine 3.8LTransmission Automatic 4-spd

Built on the RS platform, the 2004 Dodge Caravan VAN utilizes a 3.8L engine mated to an Automatic 4-spd transmission that returns EPA mpg of 16/23/18. Maintenance for this configuration requires 5 qt w/ filter of 5W-30 API oil. Regarding dependability, this model year generated 64 total owner complaints and 8 recalls, with the Fuel/Propulsion System emerging as the top complaint area. Contextualized against the model's complaint history from 1990-2017, these figures place the 2004 model between the highest year of 1996 with 1647 complaints and the lowest year of 2017 with 1 complaint.

Model year2010200920082004

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity5 qt w/ filterOEM · verified
Engine oil type5W-30 APIOEM · verified
Lug nut torque85-115 ft-lbsOEM · verified
EPA fuel economy16/23/18 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 34 · 500 CCA battery, OE oil filter 04105409AE. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 34 · 500 CCAOEM · verified
Tire sizeP215-70R15OEM · verified
Wheel / rim6.5 inOEM · verified

OE service part numbers OEM · verified

Engine oil filter04105409AE alt 05281090AB
Engine air filter04861480AA
Spark plugSP303917AC alt 68307021AA
BatteryBB34F101AA
Front wiper blades05096134AC
Serpentine belt04593684AA alt 04892444AA
Thermostat68210217AA alt 04573560AE
Cabin air filter82205905

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length189 in
Overall width78.7 in
Overall height68.9 in
Wheelbase113.4 in
Curb weight3862 lb
Track (front / rear)63 / 64.2 in
Weight distribution (front / rear)57/43

Ratings & economy EPA / vPIC

EPA city / highway / combined16 / 23 / 18 mpg
DrivetrainFront-Wheel Drive
Recommended fuelRegular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 5 qt w/ filter of 5W-30 API engine oil, 80W-90 · GL-5 in the differential, DOT 3 brake fluid. Torque lug nuts to 85-115 ft-lbs, the oil drain plug to 20.0 ft-lbs. The firing order is 1-2-3-4-5-6. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Automatic Transmission FluidATF+4
Automatic Transmission Fluid Capacity4
Brake FluidDOT 3
Differential Gear Oil80W-90 · GL-5
Differential Gear Oil Capacity1.5 Pints
Engine CoolantHOAT · MS9769
Engine CoolantETHYLENE GLYCOL
Engine Oil5W-30 · API

Engine torques

Crankshaft Pulley and/or Damper Bolts40 ft-lbs
Engine Flywheel Bolts65 ft-lbs
Engine Oil Pan Drain Plug20.0 ft-lbs
Oil Pump to Cylinder BLock Bolts/Studs9 ft-lbs

Chassis torques

Lug Nuts85-115 ft-lbs
Transfer Case Fill PlugPTU: 20.0 ft-lbs
Transfer Case Drain PlugPTU: 14.0 ft-lbs
Front Wheel Hub180 ft-lbs
Rear Wheel Hub180 ft-lbs

Ignition

Cylinder Firing Order1-3-2-4
Cylinder Firing Order1-2-3-4-5-6
Ignition Coil Secondary Resistance8500-11,500 ohms
Spark Plug Gap0.048-0.053 in
Spark Plug Torque13.0 ft-lbs

Battery & A/C

RefrigerantR134a
Oil GroupPAG
Optional BCI Group Number34
Optional BCI Cranking Performance600 cca
Standard BCI Group Number34
Standard BCI Cranking Performance500 cca

Service checks

Pressure Test15 psi
Radiator Cap Pressure Relief14-18 psi
Thermostat Opening Temperature192-198 °F
Regulated Fuel System Pressure (With Vacuum)58.0 + or - 5.0 psi
Injector Primary Resistance12
Injector Primary Resistance13-16 @ 68 degreesF ohms
Engine Compression100 Minimum psi
Engine Oil Pressure25-80 psi

Brakes

Brake ApplicationWITH TEVES / WITH TRW
Torque Caliper to Bracket26 ft-lbs
Torque to Knuckle125 ft-lbs
Brake ApplicationWITH TEVES
Torque Caliper to Bracket26 ft-lbs
Torque to Knuckle125 ft-lbs
Brake ApplicationWITH TRW
Torque Caliper to Bracket26 ft-lbs

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages
140 ft. lbs., Step 2: 9040 ft. lbs
Cylinder Head — tightening sequence 4 stages

Prep Use new bolts. Lubricate bolts with clean engine oil. · M8 Bolts:

