Dodge - Caravan :: 1999 - Moisture In Heating And Cooling System / Windshield Fogging


Oct 9, 2014

I drive two 1999 Caravans, a base model and a Sport. With both I have a persistent problem with moisture in the heating/cooling system. When I turn it on, it smells and feels moist (not like coolant), heat or A/C, summer or winter. I have pressure tested, no leaks. I have replaced heater cores, o ring seals, checked the condensate drains for blockages, replaced the metal tubes that go through the firewall on one car. There is no moisture coming from the outside. The windshield starts fogging at about 34 degrees and gets so bad when it is colder that the defroster full on with the A/C on cannot completely clear the inside glass. Really cold (for us) 20s and the windshield is so fogged that driving is scary. When I drive into a cold spot in winter, sometimes the whole windshield will fog in a few moments-- that's with the defroster on.

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1. Fuse - first tested the fuse and it was OK. Had to start with simple things first.
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4. Wiring - tested the wiring between the relay and the fans. They checked out OK (good continuity and resistance check). There is no voltage leaving the cooling fan relay. Now it's getting more complicated... I unplugged the wiring harness from the ECM and tested the wiring between the ECM and the cooling fan relay. A-OK.
5. ECM - it is unclear how to check the ECM for functionality of the cooling fan.

There are 3 wires (supply, ground, and switch wire?) The supply voltage and ground is good, but I don't know what voltage the switch wire should be. I've read that it is pulse width modulated so I can't measure this with a simple voltmeter. I've also read that the switch wire goes to ground thus triggering the relay. I don't know which is correct. Several mechanics I talked to were skeptical that the issue is with the ECM, they knew of very few instances of this being the culprit. I even replaced the new cooling fan relay with another new cooling fan relay on the off chance that the replacement was faulty. Did I miss something in my logic and diagnostics? I've resorted to wiring a switch directly to the cooling fans and toggling them on and off.

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I know there's a Chrysler recall on 2005-2006 Caravans, #J38, but my Caravan falls outside the specs by 2 mths (it was for vehicles in service between Jan 2005 and April 2006).

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