2004 Dodge Grand Caravan Fuel System Problems

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.

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.

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.

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.

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. *TR

CAR SHUTS OFF AFTER FILLING THE GAS TANK. THIS HAS HAPPENED SEVERAL TIMES. ALWAYS ON THE ROAD AND IN TRAFFIC. *TR

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. *TR

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.

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.

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. *TR

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. *TR

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. *TR

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.

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. *TR

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.

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. *TR

FUEL LEAK FROM FUEL TANK AT THE FUEL PUMP VERY CLOSE TO THE EXHAUST!!!! *TR

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. *TR

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.