DodgeCaravan20053.8L V6/dodge/caravan/2005/3-8l-v6/
RS platform

2005 Dodge Caravan — 3.8L V6

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2005 Caravan 3.8L V6.

Body VANEngine 3.8L V6Transmission Automatic 4-spd

Utilizing the RS platform, the 2005 Dodge Caravan is a VAN powered by a 3.8L V6 engine and Automatic 4-spd transmission with EPA mpg of 16/23/18 mpg. Mechanical requirements include 5W-20 API oil with a capacity of 5 qt w/ filter, and ownership data lists 537 total owner complaints alongside 9 recalls. While situated between the 1996 high of 1647 and the 2017 low of 1 within the model complaint history spanning 1990-2017, the data directs researchers to the top complaint area of Latches/Locks/Linkages.

Model year200720062005200320022001200019991998

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity5 qt w/ filterOEM · verified
Engine oil type5W-20 APIOEM · verified
Lug nut torque85-115 ft-lbsOEM · verified
EPA fuel economy16/23/18 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 34 · 500 CCA battery, OE oil filter 05281090AB. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 34 · 500 CCAOEM · verified
Tire sizeP215-70R15OEM · verified
Wheel / rim6.5 inOEM · verified

OE service part numbers OEM · verified

Engine oil filter05281090AB
Engine air filter04861480AA
Spark plugSP303917AC
Battery04727159AD alt 04686158AD
Front wiper blades05096134AC
Serpentine belt04593684AA
Thermostat68210217AA alt 04781674AA
Cabin air filter82205905

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length189 in
Overall width78.7 in
Overall height68.9 in
Wheelbase113.4 in
Curb weight3862 lb
Track (front / rear)63 / 64.2 in
Weight distribution (front / rear)57/43

Ratings & economy EPA / vPIC

EPA city / highway / combined16 / 23 / 18 mpg
DrivetrainFront-Wheel Drive
Recommended fuelRegular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 5 qt w/ filter of 5W-20 API engine oil, 80W-90 · GL-5 in the differential, DOT 3 brake fluid. Torque lug nuts to 85-115 ft-lbs, the oil drain plug to 20.0 ft-lbs. The firing order is 1-2-3-4-5-6. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Automatic Transmission FluidATF+4
Automatic Transmission Fluid Capacity4
Brake FluidDOT 3
Differential Gear Oil80W-90 · GL-5
Differential Gear Oil Capacity1.5 Pints
Differential Gear Oil80W-90 · GL-5
Differential Gear Oil Capacity1.5 Pints
Engine CoolantHOAT · MS9769

Engine torques

Crankshaft Pulley and/or Damper Bolts40 ft-lbs
Engine Flywheel Bolts65 ft-lbs
Intake Manifold to Engine BoltsUpper: 8.8 ft-lbs; Lower: 16.6 ft-lbs
Exhaust Manifold to Cylinder Head Bolts16.6 ft-lbs
Engine Oil Pan Drain Plug20.0 ft-lbs
Oil Pump to Cylinder BLock Bolts/Studs21 ft-lbs

Chassis torques

Lug Nuts85-115 ft-lbs
Front Wheel Hub118 ft-lbs
Rear Wheel Hub180 ft-lbs

Ignition

Cylinder Firing Order1-2-3-4-5-6
Ignition Coil Secondary Resistance8500
Spark Plug Gap0.048-0.053 in
Spark Plug Torque13.0 ft-lbs

Battery & A/C

RefrigerantR134a
Oil GroupPAG
Oil TypeND 8 oil
Optional BCI Group Number34
Optional BCI Cranking Performance600 cca
Standard BCI Group Number34
Standard BCI Cranking Performance500 cca

Service checks

Pressure Test15 psi
Radiator Cap Pressure Relief14-18 psi
Thermostat Opening Temperature192-198 °F
Regulated Fuel System Pressure (With Vacuum)58.0 + or - 5.0 psi
Injector Primary Resistance12
Injector Primary Resistance13-16 @ 68 degreesF ohms
Engine Compression170
Engine Oil Pressure25-80 psi

Brakes

Brake ApplicationWITH TEVES / WITH TRW
Torque Caliper to Bracket26 ft-lbs
Torque to Knuckle125 ft-lbs
Brake ApplicationWITH TEVES / WITH TRW
Torque Caliper to Bracket26 ft-lbs
Torque to Knuckle125 ft-lbs
Minimum Pad ThicknessFront: 0.312; Rear: 0.281 Specifications
Brake ApplicationWITH TEVES / WITH TRW

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages
15 ft. lbs., Step 2: 21 ft. lbs., Step 3: 905 ft. lbs
Cylinder Head — tightening sequence 4 stages

Prep Use new bolts. Lubricate bolts with clean engine oil. · M8 Bolts:

