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2010 5th Gen Dodge Grand Caravan Body Repair

184 views 16 replies 5 participants last post by  tinkering  
#1 ·
We have a 2010 Dodge Grand Caravan that needs the usual body repair ahead of the front and rear wheel wells.
What years/generations are the body panels interchangeable?
If I use a wreckers I want to locate the newest parts available for longevity reasons.

I would also like to know if anybody has come up with inner fender modifications, and pre installation treatments that will protect our new fenders from rusting out again right away?

Are all Chrysler Minivan and Dodge Caravan bodies interchangeable in the same years?
Thanks
 
#2 ·
I can't speak precisely to the interchangeability, but if you plan to go the wrecking yard route, most yards will tell you what years are cross-compatible. If buying new/aftermarket, it seems like the suppliers usually are pretty accurate on interchangeability.

Sounds like you may reside in the rust belt. As a former resident of the rust belt, historically I did several things to try to stave-off the tin worm, but ultimately it will likely win the war. You may just prolong the inevitable to some extent.

Prevention is a big help. While my vehicles were in use in winter, I regularly/frequently/obsessively washed the road salt off as soon as I could and that didn't mean waiting until spring. Road salt (mostly sodium chloride with some other additives) is water soluble and the less time it spends on vehicle components, the better. The part most people neglect is washing the vehicle undersides, undercarriage, suspension/brake components, radiator/condenser, etc. - not just the visible cosmetic surfaces. Any place salt might have seeped in, I flooded with the garden hose to try flush it out. It was a war of dilution, the more water, the better. Drive through car washes are basically worthless. Along with the above, it is very important to remove leaves, twigs, road debris in any places/crevices where it can accumulate on the car (e.g., windshield plenums, inside wheel wells, under fender lips, dead spots, you get the idea). Such stuff can act like a sponge and can speed the onset of corrosion by constantly/prolonging the areas stays salty/wet.

Moving on to replacement body panels. Whenever I sourced a good panel like a fender, first thing was to wash the inside areas/cracks/crevices thoroughly to help adhesion of the protectant(s) I would be applying. If there was ANY pre-existing surface rust, I would treat the spots with a latex-based rust conversion product (there are multiples out there) usually looks milky white in the stock container, brushes on and turns the rust to black and then dries - you've probably seen/used it. I have, depending upon the part in question and how much time I had to mess around with the repair/replacement, I would use either a decent rubberized, spray-on undercoating sourced from the auto parts store, or, Rust-o-leum oil-based, brush on paint, usually bought in quart cans. Whatever product I used, it was always applied in multiple light coats allowing for complete drying after each coat. I always made certain to get the product into every crack and crevice. I usually applied to cover as much of the inside areas of the fender or other sheetmetal part such that I thought it would be sufficient. That usually provided decent protection for the INSIDE of the part once installed as I would likely not see that area again unless I needed to get in there for some reason. Note: trying to use rust preventatives like the above while the part is installed won't ever be as good as doing it on the part when it is sitting on the workbench off the car as you won't have comparable access.

On the outside of the part, the biggest thing was to try to keep up with any chips or scratches in the paint which would allow for salt to get to the bare metal under the paint. Once salt got in and began the corrosion process, it usually turned into a bigger job thereafter. If corrosion started, I'd treat the spot with the aforementioned latex-based rust converter, allow to dry thoroughly and then use touch-up paint if needed.

Sorry, probably longer than you wanted, but I hope it helps.
 
#4 ·
Weld in pieces and rocker panel covers are available from many autobody suppliers.

There's a Forum on here dealing with corrosion.

Up here we use "stay wet"/"always creeping" corrosion protection products to prevent/arrest corrosion and protect electrical. Krown, Fluid Film, Rust Check, Woolwax, Corrosion Free, Rust Cure come to mind. There are other "stay wet" products that can be professionally applied. Different wands and sprays are used. Mist for inside spaces and direct for underbody.

The prime areas for corrosion are "inside of anything" where's there's condensation/moisture but very little ventilation - rocker panels, door panels, quarter panels, etc. Make sure all drain holes are open.

The underbody is well ventilated and not the prime area for corrosion. A drive in the rain and not sitting around wet, over grass or in a garage, helps that. It get corrosion protected as well to get into the nicks and crannies. Otherwise, the underbody of a vehicle stays pretty good on its own.

In the engine bay consider a light spray on electrical items, hoses, hose clamps, battery terminals, hood, inside hood areas, latches, mostly anything metal or requiring lubrication. Fluid Film, for example, is a great lubricant, can use it on your work boots to preserve the boots and walk faster.

To learn more:
 
#5 ·
Excellent!
The rocker and fender protection panels sound great. We'll look into that.
It's really my friends van but I will be the main brain on the repair/protection process trade. All of this info is invaluable.
I remember researching the science of all the different kinds of rust protectors and inhibitors out there at the time. I lose it, so thanks for the links.
Not sure which route he will want to go but I will keep posting the developing story and pictures.
Thanks
 
#6 ·
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#7 ·
FYI, the rear fenders rust out in part because the plastic wheel well liner/guard traps sand behind it. This, in turn, holds onto moisture like a sponge, and it is wedged between that plastic and the metal. The sand likely also has salts that speed the corrosion. Clean it out, let it dry, and spray some kind of rubberized coating. Then, top it off with some lanolin (e.g. fluid film) before putting the plastic back in.
 
#10 ·
owns 2006 DODGE GRAND CARAVAN SXE
#11 ·
#12 ·
Thank you.
oh, you have a 2010. 08, 09, & 10s were more prone to rust conditions. I do understand your request now.

Some people will do a sloppy repair to get by while others have to be a bit more into the details since it does family outings and the family will not be seen in a clunker.

If you need knowledge on more details for patch, grind, sand, paint, prep, start your own posted thread in that section and many of us can toss ideas out for you to consider. (y)
 
owns 2006 DODGE GRAND CARAVAN SXE
#17 ·
oh, you have a 2010. 08, 09, & 10s were more prone to rust conditions. I do understand your request now.

Some people will do a sloppy repair to get by while others have to be a bit more into the details since it does family outings and the family will not be seen in a clunker.

If you need knowledge on more details for patch, grind, sand, paint, prep, start your own posted thread in that section and many of us can toss ideas out for you to consider. (y)
Will do.
Fantastic!