While making left the vehicle stalled while in motion in the middle of major intersection. After a 20 or so seconds, the vehicle engine turned on. Another incident, approximately a year ago, while traveling 60+ miles on major interstate, the vehicle again shut down while in motion. I had to coast the vehicle, with loss of power, to median on the interstate. After about a minute or so, the vehicle turned on. Always upon filling the gas tank, the vehicle stalls while exiting the gas station or shortly thereafter. After a minute, the vehicle is able to turn back on.
2004 Dodge Grand Caravan fuel system complaints
Page 2 of 2: complaints 11 to 36 of 36, newest first, as owners wrote them.
Car shuts off after filling the gas tank. This has happened several times. Always on the road and in traffic.
After filling my '04 grand caravan with fuel and attempting to leave the pump my caravan shuts off. This has been on an ongoing issue for over 2 years. After several repair attempts I was told today that the vapor separator valve located on top of the gas tank is faulty. A valve that dodge does not make available for repair. The only "fix" that is offered is to replace the entire tank of which I was told today would be $1600.
Every time I fill up the van, as soon as I pull out of the gas station it will idle rough, hesitate, or die all together. I could have 1/2 tank and add maybe 5 gal of gas and it will do the same thing. I saw online that I am not the only one that had this issue. It ranges for different years and come to find our it has to do with a valve above the tank and cant be replaced singly but the whole tank for $1600 plus labor. This is a safety issue because this thing has happen in the middle of an intersection while turning. I called melloy dodge here in albuquerque nm and they right shot me down about as quick it took to dial the phone number.
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.
After taking on gas, engine will sometimes stumble and most of the time quit running. Tried not over filling it and it still will just die sometime after taking on gas. On two occasions, it did this after hitting highway speeds. It would suddenly lose power and you had to pull off the road. It would normally start back up and have no more problems until next fill up. Because of this, we don't fill up and hit the road. We drive around before driving at highway speeds. Once, it died in front of several cars and a big truck had to brake hard and swerve off the road. So far, there has not been any known accidents but feel it is a matter of time before someone gets hurt. The mechanic said it was something wrong with a valve in gas tank and that you can't buy the part. We don't loan our van to the kids anymore since my oldest daughter almost caused a wreck and almost got hit when the van lost power.
For the past four years or so, almost every time after filling up the gas tank, the 2004 dodge grand caravan anniversary edition stalls. I can be just pulling away from the pump when it happens, or stopped at a stop light within a few minutes from leaving the gas station. You can feel the car 'jump' like someone is pressing the gas pedal quickly and it jerks the van a bit forward. Then it stalls. It takes a few turns of the key and pressing the gas pedal very quickly and forcefully to get it started again. I have gotten into the habit of driving the van around a parking lot for a few minutes until it feels back to normal before pulling out into traffic, as I'm concerned it will stall out in the middle of traffic. This only happens right after filling up the gas tank. It concerns me now more than ever since my son is learning how to drive and I want him to be safe.
Engine started missing, vibrations from engine. Diagnosis electrical fault. Wiring harness brittle form harness being placed on, over and next, snaked around exhaust manifold, causing premature wiring failure. Fuel injector wiring harness unshielded in side of intake manifold / plenum. Wiring harness poorly shielded. This is a deliberate, intentional design / engineering to snake wiring harness around exhaust manifold. Causing wiring harness failure. Using sub-standard wiring components and not using shielding to cause pre-mature failure. Installing PCM (computer) in wheel well for pre-mature failure exposed to salt, road debris, water, etc. Pcm installed in open area of vehicle prone to failure. Consequential safety issues.
Tl* the contact owns a 2004 dodge grand caravan. The contact stated that the vehicle would stall immediately after refueling. The contact indicated that the failure had occurred on multiple occasions and in some instances the vehicle would stall up to two times before operating as normal. The manufacturer was notified of the failure but no solution was offered. The failure mileage was 115,000.
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.
Beginning around august 2012, my 2004 dodge grand caravan anniversary edition began to sputter and stall if I ever filled the gas tank completely. If I did not continue to feed gas to the engine, the engine would stall. At stoplights I would need to put the car in park and rev the gas and then sit in park until I was able to move. This would continue for approx 2-3 miles. In summer 2013 it began happening even if the car was not filled to capacity. Repair shops tell me it's the type of gas or there is water in the gas line, but my research tells me this is a known caravan issue. My requests for repair investigations are not taken seriously. So my solution is to never fill the car beyond 3/4 tank - super inconvenient. As a result, the sputtering does not happen as much any more, but the situation is dangerous and scary. I am just waiting for the engine to fail in the middle of a busy road simply because I've gotten fuel.
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.
This incident occurs every time I fill up with fuel. It began at approximately 35,000 miles and continues until this day at about 116,000 miles. Incident description: I enter the gas station. I fill up with fuel until the pump stops, not a "top-off". I start the ignition and begin to drive away. The engine stutters and sometimes stalls completely. After a short distance, 3 miles or so, it runs normally. Recently after my knee surgery, my wife was driving and pulled out into traffic, left hand turn, after a refuel. We were trying high-test ethanol free gasoline. Well she made it into the center turning lane and waited her turn. When an opening arrived she pressed the accelerator and the van started and failed completely, leaving us half-way in the lane for oncoming traffic. Thankfully the oncoming traffic slowed as they blew their horns and she was able to restart the van and begin to drive. This was a most miserable experience especially since we had all three of our small children in the van with us. Something really needs to be done to correct this ongoing and dangerous issue.
