Hairline cracks in fuel pump outlet just before connecting to fuel line leads to strong fuel smell and fuel vapors all around vehicle. Fuel pump needs replacement to repair this dangerous condition. Highly suggest different fuel pump design that is not prone to hairline cracks and potential fire hazard as fuel leak is about one foot away from a hot muffler and a tossed cigarette or other spark could cause a fire or explosion.
2004 Dodge Grand Caravan fuel system problems
36 complaints (31% of all complaints for this car). Typical mileage when it fails: 100,000.
- owner complaints
- 36
- of this car's complaints
- 31%
- typical mileage
- 100,000
- crashes
- 0
- recalls
- 0
Which part fails
- Storage: tank assembly2
- Delivery1
At what mileage
Complaints by mileage at the time of the problem.
0k-25k
25k-50k
50k-75k
75k-100k
100k-125k
125k-150k
150k-175k
175k-200k
200k+
Dodge Grand Caravan fuel system problems in other years
Specific symptoms reported on the 2004 Dodge Grand Caravan fuel system
Phrases found in the owners' own descriptions, so one complaint can mention several symptoms.
Related recalls
No recalls on record for this model year.
Related investigations
Engine Stall After Refueling
This defect petition evaluates July 7, 2014 allegations from an owner of a model year (MY) 2007 Dodge Grand Caravan minivan that engine stall occurs in these vehicles without warning after refueling.The petitioner's vehicle is a Chrysler RS platform minivan.The RS platform includes MY 2003 through 2007 Dodge Grand Caravan, Dodge Caravan, Chrysler Town and Country and Chrysler Voyager minivans.the federal safety agency evaluated the petition by analyzing consumer complaints submitted to the Agency, analyzing field data, reviewing technical information provided in Chrysler's response to an Agency information request and testing an RS minivan identified by its owner as experiencing post-refuel engine stalls.After completing this evaluation, the federal safety agency has concluded that further investigation is unlikely to result in a finding that a defect related to motor vehicle safety exists.The stalls occurring in these vehicles only occur immediately after filling up the fuel tank and happen at low engine speeds. The failure rate is low, even after 8 to 13 years of the vehicles being in service, and there are no reports of crashes or injuries resulting from the stall condition.In the Agency's view, additional investigation is unlikely to result in finding the existence of a safety-related defect in the subject vehicles.Given the need to allocate and prioritize the federal safety agency's limited resources to best accomplish the Agency's safety mission, the petition is denied.This action does not constitute a finding by the federal safety agency that a safety-related defect does not exist. The Agency will take further action if warranted by future circumstances. More details concerning our review can be found in the Federal Register Notice for this action.The following 161 VOQs are included in the petition evaluation: 10209242, 10229468, 10240708, 10260923, 10275939, 10276532, 10296487, 10298175, 10328669, 10330144, 10346517, 10349789, 10354758, 10363689, 10372112, 10372368, 10372514, 10378031, 10379764, 10382938, 10387448, 10394063, 10398877, 10413918, 10418652, 10420924, 10427063, 10437525, 10445392, 10446902, 10470028, 10471249, 10473733, 10502231, 10503114, 10504260, 10509862, 10511988, 10512120, 10512385, 10512650, 10513147, 10538154, 10549841, 10551763, 10555188, 10555418, 10556754, 10565367, 10574012, 10574398, 10586555, 10587212, 10587559, 10593433, 10607841, 10607913, 10608922, 10615810, 10622468, 10628141, 10632112, 10632128, 10632172, 10632175, 10632231, 10632262, 10632266, 10632270, 10632305, 10632316, 10632326, 10632370, 10632385, 10632399, 10632492, 10632542, 10632765, 10632833, 10632928, 10633197, 10633281, 10633409, 10633421, 10633483, 10633507, 10637752, 10637804, 10637950, 10637975, 10638032, 10638289, 10638290, 10638401, 10638968, 10639218, 10639623, 10641157, 10641603, 10641614, 10641836, 10644339, 10644705, 10649713, 10649895, 10649932, 10650313, 10652590, 10653147, 10653783, 10654533, 10655226, 10658900, 10659679, 10660320, 10662588, 10662645, 10662662, 10663473, 10667056, 10667437, 10668081, 10668094, 10668131, 10668612, 10668969, 10668970, 10669584, 10669678, 10669729, 10669775, 10669866, 10669895, 10669992, 10670422, 10670506, 10676348, 10676732, 10677120, 10679795, 10679934, 10680057, 10680290, 10680342, 10680714, 10681512, 10682584, 10682906, 10683022, 10683114, 10683549, 10683620, 10683697, 10683743, 10689898, 10690761, 10691284, 10691556, 10691751, 10693061, 10694300
DP14002
What 2004 Dodge Grand Caravan owners say
Most recent owner complaints, unedited.
