2005 Dodge Caravan Service and Repair Manual

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Factory-Grade Data

2005 Dodge Caravan service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • SE Mini Passenger Van 4-Door
  • C/V Mini Cargo Van 3-Door
  • Base Mini Cargo Van 3-Door
  • SXT Mini Passenger Van 4-Door

Engines covered

  • 3.3L 3301CC 201Cu. In. V6 FLEX OHV Naturally Aspirated
  • 3.3L 3301CC 201Cu. In. V6 GAS OHV Naturally Aspirated
  • 2.4L 2429CC 148Cu. In. l4 GAS DOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Payment methods

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Vehicle Safety Data

2005 Dodge Caravan Recalls & Complaints

NHTSA #06E02200013/03/2006Component: SERVICE BRAKES, HYDRAULIC

CERTAIN AFTERMARKET BRAKE HYDRAULIC MASTER CYLINDERS SOLD AS REPLACEMENT BRAKE CYLINDERS FOR CERTAIN FORD, DAIMLERCHRYSLER, AND JEEP PASSENGER VEHICLES. THESE BRAKE CYLINDERS WERE SOLD UNDER THE BRAN

Consequence

LOSS OF BRAKE FLUID CAN LEAD TO A DECREASE IN BRAKE LINE PRESSURE AND AN INCREASE IN STOPPING DISTAN

Remedy

AFFINIA (BRAKE PARTS, INC.) WILL REPLACE THE SUBJECT BRAKE HYDRAULIC MASTER CYLINDERS FREE OF CHARGE

NHTSA #10V00800011/01/2010Component: AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE-INACTIVE

CHRYSLER IS RECALLING CERTAIN MODEL YEAR 2005-2006 DODGE CARAVAN, GRAND CARAVAN AND CHRYSLER TOWN & COUNTRY VEHICLES ORIGINALLY SOLD IN OR CURRENTLY REGISTERED IN THE STATES OF CONNECTICUT, DELAWARE,

Consequence

IF THE FRONT CRASH SENSORS BECOME INOPERATIVE, THE DRIVER IS IMMEDIATELY ALERTED BY ILLUMINATION OF

Remedy

CHRYSLER WILL REPLACE THE FRONT AIRBAG SENSORS WITH A NEW DESIGN. THIS SERVICE WILL BE PERFORMED FRE

NHTSA #10E03400010/08/2010Component: EQUIPMENT

CURT MFG IS RECALLING CERTAIN CLASS 3 RECEIVER HITCHES, P/N 13347, SOLD AS AFTERMARKET EQUIPMENT FOR USE ON 1997-2007 CHRYSLER TOWN AND COUNTRY VANS, 1996-2007 DODGE CARAVANS, AND 1996-2004 PLYMOUTH V

Consequence

IF THE AREA IN QUESTION FRACTURES OR BREAKS, THIS COULD CAUSE AN UNSTABLE DRIVING CONDITION, POSSIBL

Remedy

CURT MFG WILL NOTIFY OWNERS OF RECORD AND WILL REPLACE THE HITCH FREE OF CHARGE. THE SAFETY RECALL

NHTSA #08E04800008/08/2008Component: EXTERIOR LIGHTING:HEADLIGHTS

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

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

EAGLE EYES WILL NOTIFY OWNERS AND OFFER REPLACEMENT HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN ON S

NHTSA #06V06700008/03/2006Component: VISIBILITY:WINDSHIELD WIPER/WASHER:MOTOR

ON CERTAIN VANS AND SPORT UTILITY VEHICLES, THE FRONT WINDSHIELD WIPER MOTOR ARMATURE SHAFT MAY BREAK.