The 3.8l engine stalls after almost every fuel fill-up and began in early 2010. Within 1-2 miles after a fuel up, the vehicle will buck and sputter and often turn off completely. It gets better after 3-5 miles. It apparently is a known issue with many dodge owners, not just minivans. I had two 2006 dodge chargers (r/t and srt8) that both did the same thing. I no longer own the chargers but still have the 2004 caravan. This a dangerous and unpredictable issue that has something to do with the tank mounted vapor separation valve and the vapor return system. The vehicle is not "topped off" when fueling which has been known to create the issue. Thanks.
Engine stalls within a mile or so after filling fuel tank. Issue began at 31,000 miles and vehicle currently has 35,280 miles. Has occurred every time fuel tank is filled since the first incident at 31,000 miles.
Tl* the contact owns a 2004 dodge grand caravan. The contact stated that when the vehicle was being refueled to capacity, the fuel level indicator would not register the amount of fuel in the vehicle. The vehicle was taken to the dealer, who stated that they would have to replace the fuel tank. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 87,000.
Tl* the contact owns a 2004 dodge grand caravan. The contact stated that fuel fumes were emitted into the vehicle. The contact exited the vehicle and noticed a small leakage. The vehicle was taken to an independent mechanic for inspection who stated that the fuel injector rail needed to be replaced. The vehicle was not repaired. The manufacturer was notified and they stated that there was no recall on the vehicle. The failure mileage was 47,000.
Fuel leak from fuel tank at the fuel pump very close to the exhaust!!!!
For a year or so my wife and I could smell gasoline fumes in the garage at night. I checked engine gas filler under car, but was unable to identify source of gasoline fumes. Finally about w week ago the smell of fumes was stronger. I looked under the car and noticed a wet spot on garage floor. I put the car on jacks crawled under the car and could see fuel oozing from a fitting on fuel line that was connected to the top of the tank. This fitting is some sort of quick disconnect in which you can turn easily on the white plastic fitting on top of the tank. We are now parking auto outside fearing the fumes could ignite in the garage from hot water heater. Is there a possible recall on this problem?
Our 2004 dodge grand caravan will stall out driving down the road if you fill the gas tank until the gas pump nozzles stops automatically. The only way to stop this is to replace the gas tank because of a bad valve in the top of the tank in the emissions system. I found this information on line. It has done it several times and we now under fill the tank which is not easy to do.
2004 dodge grand caravan stalls after filling up with fuel, hard to start back up, dealer did not have answer, already changed gas cap and car still stalls about 80% of the time after filling up..
Tl*the contact owns a 2004 dodge grand caravan. The contact stated that each time she added fuel to her vehicle it stalled. All of the gears illuminated and the brakes locked. The vehicle was towed to a mechanic and then to the dealer but they could not duplicate the failure. The vehicle was not repaired. The manufacturer was not called. The VIN was unavailable. The failure mileage was 90,000.
2004 dodge grand caravan fuel tank vapor float vent failure. Vehicle has 59,000 miles. After fueling vehicle it will stall intermittently at stop signs and on open highway without warning, because fuel is getting into the engine and flooding engine out via the tank venting vapor system. When fueling, a float in the orvr (onboard refueling vapor recovery) valve is designed to rises and seals the tank vent causing pressure build, backing fuel up into the fill neck and shutting it off. The orvr is apparently not sealing completely or at all, allowing liquid fuel to pass into the vent line to the vapor canister and then engine. The valve is plastic welded to the tank, which requires the tank to be replaced. Major safety issue because the power steering system stops when engine stops and vehicle is not able to be steered without the power steering aid. Vapor system failure fully described at: http://www.justanswer.com/questions/1ob81-2005-dodge-caravan-stalls presently only keeping tank fuel at a maximum of 3/4 full to avoid flooding the vapor vent system.
For the last 40,000+ miles the vehicle always stumbles or stalls after filling the fuel tank full. We're not talking about overfilling, just filling it until the auto shut-off shuts off the flow. It will buck and stumble when you are driving down the road and often dies when you are pulling out into traffic. It has stalled on my wife while she was waiting to turn left at a busy intersection. Once re-started it runs fine until the next fill-up. The dealer told me it is the purge solenoid and it would cost $190 to fix. The vehicle has 92,000 miles on it and I thought that was well below the federal emissions warranty and it also has the extended 100,000 mile warranty. I have not had it fixed yet, but just avoid topping off the tank. The date listed below is only the most recent. We are talking about literally dozens of failures of this sort -- every single time the gas tank is filled to the auto-stop without fail. The service guy at the dealership said they have had a number of complaints of this type about this vehicle.
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.
Dt: the consumer stated the location of the fuel tank causes it to be susceptible to damage and cause leaking which can lead to a fire hazard.
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