125.0 ft. lbs.; M11 Bolts:25 ft. lbs
145.0 ft. lbs.45 ft. lbs
265.0 ft. lbs.65 ft. lbs
365.0 ft. lbs.65 ft. lbs
490 degrees Do not use a torque wrench for this step.90 degrees
Main Bearings — tightening sequence 1 stages
130 ft. lbs., Step 2: 9030 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 6,000 mi; coolant every 6,000 mi. The big-interval services (every 6,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 6,000 miBrake Line (inspect) · Engine Air Filter Element (inspect) · Engine Coolant System (leak inspection) · Engine Coolant System Hoses (inspect) · Engine Oil (drain & refill) · Engine Oil Filter (replace)
Every 12,000 miCabin Air Filter (replace)
Every 18,000 miBrake Linings (inspect)
Every 30,000 miAxle Shaft Oil Seal (inspect) · CV Joint Boot (inspect) · Tie Rod (inspect)
Every 60,000 miPCV Valve (inspect)

Owner how-tos

Condensed service procedures for routine maintenance. Procedures that require dealer diagnostic equipment are identified and summarized only.

Common procedures

Key fob — remote (RKE) programming programming new fob buttons Dealer tool OEM · verified
Tool requiredDRBIII scan tool (dealer / locksmith)
WhyTransmitter codes are written into the receiver in the passenger door module
Anti-theft (SKIS) — module initialization after immobilizer module replacement Dealer tool OEM · verified
When neededAfter Sentry Key Immobilizer Module (SKIM) replacement
Tool requiredDRBIII scan tool
Also requiredThe vehicle's four-digit PIN code

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2005 Dodge Caravan registers 537 complaints, 9 recalls, 7 investigations, and 83 TSBs, making it a pronounced spike within its immediate cohort — more than eight times the 64 complaints logged in 2004 and roughly three times the 173 complaints recorded in 2006. The complaint volume is heavily concentrated in latches, locks, and linkages (149), followed by exterior lighting (61), electrical system (40), and air bags (37), though the underlying root cause for any of these clusters is not specified in the data. The 7 investigations tied to 2005 are a sharp jump from the single investigation recorded in each of 2003 and 2004 and represent the highest figure in the post-2000 era, while the 19 crash-related complaints and zero fire complaints offer some reassurance on severity. Across the broader federal record, 2005 sits at a peak that interrupts an otherwise encouraging downward trend: complaints had fallen from 1,647 in 1996 to a low of 64 in 2004 before spiking in 2005 and tapering to 82 by 2007. For a used-vehicle buyer, 2005 should be approached with caution rather than dismissed outright — the elevated investigation count and dominant latch-related complaints warrant a pre-purchase inspection of door mechanisms, verification that all 9 recalls have been performed, and a check for any open investigations, especially since the rapid improvement in 2006–2007 suggests the issues are concentrated rather than systemic.

9
Open recalls
NHTSA campaigns
83
Service bulletins
Manufacturer communications
7
ODI investigations
Office of Defects Investigation
537
Owner complaints
19 involved a crash · 0 a fire

Owner complaints filed with NHTSA, by component

All 537 complaints on record, top 8 components.

Latches/Locks/Linkages149
Exterior Lighting61
Electrical System40
Air Bags37
Electrical System,Latches/Locks/Linkages37
Steering20
Electrical System,Exterior Lighting18
Fuel/Propulsion System16

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 9 campaigns on record for this vehicle.

08E048000Exterior Lighting:HeadlightsReported 08/08/2008

EAGLE EYES IS RECALLING 11,534 HEADLAMP ASSEMBLIES, P/NOS. CS090-B001L AND CS090-B001R, SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR THE ABOVE LISTED PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE LOWER BEAM… Remedy: EAGLE EYES WILL NOTIFY OWNERS AND OFFER REPLACEMENT HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 30, 2008. OWNERS MAY CONTACT EAGLE EYES AT 1-800-568-1098.

07E104000Visibility:Glass, Side/RearReported 11/12/2007

CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT… Remedy: SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS…

Technical service bulletins NHTSA · verified

Showing 5 of 83 bulletins on record with NHTSA.

BulletinDateComponentSummary
90040092021-04-07Power TrainTransmission Kit with Torque Converter 1. All Promaster (VF) 3.6L/62TE equipped vehicles…
90040092021-03-31Power TrainTransmission Kit with Torque Converter 1. All Promaster (VF) 3.6L/62TE equipped vehicles…
90042752020-07-22Electrical SystemKEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC…
90042752020-07-22Electrical SystemKEY, Master If replacing the key/FOBIK on a WJ, KJ, TJ, or PT Cruiser, use the "AC" NIC…
23-015-202020-04-30EquipmentDisinfectant Solution Recommended for COVID-19

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Caravan. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2005 Caravan 3.8L V6 take?

5 qt w/ filter of 5W-20 API REFER TO OIL CAP, per the factory manual.

Does the 2005 Caravan have open recalls?

NHTSA lists 9 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the 3.8L V6 get?

EPA figures are 16 city / 23 highway / 18 combined mpg.