Approved Use of Weld Through Primers This bulletin documents the FCA US LLC position regarding the use of weld through primer when using Squeeze Type Resistance Spot Welding (STRSW) and Gas Metal Arc Welding (GMAW) processes when welding steel body panels and structural components.
full bulletin at NHTSA ↗2012 Dodge Grand Caravan body problems
moderate Owners of the 2012 Dodge Grand Caravan have filed 14 NHTSA complaints about the body, typically surfacing around 110,000 miles at roughly $1,500 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See body across all vehicles →
Failure mileage
Complaints
14
Recalls
0
Avg fix
$1,500
| Model year | body complaints |
|---|---|
| 2009 Grand Caravan | 6 |
| 2010 Grand Caravan | 15 |
| 2011 Grand Caravan | 11 |
| 2012 Grand Caravan (this page) | 14 |
| 2013 Grand Caravan | 17 |
| 2014 Grand Caravan | 13 |
| 2015 Grand Caravan | 18 |
| 2016 Grand Caravan | 177 |
When does it fail?
Of the 14 body complaints filed for the 2012 Dodge Grand Caravan, here's the actual mileage breakdown — failures cluster heaviest at 150,000+ mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
No new NHTSA body complaint has been filed on this vehicle in over 9 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering body on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
Approved Use of Weld Through Primers This bulletin documents the FCA US LLC position regarding the use of weld through primer when using Squeeze Type Resistance Spot Welding (STRSW) and Gas Metal Arc Welding (GMAW) processes when welding steel body panels and structural components.
full bulletin at NHTSA ↗Approved Use of Weld Through Primers This bulletin documents the FCA US LLC position regarding the use of weld through primer when using Squeeze Type Resistance Spot Welding (STRSW) and Gas Metal Arc Welding (GMAW) processes when welding steel body panels and structural components.
full bulletin at NHTSA ↗Disinfectant Solution Recommended for COVID-19
full bulletin at NHTSA ↗Repair Parts Used For Structural Repairs This bulletin involves discussing FCA US LLC position with regard to structural repair parts usage.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners report multiple distinct body and hardware failures on the 2012 Grand Caravan. Rear sliding doors (both driver-side and passenger-side) frequently lock and refuse to open, either electrically or manually, trapping occupants and creating emergency egress hazards. The rear liftgate independently pops open during acceleration or while stationary, with no warning lights. Front doors show misalignment and abnormal gaps that allow water seepage, appearing ajar even when closed—dealer realignment attempts sometimes worsen the condition.
Structural issues include premature, aggressive rust development on frames, particularly in modified conversion vehicles, with steel deteriorating rapidly enough to raise safety concerns. One 2012 conversion reported severe battery drain (dead within 16 hours despite full charge) and bizarre electrical malfunctions with unknown cause despite over 100 hours of troubleshooting by engineers.
Ride quality issues are widespread: harsh, shaky suspension that bounces excessively; rattling doors and interior trim; air and dust infiltration around seals; and whistling from the motor area. These problems manifest within the first 10,000 miles and persist despite dealer repair attempts, suggesting design or assembly defects rather than maintenance issues.
Same Dodge Grand Caravan body reports on nearby years: 2010 · 2011 · 2013 · 2014 · 2015
Failure modes owners describe
Rear sliding door locking mechanism failure
Driver-side or both rear passenger sliding doors become stuck in locked position and cannot be opened electrically or manually. Door may make clicking/jerking sounds when unlock buttons or fob are used, but does not open.
When: Various mileages from as early as new (935 miles) to 14,000 miles; one report ongoing from 2016
Symptoms owners cite: Door locked but will not open despite unlock attempts via fob and manual handle; Door makes clicking or jerking sound when unlock attempted but does not open; Manual override does not work; Single child unable to exit in emergency; potential entrapment risk
Repairs/costs cited: One report mentions computerized system update at dealer (3 visits); mechanism failure suggests latch or locking solenoid issue
Recalls/TSBs owners mention: System software update performed at authorized dealer
Rear liftgate spontaneous opening
Rear liftgate independently unlatches and pops open while vehicle is in motion or parked. Occurs particularly during acceleration from stop after left turn or while stationary.
