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2002 Dodge Caravan TSBs

101 Technical Service Bulletins across 15 categories

Engine

16 bulletins
634115

LOUD WHISTLE/SQUEALING SOUND FROM ENGINE COMPARTMENT-2002 RS/RG.

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*SLC

633487

SUBJECT REGARDING STUCK OIL PRESSURE RELIEF VALVE FOR VEHICLES BUILT PRIOR TO JANUARY 1, 2002 EQUIPPED WITH A 3.3 L OR 3.8 L ENGINE.

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*SLC

632197

SUBJECT REGARDING CAMSHAFT / BEARING SERVICE.

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*TT

630883

EXHIBITING ENGINE SAG / HESITATION AND/OR CLOSED THROTTLE START STALL, DIAGNOSTIC TROUBLE CODE P0123.

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*TT

629135

SUBJECT REGARDING BELT LIKE SQUEAL SOUND AT HIGH ENGINE RPM.

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*TT

628326

A CONDITION MAY EXIST AT IDLE, WITH THE COOLING FANS ON, A SOUND MAY BE HEARD AND / OR A VIBRATION MAY BE FELT INSIDE THE VEHICLE.

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*TT

625618

INFORMATION ON BELT-LIKE SQUEAL SOUND AT HIGH ENGINE RPM.

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*TT

623279

SOME VEHICLES WERE BUILT AND SHIPPED TO DEALERS WITH CAMSHAFTS THAT MAY HAVE AN IMPROPERLY MACHINED OIL GROOVE.

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*SLC

10223854

Service - Four Piece Oil Pan Gasket All Cummins Equipped Vehicles ONLY - The replacement oil pan gasket can be a four...

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piece gasket rather than a single piece gasket. This applies to Cummins 5.9L and 6.7L engines only. Installation: 1. Clean the oil pan T-joints.~ 2. Fill the T-joint between the pan rail/gear housing and pan rail/rear seal retainer with sealant. Use Mopar Silicone Rubber Adhesive Sealant or equivalent. 3. Apply a 2-mm [0.063-in] bead of Mopar Engine Sealant RTV Silicone Rubber Adhesive, to the oil pan flange.~ 4. The four piece gasket will need to be assembled to make a complete oil pan gasket. 5. Lay the oil pan gasket(s) onto the oil pan flange.~ 6. Ensure the oil pan gasket segment joints are properly aligned. 7. Apply a 2-mm [0.063-in] bead of Mopar Engine Sealant RTV Silicone Rubber Adhesive, to the top of the oil pan gasket.~ 8. Install the oil pan. Starting from the center and working outward, tighten the oil pan bolts to 28 Nm [21 ft. lbs.].

10191460

Valve Body. These may cause over drive cycling.

10139595

Part Description: Insulator in Lever Assembly - Valve Body - Trans Issue Description: The manual valve insulator,...

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attaching rivet and an instruction sheet are now available as a kit. If the insulator requires replacement lease order 68253099AA. Note: Insulator color is not relevant for service

10021668

CLEANING PROCEDURE FOR THE MECHANICAL THROTTLE BODY.

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*KB

10013699

RATTLE/KNOCKING SOUND FROM THE FRONT SUSPENSION.

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*SC

10006455

IRREGULAR ENGINE SNAPPING SOUND.

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*TT

10003991

KNOCKING SOUND FROM LOWER STEERING COLUMN.

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*TT

10000312

ENGINE SPARK KNOCK. *TT

Other

15 bulletins
634087

SUBJECT REGARDING REMOTE KEYLESS ENTRY PROGRAMMING PROCEDURES.

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*SLC

634072

SUBJECT REGARDING ASSIST FEATURE INOPERATIVE ON QUAD OR SPLIT REAR BENCH SEATS.

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*SLC

634070

SUBJECT REGARDING QUAD SEAT RELEASE HANDLE SCREW SHEARED OFF IN SHAFT.

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*SLC

633448

SUBJECT REGARDING COOLING FAN SOUND/VIBRATION.

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*SLC

632205

THIS BULLETIN INVOLVES INSTALLING A REVISED POWER SEAT ADJUSTER DRIVE BLOCK SCREW TO THE INBOARD SIDE OF THE POWER SEAT TRACK(S).

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*TT

629165

ON SOME VEHICLES, THE QUAD SEAT CUPHOLDER COMPENSATION FLAP IS BROKEN.

