Workshop Manuals Factory service & repair Chrysler

Chrysler common faults and how to fix them

Faults that are well known on Chrysler models we hold manuals for: what the owner notices, what causes it, and the pages in our manuals that cover the repair.

Chrysler P0456: EVAP small leak code on the Town & Country and Voyager (2001–2003)

Symptoms

The check engine light comes on with P0456, meaning the evaporative emissions system has found a very small (0.020 inch) leak. The van drives normally and the code returns after being cleared, even when the fuel cap and EVAP system are in good order.

Cause

Chrysler bulletin 18-028-03 covers the 2001–2003 Town & Country, Caravan and Voyager minivans: 2001–2002 models with the 2.4, 3.3 and 3.8 engines, and 2003 models with the 3.3 and 3.8. On vans with a properly working EVAP system, the engine computer could still detect a leak that wasn't there.

Fix

Check the fuel cap and its seal, then smoke-test the EVAP system to rule out a real leak. If the system is sound, follow the Chrysler P0456 bulletin's diagnosis. It replaces the powertrain control module where the bulletin's checks show it is needed. Clear the code and let the leak monitor run again to confirm the repair.

Repair instructions on this site

Sources: Chrysler technical service bulletin 18-028-03.

Chrysler transmission problems: delayed engagement and harsh 4–3 downshift (2002–2004)

Symptoms

A delay before the gearbox engages drive or reverse after starting, sometimes with fault codes, or a harsh downshift from fourth to third as the car slows. It affects the four-speed front-wheel-drive automatics in the 300M, Concorde, Sebring and Town & Country.

Cause

Chrysler bulletin 21-004-05 traces delayed engagement on 2002–2004 models, including the 300M, Concorde, Sebring and Town & Country, to the transmission front pump. Bulletin 21-006-03A traces the harsh 4–3 downshift on 2003–2004 models to the transmission control software.

Fix

Check the fluid level and condition first, using only ATF+4. For delayed engagement, the Chrysler transmission bulletin replaces the front pump assembly and checks that the transmission control module has the latest software. For the harsh downshift, the 300M transmission bulletin reprograms the control module. After either repair, run the quick-learn procedure so the gearbox relearns its clutch volumes.

Repair instructions on this site

Sources: Chrysler technical service bulletins 21-004-05 and 21-006-03A.

Chrysler TIPM recall: Sebring transmission shift software (2007–2008)

Symptoms

The automatic gearbox may not shift properly under certain conditions. It affects 2007–2008 Sebring models with the 2.7 or 3.5 V6 and an automatic gearbox.

Cause

Chrysler emissions recall G23 covers about 26,600 vehicles, including 2007–2008 Sebring and Dodge Avenger models with the 2.7 or 3.5 engine built up to 20 April 2007. Their Totally Integrated Power Module (TIPM), the main fuse and relay box that also handles some control functions, was programmed with software that may stop the transmission shifting properly. That can also raise exhaust emissions above federal and California limits.

Fix

Check with a Chrysler or Dodge dealer that recall G23 has been done; the remedy reprograms the TIPM with corrected software, free of charge. Keep the battery on a charger during reprogramming, as the recall instructions advise. The Chrysler TIPM recall notice gives the build dates and engines covered. If shifting problems continue after the update, diagnose the gearbox in the usual way.

Repair instructions on this site

Sources: Chrysler emissions recall G23 (June 2007).