Car Problem Reports

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

Dodge Caravan Problem
29 Reports
Me Too

Model Years Affected: 2004, 2005, 2006, 2007

Engines Affected: 2.4L 4 Cylinder, 3.3L V6

Average Mileage: 57,865 mi (10,500 mi - 91,000 mi)


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.

  • Visitor, , 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.

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  • Visitor, , 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

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  • Visitor, , 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 ......

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  • Visitor, , 3.3L V6, 65,000 mi

    Replaced engine

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  • Visitor, , 2.4L 4 Cylinder, 38,000 mi

    front seal poped out

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  • Visitor, , 2.4L 4 Cylinder, 45,545 mi

    front crankshaft seal poped out

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  • Visitor, , 2.4L 4 Cylinder, 49,283 mi

    Seal Popped out. End play = .078

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  • Visitor, , 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+.

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  • Visitor, , 2.4L 4 Cylinder, 91,000 mi

    not fixed---caravan not running!!!

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  • Visitor, , 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

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