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*TT

628210

SOME CUSTOMERS MAY COMPLAIN OF A HOWL/ DRONE/ MOAN/ HUMMING/CYCLIC SOUND WHEN DRIVING AT SPEEDS BETWEEN 45 AND 70 MPH.

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*TT

628186

SOME VEHICLES MAY EXHIBIT MODERATE TO SEVERE HIGH WAY SPEED 45-60 MPH VEHICLE SURGE.

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*TT

625620

SUBJECT REGARDING SAFETY SYSTEMS - VEHICLE MODIFICATIONS / REPAIR.

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*TT

10220101

Use of Aftermarket Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry...

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awareness regarding the use of aftermarket parts.

10220097

Repair Parts Used For Structural Repairs This bulletin involves discussing FCA US LLC position with regard to...

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structural repair parts usage.

10175743

Disinfectant Solution Recommended for COVID-19

10169249

Use of Aftermarket Parts This bulletin involves discussing FCA US LLC position with regard to collision repair industry...

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awareness regarding the use of aftermarket parts.

10169245

Repair Parts Used For Structural Repairs This bulletin involves discussing FCA US LLC position with regard to...

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structural repair parts usage.

10129008

82212076, 82203694 - Fabric Cleaner This "fabric cleaner" is not intended for sale in California, the otc states ...

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(Connecticut, Delaware, Massachusetts, Maine, New Hampshire, New Jersey, New York, Pennsylvania, Virginia, and Washington dc), and some ladco states (Illinois, Michigan, and Ohio). Mopar offers an alternative product (82213192) which is a water based product approved for sale in the aforementioned states.~ ~ Please inform the customer & your prep dept that spraying excessive amounts of the fabric protector on load floors will result in the breaking down of the adhesive (glue) that is used to create the bond between the fabric (carpet) and the load floor. This will apply to any vehicles equipped with rear load floors such as WK, WD, PM, MK, KA, KK. The carpet will appear to be loose, wrinkly, or bunch up~

Brakes

11 bulletins
635728

SOME VEHICLES NOT EQUIPPED WITH ANTI-SKID BRAKE SYSTEM (ABS) MAY HAVE THE ABS, BRAKE AND TRAC OFF LAMPS ILLUMINATED ON THE INSTRUMENT CLUSTER.

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*TT

635674

CONCERNS WITH THE ABS, BRAKE AND TRAC OFF CLUSTER LAMPS ILLUMINATED ON VEHICLES NOT EQUIPPED WITH ABS BRAKES.

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*TT

635672

SUBJECT REGARDING REAR BRAKE CYCLIC RUBBING SOUND FROM REAR OF VEHICLE DURING MEDIUM TO LIGHT BRAKE APPLICATION ON VEHICLES WITH REAR DRUM BRAKES.

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*TT

630800

SNOW/WATER INGESTION INTO REAR BRAKE DRUM.

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*YD THIS BULLETIN SUPERSEDES 05-001-02 DATED MARCH 4, 2002. *TT

628198

ON SOME VEHCLES, THE POWER SEAT HAS SLIGHT FORE/AFT MOVEMENT MOST NOTICEABLE DURING ACCELERATION OR BRAKING.

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*TT

10020494

SNOW/WATER INGESTION INTO REAR BRAKE DRUM.

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*KB

10019632

SNOW/WATER INGESTION INTO REAR BRAKE DRUM.

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*TT

10011941

ANTI-LOCK BRAKE REAR WHEEL SPEED SENSOR REPLACEMENT.

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*TT

10005996

SNOW/WATER INGESTION INTO REAR BRAKE DRUM.

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*TT

10003534

ANTI-LOCK BRAKE REAR WHEEL SPEED SENSOR REPLACEMENT.

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*TT

10002040

VEHICLES NOT EQUIPPED WITH ANTI-LOCK BRAKE SYSTEM (ABS) BRAKES MAY HAVE THE ABS, BRAKE, AND TRAC OFF LAMPS ILLUMINATED...

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ON THE INSTRUMENT CLUSTER OR VEHICLES NOT EQUIPPED WITH SENTRY KEY IMMOBILIZER (SKIM) MAY HAVE THE SECURITY/VTA LAMP ILLUMINATED ON THE INSTRUMENT CLUSTER. *TT

Steering

10 bulletins
634092

SUBJECT REGARDING STEERING SHUDDER.

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*SLC

628332

EXPERIENCING A SHUDDER (VIBRATION) FELT INSIDE THE VEHICLE WHILE TURNING THE STEERING WHEEL.

