96 caravan w/frustrating elec. problem

Bought my wife this used caravan 2 years ago and we love it. over the last 6 months, she started to notice a bit of a rough idle sometimes, especially with ac on. Also on two occasions at freeway speed, the engine just quit. then when stopped, it restarted back up no problem. Then last week we were driving in the rain at night on the freeway, and the tranny shifted down to limp mode at 70 mph (a bit scary with the kids in the car... at the same time, while limping home, the windshield wipers would not turn off, and the dash was doing crazy things. Had it into a very reputable mechanic who had it for 2 weeks, and couldnt figure anything out.
Currently, It still has the hesitation which will occasionally cause a misfire, but has not recently done the tranny thing since last long trip.
I am fairly mechanical, and have done most of the obvious (tranny fluid, filter, fuel filter, plugs, wires...) but I wish I had an idea of if this is more then one problem, and where I should start. I'm not blessed with the finances to have a dodgle dealer "go to town" replacing things. Any good advice would be very much appreciated. Thanks in advance.
Melsailsnorth

Bought my wife this used caravan 2 years ago and we love it. over the last 6 months, she started to notice a bit of a rough idle sometimes, especially with ac on. Also on two occasions at freeway speed, the engine just quit. then when stopped, it restarted back up no problem. Then last week we were driving in the rain at night on the freeway, and the tranny shifted down to limp mode at 70 mph (a bit scary with the kids in the car... at the same time, while limping home, the windshield wipers would not turn off, and the dash was doing crazy things. Had it into a very reputable mechanic who had it for 2 weeks, and couldnt figure anything out.
Currently, It still has the hesitation which will occasionally cause a misfire, but has not recently done the tranny thing since last long trip.
I am fairly mechanical, and have done most of the obvious (tranny fluid, filter, fuel filter, plugs, wires...) but I wish I had an idea of if this is more then one problem, and where I should start. I'm not blessed with the finances to have a dodgle dealer "go to town" replacing things. Any good advice would be very much appreciated. Thanks in advance.
Melsailsnorth

Maybe someone else can explain more but what I have heard...there are some wiring corrosion problems in or under the PDC-Power Distribution Center. Maybe that's the area that needs to be looked at?

The "body control module" (computer) controls most of the vans lighting and other electrical inputs including wipers. Its mounted somewhere behind the dash on the inside of the van. With your electrical problems associated with rain I would assume the problem isn't the computer itself but an input to the computer getting wet and intermittently shorting. I would check the wire harnesses/connectors in the engine compartment and under the dash and look for breaks in the protective wrap. Under the dash look for any evidense of a water leak. Make sure the ventilation system is getting rid of built up moisture. Window condensation could collect through a bad dash seal.
As for the tranny problem - short of taking it to a tranny shop, get the fluid flushed not just drained. You probably know but, when you drain the fluid you only get 1/3 of the fluid out at best. It's a given that if there is any other fluid besides ATF-3 in the tranny, problems could erupt. Many shops will put Dexron III in it because the manual says its OK. IT"S NOT OK. Read the many threads here on this subject and go to allpar.com. You bought the car used so anything could be in it.
As for the engine quiting - thats an ugly one! Years ago I had a Dodge with the same problem. Turned out to be a bad thermistor in the "Spark control Computer". Changed the computer and all was well. Not sure what performs the same function on the van.
I've also got a 96GC. It's had it's problems but, I would hate to get rid of it. We've had it all over the southwest and never had a breakdown. Most expensive problem it's had was a $700 tranny removal/reinstall due to a leaking forward pump seal. Hope yours gets better soon. Cheers!

I agree with RIP, I have gotten used to my '96 GC and would hate to give it up. It's worth the effort to iron out these problems, assuming it doesn't get "too" costly.

melsailsnorth - If you haven't already read blade007's thread dated 18 Jan. It sounds similar. thunder1 gives you a good start point.

Just wanted to give a BIG thanks to the replies thus far to my problems with my 96 GC. Currently in the process of doing the suggestions posted, but just wanted to give thanks to you for taking the time to consider such a strange set of probs, and reply with suggestions. Any further ideas will be greatly welcomed. This was our familys first minivan, and despite this frustrating problem, a just cant tell you how much we love this vehicle!!! It is definetly worth the effort to figure out whats going wrong! The comfort and versatility of this van is great, and comparing it to the 20 or so other cars/trucks I have owned, it is just a fun, pleasurable car to drive... I know many that will disagree, sighting the tranny probs, and electric probs, but I'm sold on it despite this. Thanks again, and Hope to find some answers!!!

I had something similar to your hesitation on my 96 voyager. When it did it, I played with wires under the hood on top of the engine and suddenly the engine started to go smooth. My problem was bad contact in the big plug or connector which had to be pushed together to have good contact. Since then I had no problem. However, this car is a lemon. I changed everything changeable - fuel pump, 2x water pump, computer, rebuild transmission, spring clock, 2 speed sensors controling transmission shifting, my rear wiper pump got crazy and to stop it, it had to be disconnected. My A/C does not work, the clutch on compressor is squeeky and noisy and pressure sensor on compressor burned the solid state relay controling cooling fans. I by passed the relay by manual switch inside, to allow me to cool the engine manualy when needed. Lately, I seem to have some grounding problems - my front wipers stopped working and my hi and low head lights are dead. Tension mechanism on the main belt is jamed and will have to be changed. Both front drive axels were replaced. The top portion of the body where front drivers' side shock is attached under the hood is completely rusted and will require big welding job to renew the body strenth in this area. I have 150,000 miles on it. When I bought it, it had 50,000 miles and I was told, that the transmission was already changed. Engine runs good and it is very confortable car to drive, but I will carefuly consider wheather to go back to Chrysler...

I have exactly the same problem with my 96, I'm gonna work on the van during this weekend I'll let you all know if I figure the thing out.

Carlos.-

Ok, I just did a computer scan and so far I can say that there is nothing wrong with the transmission itself. I only got a faulty transmision relay code but as far as a know a relay doesn't come back from death so i think it has to be the BCM or a bad connection some where.
Some how when I turn the wipers on, the BCM cause the Powertrain Control Module to shoot down for a second and it kills the transmission until is reset. I have also another code telling me that the battery has been disconected during the last 50 key cicles, of course is not true, that code comes when the PCM is without power.

Ok my 96 van is fixed. The problen was at the ground what is under the hood on the firewall at the pasenger side, Desconect the positive on the battery, Loose the nut up, clean everything with some dw-40 and put it back tie an nice. it should work.

Carlos.-