Why do the power windows have intermittent problems on a 2001 Dodge Caravan Sport?

Answer 1

If its only the drivers switch that has the problem, then it's probably just the switch...

if the passenger side switch also has intermittent problems, it may be the power window relay, or power supply circuit....

You should be able to find a shop manual at your local library with the right info...make copies as they are usually only in the REFERENCE section....good luck:)

AnswerI had this scenario exactly on an '01 T&C van. Very low miles, like new condition. I found the problem to be inside the motor itself. I am a technically skilled and usually don't rest until I find fixes for things, as I'm also cheap and hate buying overpriced parts. This fix wont be for everyone, but it wasn't real difficult, once I figured it out. Getting the door panel off, and getting the motor removed was far worse than the repair itself. With motor in hand, 2 screws opens it up and out comes the guts, leaving the brush holders in plain site. Built in to the circuit from the power wires to the brushes themself, is a thin flat device that looks like nothing at all, its just passing current thru so it seems. In reality, its some type of thermal or current overload protection, and when 'tripped', will 'close' again after some cooling time. Thus the intermittent operation. In MY case, would trip after almost no time of operation, and I knew it couldn't possibly be hot or overloaded. It was obviously a defective device. Of course, no internal motor parts are available, so instead of a new motor (with all window regulator cables attached) (more labor), for 'big bucks', I simply soldered a wire in place to bridge this device and its never hesitated again. I figured I had nothing to lose, and I was confident that this motor could never get overloaded enough to be a safety hazard. With the cost of everything nowdays, I don't see how people make it if they have to 'pay the price' for all these silly things that go wrong on a daily basis! Being able to repair for yourself is such a huge financial advantage!

THE BRUSHES INSIDE THE MOTOR CASE EVENTUALY TO NOT TOUCH THE MOTOR. TAKE OFF DOOR PANNEL, REMOVE BOTH PHILIPS SCREWS TO THE BLACK MOTOR CASE AND USE A SCREW DRIVER TO PRESS THE LOWER LEFT AND RIGHT BRUSHES CLOSER TO THE MOTOR. u may need to remove the motor to get the proper tension reinstall and test it out

Update:

No offense, but simply pressing in on the brushes may get the motor to spin temporarily, but it will certainly fail in very short order. The only real solution is to replace the worn out brushes. They are held in place by a small spring clip. Push in and up on the clip and it will then swing open and release the brush. Then take a very small pair of needle nose pliers and follow the brush wire to where it connects to the motor assembly, pulling straight up on the spade connector. You may not be able to see the connector, but its there.

I shopped around on the web and found a site in Santa Fe Springs, CA. that carries the brushes. Just search for carbon brush and the size you are looking for. They have an exact fit (.17"x.17"x.5") for $7.75 ea. (the motor takes 2), or I found one that was ever so slightly larger (.17"x.19"x.625") for about $2.09. Carbon brushes are VERY soft, so about 10 seconds on a standard flat file and the $2 brushes worked just fine. They came with a round screw connector instead of the female spade connector, so I had to change that out before installation.

Honestly, it took longer to get the door panel apart so that I could get to the motor than it did to change the brushes. I hope this helps someone else save the cost of the motor.

Hope this helps...Keep your ride alive!