2004 Dodge Grand Caravan: fuel pump failure

Filed Sep 4, 2019 · Fuel system · 260,000 miles · WV

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.

Filed Jun 30, 2015 · Engine, Fuel system · 100,000 miles · TX

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.

Filed May 15, 2015 · Fuel system · 109,000 miles · OR

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.

Filed Dec 19, 2014 · Fuel system · IN

The fuel pump has hair line fractures in multiple places of fuel pump in and is leaking gas looks like its been there for awhile but I just noticed it in july iv been reading up on it and there's. Been alot of people with the same problem with 04 dodge grandcare vans sxt and others models also...... Thanks.

Filed May 25, 2014 · Fuel system · 180,000 miles · FL

Noticed fuel smell and vehicle stalling or hesitating after fueling, found fuel leak coming from very small cracks on fuel pump housing top located on the passenger side of the van close to the exhaust system.

Filed Oct 14, 2013 · Fuel system · 155,000 miles · TX

My van left small fuel marks in driveway, I investigated it physically and found fuel to be leaking by fuel pump housing near a fuel line, I assumed it was leaking from the o-rings on quick disconnect line. I replaced o-rings and the problem still exists. I googled the issue and to my surprise there are many similar issues, people explaining how their vehicles where leaking in the same location. After browsing I found a website where there was a picture showing fractures on the housing near the fuel line that I had worked on. Sure enough I rechecked my vehicle and there were the fractures. Leaking fuel. I just wanted to post this on this website to inform other owners, that if they smell fuel from their van, they should get this issue checked asap. This is a real hazard, and could be really dangerous.

Filed Sep 26, 2012 · Fuel system · 88,000 miles · VA

Fuel leak from fuel tank at the fuel pump very close to the exhaust!!!!

Filed Oct 8, 2007 · Fuel system · 50,000 miles · OH

Shortly after filling up with gas, I often experience difficulty with the vehicle. It sometimes stalls. It acts up within a minute or two by trying to stall. I try to give it as much gas as I can and it eventually stops acting up if it doesn't stall first. The dealer says they cannot replace the fuel filter, because it is part of the whole gas tank setup. It is not replaceable like most fuel filters are. It seems to me that it is the fuel filter needing to be cleaned. I do believe it is ruining my fuel pump slowly. I am concerned about when it stalls that someone may run into the back of me.