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: 63,465 (10,500–150,000)
Engines affected: 2.4L 4 Cylinder, 3.3L V6
4 model years affected: 2004, 2005, 2006, 2007
32 people reported this problem
27 people shared problem details
2007 Dodge Caravan- 2.4L 4 Cylinder75,000
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 Cylinder61,546
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- 2.4L 4 Cylinder38,000
front seal poped out
2005 Dodge Caravan- 2.4L 4 Cylinder91,000
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 ......
2005 Dodge Caravan- 3.3L V665,000
Replaced engine
2005 Dodge Caravan- 2.4L 4 Cylinder45,545
front crankshaft seal poped out
2006 Dodge Caravan- 3.3L V6150,000
Oil leaks out. Replaced seal 3 times
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 Cylinder61,000
Massive oil leaking from seal, found excessive crank end play, crank damaged and needed to replace short block.
2007 Dodge Caravan- 2.4L 4 Cylinder49,283
Seal Popped out. End play = .078
2007 Dodge Caravan- 2.4L 4 Cylinder82,280
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 Cylinder91,000
not fixed---caravan not running!!!
2004 Dodge Caravan- 2.4L 4 Cylinder32,000
massive oil leak at seal.. Dealer says problem end play.. Cannot help me!!!Called Dodge same rely. Engine needs to be replaced
2005 Dodge Caravan- 2.4L 4 Cylinder66,000
Popped oil seal immediately popped back out after repair--still on on the mechanics rack! 500.00 for nothing
2006 Dodge Caravan- 2.4L 4 Cylinder40,000
Front oil seal gets pushed out and oil spills out. Can it be glued on or sodered on to solve this problem?
2006 Dodge Caravan- 2.4L 4 Cylinder64,000
Crankshaft seal leaking. Took to dealer service, was told the play in the crankshaft wore into the block and would need a new shrt bloct, around $6000
2007 Dodge Caravan- 2.4L 4 Cylinder62,000
suddenly backing out driveway oil poured out of front seal
2006 Dodge Caravan- 2.4L 4 Cylinder45,600
still working on a solution.
2007 Dodge Caravan- 2.4L 4 Cylinder82,280
The timing belt broke. The mechanic went ahead and replaced the crankshaft seal also while he was working on it. The seal started leaking profusely the same day. A second seal has not solved the problem. He checked the play on the shaft and it was way out.
2006 Dodge Caravan- 2.4L 4 Cylinder60,000
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
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