2003 Dodge Caravan TSBs
70 Technical Service Bulletins across 13 categories
Categories
Engine
13 bulletinsPart 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.
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.].
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.
Valve Body. These may cause over drive cycling.
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
CLEANING PROCEDURE FOR THE MECHANICAL THROTTLE BODY.
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*KB
RATTLE/KNOCKING SOUND FROM THE FRONT SUSPENSION.
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*SC
IRREGULAR ENGINE SNAPPING SOUND.
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*TT
KNOCKING SOUND FROM LOWER STEERING COLUMN.
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*TT
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
PROCEDURE TO REMOVE THE INSTRUMENT PANEL WHEN SERVICING THE FRONT BLOWER MOTOR WITHOUT REMOVING THE HVAC ASSEMBLY.
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UPDATE. *TT
ROUGH/FLUCTUATING IDLE, NO-START, START AND STALL, MALFUNCTION INDICATOR LAMP ILLUMINATION, DIAGNOSTIC TROUBLLE CODES (DTCS) P0508/P0509.
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*TT
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 bulletinsSOME 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
CONCERNS WITH THE ABS, BRAKE AND TRAC OFF CLUSTER LAMPS ILLUMINATED ON VEHICLES NOT EQUIPPED WITH ABS BRAKES.
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*TT
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
SNOW/WATER INGESTION INTO REAR BRAKE DRUM.
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*YD THIS BULLETIN SUPERSEDES 05-001-02 DATED MARCH 4, 2002. *TT
SNOW/WATER INGESTION INTO REAR BRAKE DRUM.
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*KB
SNOW/WATER INGESTION INTO REAR BRAKE DRUM.
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*TT
ANTI-LOCK BRAKE REAR WHEEL SPEED SENSOR REPLACEMENT.
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*TT
SNOW/WATER INGESTION INTO REAR BRAKE DRUM.
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*TT
ANTI-LOCK BRAKE REAR WHEEL SPEED SENSOR REPLACEMENT.
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*TT
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 bulletinsTRANSMISSION DELAY ENGAGEMENT.
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*EH
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
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
TRANSMISSION HARSH 4-3 DOWNSHIFT.
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*TT
TRANSMISSION TRANSFER GEAR WHINE SOUND.
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*TT
TRANSMISSION HARSH 4-3 DOWNSHIFT ON VARIOUS MODELS INCLUDING THE 2004 PACIFICA, SEBRING, INTREPID AND 2003 SX2.0.
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*TT
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
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
DELAYED TRANSAXLE ENGAGEMENT AFTER INITIAL START UP.
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*TT
Body & Paint
8 bulletinsPOWER SLIDING DOOR ADJUSTMENT AND DIAGNOSIS AID.
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*KB UPDATED 10/26/07. *NJ
UPPER BODY SEAM SEAL APPEARANCE CONCERN WATER LEAK.
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*EH
POWER LIFTGATE (PLG) SERVICE.
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*TT
PASSENGER COMPARTMENT FLOOR WATER LEAK.
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*TT THIS BULLETIN SUPERSEDES BULLETIN 23-010-04 DATED 04-29-04. *TT
INSTRUMENT PANEL ILLUMINATION.
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*TT
UPPER BODY SEAM SEAL WATER LEAK.
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*TT
POWER SLIDING DOOR AND / OR POWER LIFTGATE WILL POP OFF BUT NOT POWER OPEN.
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*TT
POWER SLIDING DOOR AND/OR POWER LIFTGATE WILL POP OFF BUT NOT POWER OPEN.
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*TT
Other
7 bulletinsUse 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.
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.
Disinfectant Solution Recommended for COVID-19
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.
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.
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~
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 bulletinsCharging 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.
POWERTRAIN CONTROL MODULE INITIALIZATION.
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*KB
POWERTRAIN CONTROL MODULE INITIALIZATION.
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*SC
POWERTRAIN CONTROL MODULE (PCM) ELECTRICAL CONNECTOR SEAL CUSTOMER SATISFACTION NOTIFICATION NO.
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C30. *TT
SERVICE ACTION 03014 - POWERTRAIN CONTROL MODULE (PCM) ELECTRICAL CONNECTOR SEAL INSPECTION/REPAIR PROCEDURE.
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*TT
BATTERY LIGHT ILLUMINATION, ERRONEOUS DIAGNOSTIC TROUBLE CODE (DTC) P1594.
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*TT
Lighting
5 bulletinsUse 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.
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.
ERRONEOUS ACTUATION OF HORNS, HEADLAMPS, AND PARKING LAMPS WHILE VEHICLE IS PARKED.
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*TT
NO-START, START & STALL MALFUNCTION INDICATOR LAMP ILLUMINATION, DIAGNOSTIC TROUBLE CODES (DTCS) P0508/P0509.
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*TT
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 bulletinsREVISED POWER STEERING SYSTEM BLEEDING PROCEDURES.
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*SC
POP/TRICK/CREAK SOUND IN STEERING COLUMN.
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*MJ *EH
STEERING SHUDDER. *TT
POWER STEERING FLUID COOLER HOSES MAY SPLIT AND CAUSE A LOSS OF POWER ASSIST - CUSTOMER SATISFACTION NOTIFICATION NO.
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C20. *TT
POP/TICK SOUND IN STEERING WHEEL AREA.
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*TT *MJ
Pre-Delivery & Maintenance
2 bulletinsKEY, 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.
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 bulletinsCREAKING/SQUAWKING SOUND FROM FRONT STRUT AREA.
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*TT
MUFFLED RATTLE SOUND FROM FRONT SUSPENSION.
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2004 VOYAGER INCLUDED. *TT
Software & Calibration
1 bulletinFLASH PROGRAMMING FAILURE RECOVERY.
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*SLC
Tires & Wheels
1 bulletinCHROME WHEEL CARE. *SLC
Fuel System
1 bulletinVEHICLE 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