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*TT

628194

EXPERIENCING A POP/TICK SOUND HEARD COMING FROM THE STEERING WHEEL AREA WHILE THE VEHICLE IS IN MOTION.

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*TT

623172

INFORMATION ON NEW POWER STEERING FLUID.*SLC

10017651

REVISED POWER STEERING SYSTEM BLEEDING PROCEDURES.

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*SC

10007928

POP/TRICK/CREAK SOUND IN STEERING COLUMN.

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*MJ *EH

10003546

STEERING SHUDDER. *TT

10003545

POP/TICK SOUND IN STEERING WHEEL AREA.

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*TT

10002055

POWER STEERING FLUID COOLER HOSES MAY SPLIT AND CAUSE A LOSS OF POWER ASSIST - CUSTOMER SATISFACTION NOTIFICATION NO.

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C20. *TT

10001106

POP/TICK SOUND IN STEERING WHEEL AREA.

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*TT *MJ

Transmission

9 bulletins
635719

SOME VEHICLES MAY HAVE A TRANSAXLE THAT WILL NOT MOVE OR SLIPS IN REVERSE OR FIRST GEAR.

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*TT

635706

SOME VEHICLES MAY EXPERIENCE A SLIPPING OR NO DRIVE CONDITION IN REVERSE OR FIRST GEAR.

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*TT

635704

SOME VEHICLES MAY EXPERIENCE A SLIPPING OR NO DRIVE CONDITION IN REVERSE OR FIRST GEAR.

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*TT

621898

AUTOMATIC TRANSMISSION FLUID USAGE ATF+4.

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*TT *MJ

10012343

TRANSMISSION DELAY ENGAGEMENT.

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*EH

10007934

SURGE WITH TRANSMISSION AT FULL LOCK-UP.

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*MJ

10003524

AUTOMATIC TRANSMISSION DIAGNOSTIC TEARDOWN PROCEDURE.

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VARIOUS MODELS INCLUDING THE 2004 RAM TRUCK, DURANGO, SEBRING CONVERTIBLE, CHEROKEE, VISION, NEON, AND VOYAGER. *TT *SC

10000330

THE TRANSAXLE LOW/REVERSE ACCUMULATOR COVER O-RING ON CERTAIN VEHICLES MAY BECOME DISLODGED.

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*TT

10000329

DELAYED TRANSAXLE ENGAGEMENT AFTER INITIAL START UP.

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*TT

Body & Paint

9 bulletins
634077

SUBJECT REGARDING OUTSIDE REARVIEW MIRROR GLASS REPLACEMENT.

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*SLC

634074

SUBJECT REGARDING QUARTER WINDOW WEATHERSTRIP LOOSE.

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*SLC

628308

SUBJECT REGARDING POWER SLIDING DOOR REVERSES DIRECTION DURING THE POWER CLOSE CYCLE, FALSE OBSTACLE DETECTION.

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*TT

625650

SUBJECT REGARDING OUTSIDE REARVIEW MIRROR GLASS REPLACEMENT.

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*TT

10022182

POWER SLIDING DOOR ADJUSTMENT AND DIAGNOSIS AID.

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*KB UPDATED 10/26/07. *NJ

10006965

PASSENGER COMPARTMENT FLOOR WATER LEAK.

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*TT THIS BULLETIN SUPERSEDES BULLETIN 23-010-04 DATED 04-29-04. *TT

10005994

INSTRUMENT PANEL ILLUMINATION.

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*TT

10000869

POWER SLIDING DOOR AND / OR POWER LIFTGATE WILL POP OFF BUT NOT POWER OPEN.

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*TT

10000327

POWER SLIDING DOOR AND/OR POWER LIFTGATE WILL POP OFF BUT NOT POWER OPEN.

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*TT

Electrical

8 bulletins
632208

INFORMATION ON REMOVABLE FLOOR CONSOLE ELECTRICAL CONNECTOR.

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*TT

631824

INFORMATION REGARDING THE MINIVAN ELECTRICAL SYSTEM.

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*SLC

623298

CONCERNS WITH WIRING HARNESS CHAFING.*SLC

10175735

Charging System, Battery Diagnostic Tools and Warranty This information only bulletin discusses using the correct test...

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equipment for testing batteries and charging systems, and also warranty reimbursement when battery replacements are necessary.

10021239

POWERTRAIN CONTROL MODULE INITIALIZATION.

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*KB

10013731

POWERTRAIN CONTROL MODULE INITIALIZATION.

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*SC

10003536

POWERTRAIN WIRING HARNESS BRACKET PACKAGE.

