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

Problem Description and Possible Solution

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.

Problem Data
RepairPal Verified
Average mileage: 71,860 (10,500–167,000)
Engines affected: 2.4L 4 Cylinder, 3.3L V6
5 model years affected: 2000, 2004, 2005, 2006, more2007
44 people reported this problem
Viewing 1 - 20 of 35 comments
Front oil seal gets pushed out and oil spills out. Can it be glued on or sodered on to solve this problem?
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.
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 seal poped out
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
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
Massive oil leaking from seal, found excessive crank end play, crank damaged and needed to replace short block.
Seal Popped out. End play = .078
Replaced engine
front crankshaft seal poped out
Oil leaks out. Replaced seal 3 times
Hello, I'm hoping this info might help a few with this problem. Crankshaft end play also known as "crank walk" on 2006 dodge stratus sxt 2.4.
I bought this car used and knowing it had severe oil leak from front seal and thinking seal just needed replaced. I replaced myself (I work on a lot of vehicles myself) and after 2 minutes run time the seal came out and was leaking again. I did notice crank walk before hand but did not think it significant enough to cause seal to pop out, I was wrong. Because of main bearing thrust washer wear (mine is an automatic but happens more on manual vehicles) the oil journals are partially blocked due to shift in crankshaft causing oil back pressure to build and pop out seal. The only fix is to replace main bearing thrust washer. The job is not too difficult if you are familiar with basic hand tools and some knowledge. This is a very common problem on 2005 and 2006 dodge 2.4 due to miscalculated tolerances and very poor manufacturing of this part. The pieces are welded together and not one solid piece causing wear on the joints and eventually failure. The revised parts are one whole piece. The engines were designed in the US but made and assembled in Mexico where the design flaw originated by a miscalculation of how the part should be made. I can give full detailed instructions on how to perform your own repairs if you decide to tackle the job yourself. Get your main bearing thrust washer from the Dodge dealership for $30 because its the revised one piece part. For further help and step by instructions you can email me direct at paul perlongo at yahoo dot com (all one word) free of charge. If you have a 2006 2.4 and decide to replace engine you can ONLY use an engine from 2006 dodge stratus 4 door or 2006 Chrysler Sebring coupe. These are the ONLY compatible models. Other years will not fit. Hope this helps.
I have this same probllem. For me it's the cam seals lAND crank seals. leaks oil all over the timing belt too
It is leaking but not fixed yet.
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.
Oil drained everywhere
oil pouring out crankshaft seal.no past oil leaking.shop said shaft moving in and out to much ,metal rubbing alumnum .rebuild or new engin.
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.
front crankshaft seal oil pouring out.no past problems of oil leak.the shop said new engin or rebuilt .shaft is moving more then it should ,metal rubbing on alumnum.
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+.