This is an old revision of the document!
[note from Secessus – this page is updated as I gain verifiable information. Problems listed (or not listed) below do not mean one is better than the other. I may have researched some more than others so far. Truly, I don't care what van you buy and live in. It's your home, not mine. ]
All vans have issues
Everybody thinks their pet van is the best, and that all others will drain your wallet and/or leave you to die a gruesome death on the side of the road. As has been observed in a different context:
That is the way of us chili men. Each of us knows that his chili is light years beyond other chili in quality and singularity; each of us knows that all other chili is such vile slop that a coyote would turn his back on it.
1)
In actuality, all vans have issues. The challenge is to find a van that meets your needs, not to find some mythically perfect unicorn that was designed directly by god, never breaks, never needs maintenance and runs forever on one tank of gas and one crankcase of oil. It's like dating: find a van whose weirdnesses don't bother you, and that you can personally live with.
on the likelihood of problems
Only a small percentage of failures occur on any particular vehicles; it's not like “this is guaranteed to happen to you!” It's more a list of things to look for, to be aware of. Forums and complaint sites list tons of problems because people with problems are more likely to post. It is rare to see a post saying “drove my van for a year and nothing happened!”. Beware of people who claim “the [fill in the blank] forum is full of unhappy owners!!!” without mentioning unhappy owners of their vans on their forums. Forum links are included below for further research.
Timely maintenance is likely to prevent or lessen the impact of the issues listed below. If your van has recalls or TSBs, try to have it fixed under warranty while it's still free.
You may also want to think about Total Cost of Ownership or average annual repair costs.
Chevy Astro
The Astro/Safari have a cult following due to their mid-size and available AWD.
Learn about this van on the Astro/Safari forum
steering knuckles that cut ball joint boots
2)
door handles break off
1998-1999 particularly hard hit by transmission valve body failures
3) “Less common problems are the failures of the transmission's fluid pressure (TFP) switch, failure of the transmission's “reaction sun shell” and failure of the transfer case shift motor.”
power locks fail: “grease them once a year with lithium spray in grease. The rear door lock may be fixed by drilling a hole through the piece of zinc to repair the piece that broke off.”
4)
power windows fail - switch failure?
ABS controller failure
rough idle or misfires: “problems with the spark plugs, ignition systems and poor vacuum seals have been implicated in some cases”
5) “Get a good [distributor] cap with brass contacts.”
idler/pitman arm failure
transmission output seal failures
intake manifold gasket leaking oil or coolant
1984-early 1985 models may have oil pressure idiot light incorrectly wired to CHOKE indicator
fuel pump failure – earlier than normal fuel filter changes may help alleviate
P1870 This can be caused by wear of the bore for the TCC isolator and regulator valves in the valve body.
alternator failures
Chevy Express / Savanna
Transmissions are regarded as generally good, with lifespans like 120,000-180,000 miles on the 4-spd auto 4L80E and 130,000-200,000 miles for the 6-spd 6L90.6)
Learn more about these vehicles on the Express/Savanna subforum.
Chrysler Pacifica
the Pacifica has historically been slightly larger than it had to be in order to “package protect” (plan) for AWD which only came out in 2020.
10)
2004-2008 rust, especially in the engine cradle area
11)
TIPM issues, as with the other FCA minivans since 2008.
approx 15k 2007 (?) models had faulty torque converters, causing shuddering while driving. Sometimes described as “like driving over rumble strips”.
hard shifting
some 2017 have engine vibration due to incorrectly-drilled balance shaft
12)
2017 hybrids may have defective inverter (recalled)
Dodge B-series
Made from 1971 - 2003, and hardly changed in the interim. This can be a good thing, as known issues are stable over time. It can be a bad thing in that deficiencies are not addressed over time.
Dodge Caravan / Town & Country
Caravans may be available cheaper than T&C as they generally had fewer options (and less stuff to break).
Learn more about these vehicle on the Chrysler minivan forum.
Ford E-Series
early ignition coils/packs failure
ball joint failure
leaking cylinder head gasket
1997-2004 Ford F-350 may be affected by the 2-valve Triton engine spark plug ejection issue
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3-val 5.4 Tritons with Variable Valve Timing can have timing chain, tensioner, or cam phaser issues – listen for noises at startup.
15)
2004-2007 3-valve 4.6L, 5.4L and 6.8L can experience spark plug breakage or head damage during removal.
16)
5.4 Tritons can experience oil pan gasket leaks. The part costs ~$20 but replacement runs about $1000, due to requirement to lift the engine.
2005 – 2006 E-150 w/4R75E
17) Transmission can experience slipping. Replace forward clutch drum and update ECU with program 06B06.
sticking solenoid regulator on 4R100
18) Transmission (P0715, P0716 & P0717)
The International VT365 (rebadged as Ford 6.0 L PowerStroke) found in 2003-2010 model year Ford E-Series vans/chassis “has the reputation as being the worst diesel engine ever put into a pickup truck”.
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Ford Transit
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transmission filter cannot be accessed for normal service; requires removal of front subframe which may be difficult due to seized bolts. Normal service is done by a fluid exchange machine at the Ford dealer.
Ecoboost carbon fouling on intake valves
Ecoboost shuddering from plug fouling
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speed sensor failure causes limp mode
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cabin leak near passenger footwell
transmission solenoid failure (SSM 45065) requires removal of transmission.
heater core failure - TSB 18-2172. Flushing with
Prestone Cor-Guard and refilling (as in the TSB) may be good preventative maintenance.
TSBs
2015 Transit – Interior High Intensity LED Cargo Lamps May Emit A Low Glow When They Should Be Off – Built On Or Before 4/22/2015
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Ford Transit Connect
Ford Windstar
Honda Odysssey