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*TT

10002041

BATTERY LIGHT ILLUMINATION, ERRONEOUS DIAGNOSTIC TROUBLE CODE (DTC) P1594.

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*TT

Fuel System

6 bulletins
634120

SUBJECT REGARDING MALFUNCTION INDICATOR LAMP ILLUMINATION, ERRONOUS DIAGNOSTIC TROUBLE CODE (DTC) P0456, EVAP LEAK MONITOR 0.020 LEAK DETECTED.

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*SLC

634090

SUBJECT REGARDING FUEL CAP DIFFICULT TO REMOVE.

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*SLC

632199

SUBJECT REGARDING EXHAUST GAS RECIRCULATION (EGR) SYSTEM ELIMINATION.

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*TT

628184

A CONDITION MAY EXIST WHERE THE FUEL GAUGE INDICATOR VISIBLY DROPS 1/4 TO 1/2 TANK WHILE DRIVING.

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*TT

10003419

VEHICLE WITH PROPERLY FUNCTIONING EVAPORATIVE EMISSIONS SYSTEM REPEATEDLY SETS DIAGNOSTIC TROUBLE CODE P0456 WHEN...

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CUSTOMER REGULARLY COMMUTES ON A STEEP GRADE. *TT

10000310

FUEL CAP DIFFICULT TO REMOVE.

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*TT

Lighting

5 bulletins
628231

CONCERN WITH TAIL LAMP EXPERIENCING A LOOSE CONDITION.

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*TT

10220099

Use of Salvage/Recycled Parts This bulletin involves discussing FCA US LLC position with regard to collision repair...

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industry awareness regarding the use of recycled or salvage parts.

10169247

Use of Salvage/Recycled Parts This bulletin involves discussing FCA US LLC position with regard to collision repair...

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industry awareness regarding the use of recycled or salvage parts.

10006129

MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATION, DIAGNOSTIC TROUBLE CODE (DTC) P0442, P0455, OR P0456 - LEAK DETECTION PUMP (LDP), LEAK DETECTED.

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THIS BULLETIN SUPERSEDES 25-001-02 DATED FEB 11, 2002. *TT

10005995

ERRONEOUS ACTUATION OF HORNS, HEADLAMPS, AND PARKING LAMPS WHILE VEHICLE IS PARKED.

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*TT

HVAC & Climate

3 bulletins
635697

SUBJECT REGARDING AIR CONDITIONER TEMPERATURE DIFFERENTIAL (STRATIFICATION) BETWEEN LEFT AND RIGHT FRONT PANEL OUTLETS.

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*TT

635694

CUSTOMER MAY COMPLAIN THAT THE HVAC DRAIN WATER LEAKS UNDER PASSENGER SIDE CARPET.

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*TT

634129

SUBJECT REGARDING POOR REAR AIR CONDITIONER PERFORMANCE - LOW OUTPUT FROM HEADLINER VENTS.

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*SLC

Pre-Delivery & Maintenance

3 bulletins
620066

SUBJECT REGARDING GENERIC SCAN TOOL (GST), PUBLICATION NO.

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81-170-00008 PROVIDED WITH THIS TECHNICAL SERVICE BULLETIN TO PROVIDE REFERENCE INFORMATION WHEN USING GENERIC SCAN TOOL ON OBDII VEHICLES. *TT

10229256

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number.

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The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicle, use the "AC" NIC level part and submit a part warranty.

10221686

KEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC level part number.

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The "AB" NIC level will not program to these platforms. For all other platforms, if the "AB" NIC level will not program to the vehicle, use the "AC" NIC level part and submit a part warranty.

Tires & Wheels

2 bulletins
635708

SUBJECT REGARDING MONRONEY LABEL TIRE DISCREPANCY.

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*TT

634082

CHROME WHEEL CARE. *SLC

Suspension

2 bulletins
620059

SUBJECT REGARDING AIRBAG / CLOCK SPRING SERVICE FOR VARIOUS MODELS INCLUDING 2002 MODEL YEAR JEEP LIBERTY.

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*TT

10016751

CREAKING/SQUAWKING SOUND FROM FRONT STRUT AREA.

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*TT

Software & Calibration

1 bulletin
634272

FLASH PROGRAMMING FAILURE RECOVERY.

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*SLC

Infotainment

1 bulletin
623312

INFORMATION REGARDING VEHICLES EQUIPPED WITH RADIOS WILL HAVE A NEW LOCKING RADIO ANTENNA CONNECTOR.

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*SLC