After filling the gas tank, within a few miles the vehicle will stall. Dodge already has extended the warranty on the fuel tank of vehicle built after september 2003 but mine was built august 5 2003 so it is outside their window. This is a very dangerous issue because it has happened to me on the highway at 55 miles an hour and I then have no power and need to get out of the way of traffic that is going to run me over.
Every time we fill the fuel tank the caravan cuts off and rides very rough. The recall on the dodge caravan was on vans build starting on 09/01/2003 my caravan was built on 09/29/2013.
Tl* the contact owns a 2004 dodge grand caravan. The contact stated that after refueling the vehicle, it stalled without warning. After several attempts the vehicle was able to restart but the failure recurred. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The approximate failure mileage was 70,000.
Engine stalls out 10 or 15 seconds after filling the gas tank. Usually on the highway you are turning on to. Its been doing this for a couple of years.
The vehicle stalls out after filling at the gas station. Reportedly due to an issue with the check valve and requires the entire fuel tank to be replaced.
Tl* the contact owns a 2004 dodge grand caravan. While driving 45 MPH, the temperature gauge on the instrument panel started going to the red side; indicating that the vehicle was having trouble regulating the engine cooling system. The contact also stated that there was a strong odor of fuel entering the vehicle. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel pump and carbon filter needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 100,000.
I went to the gas station and filled my gas tank, not topping it off, and as soon as I turned out of the station on a major road the vehicle stalled and almost resulting in an accident. After a quick restart the van ran fine and I was able to drive from nashville, tn to atlanta, ga with no problems. But when I filled up again in atlanta, right after pulling out of the gas station the vehicle stalled again, in the middle of a busy intersection. This problem is widely reported across dodge and chrysler vans, with over 100 complaints on this website. I'm hoping this issue with the gas tank/sensors will be address. Thank you.
After fueling the check engine light is now on and indicates an emissions leak which causes vapors to now build up inside the van after every refueling. If filled to capacity the vehicle will also stutter and sometimes completely stall shortly after fueling.
Every time I fill my tank (I do not top off), within a few minutes of leaving the station, the van dies. It normally re-starts, but it takes quite a lot of gas pedal pumping. This is dangerous when it happens in the middle of an intersection. I had the fuel pump and filter replaced and that did not solve the problem. Now I understand that the valve on top of the tank is at fault, but you have to replace the entire tank. This is a design flaw and needs to be corrected.
Questions about the 2004 Dodge Grand Caravan fuel system
Does the 2004 Dodge Grand Caravan have fuel system problems?
Owners have filed 36 complaints about the fuel system of the 2004 Dodge Grand Caravan, 31% of all its complaints, more than any other problem.
At what mileage do 2004 Dodge Grand Caravan fuel system problems start?
The typical (median) mileage in owner complaints is 100,000 miles.
Was there a recall on the 2004 Dodge Grand Caravan fuel system?
There is no recall for this problem on this model year.
What year does the Dodge Grand Caravan have the most fuel system problems?
The Dodge Grand Caravan model years with the most fuel system complaints are 1996 (180 complaints), 2011 (137 complaints) and 2012 (74 complaints).
Other 2004 Dodge Grand Caravan problems
Engine 20Brakes 15Electrical 13Steering 13Locks 9Airbags 5Body 4Lights 4Tires 3Transmission 3Visibility 3Seats 2Suspension 2Seat belts 1
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