Problem Reports

Front crankshaft seal has popped out for the 2nd time. First time was at 68,000 miles during Chrysler Bankruptcy and was told it was not a warranty issue. Since then I have learned this is a fairly common problem in this engine and has been known about by Chrysler for many years without issuing a recall. VERY disappointed in Chrysler ......

front crankshaft seal poped out

We blew the Front mail seal at 75000 miles and it was replaced. The mechanic didn't even stop to wonder what would make a seal fall out. Less than 1 oil change later, it came out again, this time I did my own research and found several sites like this one. Notice: although many mechanics claim there are TSB's relating to this problem, there are none specifically identifying the problems with 2.4 Caravan engines. The TSBs all refer to other models, which makes it more difficult to get people on board with the solution. Also the title of this post / problem refers to corrective thrust washers. How are you supposed to get "Corrective thrust washers" when Dodge hasn't even acknowledged the problem in this model? Shame on Dodge!

I called the Dodge Dealer inquiring about corrective thrust washers and they said they didn't know what I was talking about.

The second time, the dealer(I bought the car from a Ford dealer) recommended a total replacement of the lower engine assembly to get rid of the crank endplay. The warranty company agreed to it and we now have a whole new bottom end. Approx 3500 miles later, the seal came out again. Took the car back to the mechanic who admitted his tech should have known the aftermarket seal (Car Quest)did not fit correctly. Finally the dumb a... consulted the Dodge Dealer and got the OEM seal with the "lube and sealer that is supposed to be used with it" and has installed it. We are at about 5000 miles now with no problems.

If you have excessive end play in your crank, replacing the seals is not going to resolve the problem. The repairs are around $3200 or so. If you don't have a warranty contract, I would recommend doing the work yourself. It basically involves replacing the crank and bearings, and possibly the oil pump which is used like a thrust washer. If you are going to try to resolve the problem by replacing the Main Seal, Go to the Dodge dealer and get the Dodge seal, consult a tech on installing it and use the lube, sealer that comes with it.

still working on a solution.

Engine oil leaked out very quickly. I am being told by the mechanic that there is excessive end play resulting in the oil leak. The recommendation is to strip open the engine to fix the issue or to get a new engine. Both are expensive solution. Looks like a product/engineering defect. I am going to call dodge and complain