Consequence

DURING CERTAIN OPERATING CONDITIONS, LOSS OF FRONT WINDSHIELD WIPING CAPABILITY COULD OCCUR, AND THE

Remedy

DEALERS WILL INSPECT AND REPLACE THE WINDSHIELD WIPER MOTOR FREE OF CHARGE. THE RECALL BEGAN ON JU

NHTSA #04V04700003/02/2004Component: SEAT BELTS:FRONT:RETRACTOR

AFTER PERFORMING THE NCAP TEST, IT WAS DISCOVERED THAT ON CERTAIN MINIVANS EQUIPPED WITHOUT THE AVAILABLE "STOW 'N GO" SEATING OPTION, THE RIGHT FRONT SEAT BELT RETRACTOR ASSEMBLY MAY HAVE BEEN IMPROP

Consequence

AS A RESULT, THE SEAT BELT MAY NOT PROPERLY RESTRAIN THE OCCUPANT DURING CERTAIN CRASH CONDITIONS, W

Remedy

DEALERS WILL INSPECT THE RETRACTOR ASSEMBLIES AND ANY SEAT BELT ASSEMBLY THAT DOES NOT HAVE THE STAK

TSB #10229256

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicl

TSB #10221686

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number. The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicl

TSB #10221097

Transmission Kit with Torque Converter 1. All Promaster (VF) 3.6L/62TE equipped vehicles. If the transmission bracket to the transmission case fasteners are removed during servicing, the fasteners (Part Number 06511385A$) are one-time usage

TSB #10220840

Transmission Kit with Torque Converter 1. All Promaster (VF) 3.6L/62TE equipped vehicles. If the transmission bracket to the transmission case fasteners are removed during servicing, the fasteners (Part Number 06511385A$) are one-time usage

TSB #10219763

Extended Warranty on the Fuel Tank/Vapor Cannister

TSB #10218069

This bulletin involves replacing the fuel tank and vapor canister.

TSB #10209634

Extended Warranty on the Fuel Tank/Vapor Cannister

TSB #10191460

Valve Body. These may cause over drive cycling.

Showing the 8 most recent of 83 technical service bulletins on file with NHTSA.

20160726Component: SEAT BELTSCrash reported3 injured

DURING A LEFT SIDE IMPACT COLLISION WITH A SEMI TRUCK THE LEFT SEATBELT OF THE MIDDLE ROW SEAT FAILED TO LOCK. IT CAUSED MY BACKSEAT PASSENGER TO BE THROWN FROM SIDE TO SIDE IN THE VAN BECAUSE OF THE

20070506Component: SEAT BELTS:FRONTCrash reported2 injured

I WAS IN AN AUTOMOBILE ACCIDENT 11/02/06. I WAS THE DRIVER AND MY FATHER WAS A PASSANGER. WE WERE REARENDED AND MY FATHERS SEAT BELT DIDN'T CATCH. MY SEAT BELT CAUGHT.

20191204Component: UNKNOWN OR OTHERCrash reported1 injured

TL* THE CONTACT OWNS A 2005 DODGE CARAVAN. WHILE DRIVING 30 MPH, THE BRAKE PEDAL WAS DEPRESSED, BUT THE VEHICLE FAILED TO STOP. ALSO, THE CHECK ENGINE INDICATOR ILLUMINATED. THE CONTACT ALSO MENTIONED

20170511Component: AIR BAGSCrash reported1 injured

MYSELF AND TWO OTHERS JUST RECENTLY GOT INTO A CAR ACCIDENT AND MY AIRBAGS DIDNT GO OFF . THANK GOD THAT WE HAD OUR SEATBELTS ON. A CAR CUT A BUS OFF ON HWY44 WWST IN INVERNESS FL, WE ALL HAD TO HIT O

20170511Component: SERVICE BRAKESCrash reported1 injured

MYSELF AND TWO OTHERS JUST RECENTLY GOT INTO A CAR ACCIDENT AND MY AIRBAGS DIDNT GO OFF . THANK GOD THAT WE HAD OUR SEATBELTS ON. A CAR CUT A BUS OFF ON HWY44 WWST IN INVERNESS FL, WE ALL HAD TO HIT O

Showing the 5 most serious of 691 complaints filed with NHTSA.

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