Front Crankshaft Seal May Pop Out Due to End Play on Dodge Caravan

Due to the crankshaft end play being out of specification, the front crankshaft seal can be popped or pushed out. Revised crank main thrust bearings will solve the problem.

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Average mileage: 68,663 (10,500–156,000)
Engines affected: 2.4L 4 Cylinder, 3.3L V6
5 model years affected: 2000, 2004, 2005, 2006, more2007
40 people reported this problem
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Viewing 1 - 20 of 33 problem details
2007 Dodge Caravan - 2.4L 4 Cylinder 75,000 mi,
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.
2006 Dodge Caravan - 2.4L 4 Cylinder 40,000 mi,
Front oil seal gets pushed out and oil spills out. Can it be glued on or sodered on to solve this problem?
2005 Dodge Caravan - 2.4L 4 Cylinder 91,000 mi,
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 ......
2007 Dodge Caravan - 2.4L 4 Cylinder 38,000 mi,
front seal poped out
2006 Dodge Caravan - 2.4L 4 Cylinder 61,546 mi,
took vechicle to dealer for front seal leak. Car out of warranty dealer replaces front seal. 396 miles and 10 weeks later front seal pops out again. go back to dealer who denies any known issue. will not fix because it was longer than 1 month. Take to private repair shop explains issue and problem tryies to fix best he can no warranty because of faluaty engine design. front seal pops out 36 miles later. Caravan now a lawn decoration. Shit vechicle and self absorbed company does not aknowledge problem. I will not buy Dodge again and you should not either
2007 Dodge Caravan - 3.3L V6 125,000 mi,
not fixed told 1 time it was tie rods 1 time it was bearings 1 time there was nothing wrong now it is the seal why is this not a recall
2005 Dodge Caravan - 2.4L 4 Cylinder 61,000 mi,
Massive oil leaking from seal, found excessive crank end play, crank damaged and needed to replace short block.
2005 Dodge Caravan - 3.3L V6 65,000 mi,
Replaced engine
2005 Dodge Caravan - 2.4L 4 Cylinder 45,545 mi,
front crankshaft seal poped out
2006 Dodge Caravan - 3.3L V6 150,000 mi,
Oil leaks out. Replaced seal 3 times
2007 Dodge Caravan - 2.4L 4 Cylinder 49,283 mi,
Seal Popped out. End play = .078
2000 Dodge Caravan - 3.3L V6 156,000 mi,
It is leaking but not fixed yet.
2006 Dodge Caravan - 2.4L 4 Cylinder 94,000 mi,
Engine and oil lights, first sign then every time I checked oil it was over a quart low. Took to local shop, they said front seal was leaking but they make a kit that includes everything you have to go through to get to it. When we got it back, it leaked much worse than before dumping loads of oil all over our driveway. Took it back, they tried again. This time the leak has slowed but still leaking way too much. I hate this too because up until now, we've been very please with it. So far, repair costs... $470.00.
2006 Dodge Caravan - 2.4L 4 Cylinder 136,000 mi,
Oil drained everywhere
2007 Dodge Caravan - 2.4L 4 Cylinder 60,000 mi,
oil pouring out crankshaft past oil said shaft moving in and out to much ,metal rubbing alumnum .rebuild or new engin.
2007 Dodge Caravan - 2.4L 4 Cylinder 93,600 mi,
Massive oil leak. Replaced seals and belts. Mechanic said he has never seen so much play in a crankshaft and that this will just keep happening unless we replace the engine.
2007 Dodge Caravan - 2.4L 4 Cylinder 60,000 mi,
front crankshaft seal oil pouring past problems of oil leak.the shop said new engin or rebuilt .shaft is moving more then it should ,metal rubbing on alumnum.
2007 Dodge Caravan - 2.4L 4 Cylinder 82,280 mi,
I had the same problem with the front seal, as I have mentioned earlier. I ended up placing a new engine in the Caravan at $2,700+.
2007 Dodge Caravan - 2.4L 4 Cylinder 91,000 mi,
not fixed---caravan not running!!!
2004 Dodge Caravan - 2.4L 4 Cylinder 32,000 mi,
massive oil leak at seal.. Dealer says problem end play.. Cannot help me!!!Called Dodge same rely. Engine needs to be replaced