When: Starting around 14,000 miles in one case; another case ongoing from October 2016
Symptoms owners cite: Liftgate pops open without being actuated; Occurs during acceleration from complete stop (20–30 mph); No door-ajar warning lights illuminate; Happens repeatedly; owner resorts to tying door shut
Repairs/costs cited: Suspected latch connection issue; owner queried whether repair needed or if simple latch adjustment sufficient
Recalls/TSBs owners mention: Computerized system updated at authorized dealer (three visits)
Front door misalignment and gap issues
Driver and passenger front doors misaligned, creating abnormally large gaps that make doors appear ajar. Water seeps around door frame perimeter, though does not enter vehicle interior.
When: Present early in vehicle ownership (935 miles at first report; 934–1457 miles at multiple dealer visits)
Symptoms owners cite: Visible gaps between door and frame appear excessively large; Doors look ajar even when closed; Water enters around frame perimeter; Gap remains larger than comparable vehicles on lot after adjustment attempts
Repairs/costs cited: Dealer attempted strike plate adjustment (7/5/2012) but caused bottom of doors to move excessively inward; scheduled full four-door realignment; multiple return visits for re-adjustment (934, 1285, 1457 miles)
Recalls/TSBs owners mention: Dealer identified as manufacturing defect; dealer assured vehicle not damaged in transport
Excessive rust on vehicle frame and body
Severe rust develops rapidly on frame and body structure, described as abnormally fast onset. Appears to include galvanic corrosion issues. Vehicle is VMI Northstar conversion (modified by third-party handicapped-accessible specialist), which involves frame replacement.
When: Within 16 hours of battery charge in one case; abnormal onset characterized as unusual by VMI; unspecified timeline in other context
Symptoms owners cite: Frame rust described as severe and progressing rapidly; Steel separates 'like cheese slices' per owner description; Rust accumulates despite rust treatment applied post-settlement; Frame degradation raises structural safety concerns for wheelchair-dependent occupant
Repairs/costs cited: Rust treatment applied; collision shops decline repair citing liability concerns; estimated cost of $11,000 mentioned for electrical malfunctions and rust issues
Recalls/TSBs owners mention: VMI initially acknowledged rust 'very unusual' but released liability post-settlement; advised against vehicle use due to safety concerns
Battery drain and electrical malfunctions
Battery drains abnormally, discharging fully within 16 hours despite full charge. Multiple batteries fail. Associated with bizarre electrical malfunctions. Root cause not identified despite extensive troubleshooting.
When: Early in ownership; three batteries affected
Symptoms owners cite: Battery dead 16 hours after full charge; Multiple batteries progressively fail; Bizarre electrical malfunctions occur; Multiple electrical issues without clear diagnostic path
Repairs/costs cited: Battery disconnect installed to stop abnormally high drainage; over 100 hours of engineering work by VMI and local dealer unable to isolate short circuit causing drain; suspected galvanic corrosion related to rust
Recalls/TSBs owners mention: Attributed to unknown short circuit; no successful resolution despite extensive dealer and manufacturer effort
Harsh ride quality and structural rattling
Van rides harshly and shakes excessively, with prominent rattling throughout body and interior. Air and dust infiltrate around door seals. Whistling noise from motor/hood area. Behavior inconsistent with demo test-drive vehicles.
When: Present from first day of ownership (purchased May 22, 2012, with less than 10,000 miles at first dealer visit)
Symptoms owners cite: Van shakes and bounces as if lacking shock absorbers; Rattling from doors and interior components; Air and dust enter around all door seals; Whistling sound from motor or front underhood area; Middle seats do not fold properly into stow-away configuration; Rides like 'freight truck,' harsh compared to demo units
Repairs/costs cited: Dealer visited twice; claimed repair performed at first visit but issue persisted; dealer attributed apparent poor ride to normal break-in (2,000–3,000 miles or first oil change), which did not occur
Recalls/TSBs owners mention: Dealer claimed repair completed but ineffective
Synthesized from 14 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
I have continuous problems out of this vehicle, sensors, and the vehicle down shifts regular on a strait way, and up slight hills, loses speed ,extreme loss of fuel mileage
Had body trouble with your 2012 Dodge Grand Caravan?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the body problem on the 2012 Dodge Grand Caravan?
It's a documented issue but not catastrophic. 14 complaints have been filed. Repairs average $1,500 and most owners catch it before it causes a breakdown.
At what mileage does the body typically fail?
Across the 9 complaints that reported odometer mileage, most body failures cluster between 37,000 and 142,000 miles, with the median around 110,000. A quarter of owners report trouble before 37,000; a quarter make it past 142,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,500 for body repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to body?
No active recalls currently cover body issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2012/Dodge/Grand Caravan.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.