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2003 Dodge Caravan TSBs

70 Technical Service Bulletins across 13 categories

Engine

13 bulletins
10229181

Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications.

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An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine.

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.].

10223602

Part Description: 5.7L Long Block Issue Description: This 5.7L Long Block Assembly is compatible with both EGR and Non-EGR applications.

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An EGR Block-Off Plate (53032739AA) must be ordered when installing this Long Block Assembly in a Non-EGR application. Unless, the EGR Block-Off Plate is being transferred from the old engine.

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

10003985

ENGINE NO START (ENGINE WILL START IMMEDIATELY AFTER CYCLING THE IGNITION KEY), MALFUNCTION INDICATOR LAMP ILLUMINATION...

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WITH FALSE DIAGNOSTIC TROUBLE CODES (DTC) P0016, P0116, P0335, P0339, P0340, P0462, P0498, P0499, P0522, P0622, P1604, P1681, P1686, P1698. *TT

10003811

PROCEDURE TO REMOVE THE INSTRUMENT PANEL WHEN SERVICING THE FRONT BLOWER MOTOR WITHOUT REMOVING THE HVAC ASSEMBLY.

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UPDATE. *TT

10002400

ROUGH/FLUCTUATING IDLE, NO-START, START AND STALL, MALFUNCTION INDICATOR LAMP ILLUMINATION, DIAGNOSTIC TROUBLLE CODES (DTCS) P0508/P0509.

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*TT

10002044

ENGINE NO START (ENGINE WILL START IMMEDIATELY AFTER CYCLING THE IGNITION KEY), MALFUNCTION INDICATOR LAMP ILLUMINATION...

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WITH FALSE DIAGNOSTIC TROUBLE CODES (DTC) P0016, P0335, P0339, P0340, P0462, P0498, P0499. *TT

Brakes

10 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

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

Transmission

9 bulletins
10012343

TRANSMISSION DELAY ENGAGEMENT.

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*EH

10003550

DELAYED OR TEMPORARY LOSS OF TRANSMISSION ENGAGEMENT AFTER INITIAL START UP ON VARIOUS MODELS INCLUDING THE 2004...

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PACIFICA, SEBRING CONVERTIBLE, SEBRING SEDAN, INTREPID AND 2003 SX2.0. *TT

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

10003522

TRANSMISSION HARSH 4-3 DOWNSHIFT.

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*TT

10002401

TRANSMISSION TRANSFER GEAR WHINE SOUND.

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*TT

10002046

TRANSMISSION HARSH 4-3 DOWNSHIFT ON VARIOUS MODELS INCLUDING THE 2004 PACIFICA, SEBRING, INTREPID AND 2003 SX2.0.

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*TT

10002045

DELAYED OR TEMPORARY LOSS OF TRANSMISSION ENGAGEMENT AFTER INITIAL START UP ON VARIOUS MODELS INCLUDING THE 2004...

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PACIFICA, SEBRING CONVERTIBLE, SEBRING SEDAN, INTREPID AND 2003 SX2.0. *TT *MJ

10001528

TRANSAXLE WIRING HARNESS CORROSION WHICH COULD CAUSE THE MALFUNCTION INDICATOR LIGHT (MIL) TO ILLUMINATE AND THE TRANSMISSION TO SHIFT INTO 2ND GEAR.

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*TT

10000329

DELAYED TRANSAXLE ENGAGEMENT AFTER INITIAL START UP.

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*TT

Body & Paint

8 bulletins
10022182

POWER SLIDING DOOR ADJUSTMENT AND DIAGNOSIS AID.

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*KB UPDATED 10/26/07. *NJ

10012340

UPPER BODY SEAM SEAL APPEARANCE CONCERN WATER LEAK.

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*EH

10012260

POWER LIFTGATE (PLG) SERVICE.

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*TT

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

10000910

UPPER BODY SEAM SEAL WATER LEAK.

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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

Other

7 bulletins
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~

10005660

DAIMLERCHRYSLER CARGO VAN ORIGINAL EQUIPMENT (OE) FITMENT.

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BRIDGESTONE TURANZA EL42+ 215/65R16 98T - ARTICLE # 122-076. THIS IS BRIDGESTONE FIRESTONE TECHNICAL BULLETIN. *TT

Electrical

6 bulletins
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

10005354

POWERTRAIN CONTROL MODULE (PCM) ELECTRICAL CONNECTOR SEAL CUSTOMER SATISFACTION NOTIFICATION NO.

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C30. *TT

10003520

SERVICE ACTION 03014 - POWERTRAIN CONTROL MODULE (PCM) ELECTRICAL CONNECTOR SEAL INSPECTION/REPAIR PROCEDURE.

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*TT

10002041

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

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*TT

Lighting

5 bulletins
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.

10005995

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

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*TT

10005982

NO-START, START & STALL MALFUNCTION INDICATOR LAMP ILLUMINATION, DIAGNOSTIC TROUBLE CODES (DTCS) P0508/P0509.

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*TT

10000318

HEADLAMPS ON WITH WIPERS FEATURE IS INOPERATIVE WHEN THE CUSTOMER ENABLES THE FEATURE USING THE ELECTRONIC VEHICLE...

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INFORMATION CENTER (EVIC) OR THE FEATURE IS ENABLED USING THE DRBIII. *TT

Steering

5 bulletins
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

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

Pre-Delivery & Maintenance

2 bulletins
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.

Suspension

2 bulletins
10016751

CREAKING/SQUAWKING SOUND FROM FRONT STRUT AREA.

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*TT

10003978

MUFFLED RATTLE SOUND FROM FRONT SUSPENSION.

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2004 VOYAGER INCLUDED. *TT

Software & Calibration

1 bulletin
634272

FLASH PROGRAMMING FAILURE RECOVERY.

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*SLC

Tires & Wheels

1 bulletin
634082

CHROME WHEEL CARE. *SLC

Fuel System

1 bulletin
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