125.0 ft. lbs.; M11 Bolts:25 ft. lbs
145.0 ft. lbs.45 ft. lbs
265.0 ft. lbs.65 ft. lbs
365.0 ft. lbs.65 ft. lbs
490 degrees Do not use a torque wrench for this step.90 degrees
Main Bearings — tightening sequence 1 stages
130 ft. lbs., Step 2: 9030 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; coolant every 100,000 mi. The big-interval services (every 100,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 6,000 miCV Joint Boot (inspect) · Engine Air Filter Element (inspect) · Exhaust System (Complete) (inspect) · Tire & Wheel Assembly (rotate)
Every 7,500 miEngine Oil (drain & refill) · Engine Oil Filter (replace)
Every 12,000 miCabin Air Filter (replace)
Every 18,000 miBrake Linings (inspect)
Every 30,000 miPCV Valve (inspect) · Tie Rod (inspect)
At 60,000 miPCV Valve (inspect)
Every 60,000 miPCV Valve (inspect)
Every 100,000 miEngine Coolant System (drain, flush & refill)

Owner how-tos

Condensed service procedures for routine maintenance. Procedures that require dealer diagnostic equipment are identified and summarized only.

Common procedures

Key fob — remote (RKE) programming programming new fob buttons Dealer tool OEM · verified
Tool requiredDRBIII scan tool (dealer / locksmith)
WhyTransmitter codes are written into the receiver in the passenger door module
Anti-theft (SKIS) — module initialization after immobilizer module replacement Dealer tool OEM · verified
When neededAfter Sentry Key Immobilizer Module (SKIM) replacement
Tool requiredDRBIII scan tool
Also requiredThe vehicle's four-digit PIN code

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2004 Dodge Caravan sits at a remarkable low point in a generally improving federal record, registering just 64 complaints, 8 recalls, 1 investigation, and 69 TSBs—the lowest complaint volume in any year shown since 1990 and a steep drop from the 526 logged in 2000. Across the broader 1990s arc, complaints had been far higher (peaking at 1,647 in 1996), so the 2001–2004 stretch represents a maturing fourth generation, with 2004 marking the cleanest year in that run before a sharp 2005 rebound to 537 complaints and 7 investigations—suggesting 2004 likely precedes emerging issues that the data does not specify by root cause. The top complaint areas for 2004 (Fuel/Propulsion System at 10, Service Brakes/Hydraulic at 5, and Electrical System and Fuel System/Gasoline tied at 4) are relatively modest in volume and consistent with the van's overall mechanical theme rather than a single dominant defect, and the 3 fire and 2 crash complaints are low but not zero, warranting a pre-purchase inspection focused on the fuel and brake systems. Recall count of 8 is on the higher side for the 4th-gen era, so a buyer should verify all applicable recall campaigns have been completed. Bottom line: 2004 is arguably the strongest used-buy candidate in the 2001–2005 window based on this record, but the subsequent 2005 spike is a cautionary signal—have a mechanic specifically inspect fuel delivery and brake hydraulics before purchase.

8
Open recalls
NHTSA campaigns
69
Service bulletins
Manufacturer communications
1
ODI investigations
Office of Defects Investigation
64
Owner complaints
2 involved a crash · 3 a fire

Owner complaints filed with NHTSA, by component

All 64 complaints on record, top 8 components.

Fuel/Propulsion System10
Service Brakes, Hydraulic5
Electrical System4
Fuel System, Gasoline4
Structure4
Seats3
Engine & Engine Cooling3
Equipment3

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 8 campaigns on record for this vehicle.

08E048000Exterior Lighting:HeadlightsReported 08/08/2008

EAGLE EYES IS RECALLING 11,534 HEADLAMP ASSEMBLIES, P/NOS. CS090-B001L AND CS090-B001R, SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR THE ABOVE LISTED PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE LOWER BEAM… Remedy: EAGLE EYES WILL NOTIFY OWNERS AND OFFER REPLACEMENT HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 30, 2008. OWNERS MAY CONTACT EAGLE EYES AT 1-800-568-1098.

07E104000Visibility:Glass, Side/RearReported 11/12/2007

CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT… Remedy: SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS…

Technical service bulletins NHTSA · verified

Showing 5 of 69 bulletins on record with NHTSA.

BulletinDateComponentSummary
S22080001362022-07-09Electrical SystemSecurity Module Lock Out After Entering the PIN to Unlock The Wireless Control Module…
S22080001362022-07-09Electrical SystemSecurity Module Lock Out After Entering the PIN to Unlock The Wireless Control Module…
90042752020-07-22Electrical SystemKEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC…
90042752020-07-22Electrical SystemKEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC…
23-015-202020-04-30EquipmentDisinfectant Solution Recommended for COVID-19

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Caravan. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2004 Caravan 3.8L take?

5 qt w/ filter of 5W-30 API, per the factory manual.

Does the 2004 Caravan have open recalls?

NHTSA lists 8 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the 3.8L get?

EPA figures are 16 city / 23 highway / 18 combined mpg.