2005 Dodge Grand Caravan Engine Problems

Several times in past year after filling the gas tank, shortly after driving away from gas station the engine misfires and stalls. This has been a safety hazard when merging into traffic. This problem is widely noted in forums on the internet for Chrysler minivans, for many other model years including the 2005. The best explanation being given (link follows) is that the vapor/liquid separator valve on top of the fuel tank has failed, a part that is not replaceable--the entire fuel tank must be replaced. Some report it happened when their minivan was brand new. https://ricksfreeautorepairadvice.com/engine-stalls-after-filling-tank-chrysler-minivan/

CAR WILL STALL A FEW MINUTES AFTER FILLING THE GAS TANK. IT WILL STALL IN THE MIDDLE OF DRIVING ON THE ROAD AND WILL NOT RESTART FOR 20 MINUTES CAUSING A DANGEROUS SITUATION.

2205 DODGE GRAND CARAVAN STALLS AFTER REFUELING. MULTIPLE OCCURENCES. HAPPENS IN MOTION STRAIGHT LINE, WHILE ACCELERATING.

EVERY TIME I FILL UP THE VEHICLE WITH GAS, IT STALLS EVERY TIME WITHIN THE FIRST FEW MINUTES, LAST WEEK DAUGHTER WAS MERGING INTO TRAFFIC WHEN IT HAPPENED AND ALMOST GOT REAR-ENDED. THIS HAS BEEN HAPPENING FOR A WHILE NOW. LAST WINTER I WASN'T ABLE TO FILL THE VEHICLE, THE PUMP KEPT SHUTTING DOWN BUT THAT WENT AWAY AFTER THE WEATHER WARMED UP.

TL* THE CONTACT OWNS A 2005 DODGE GRAND CARAVAN. AFTER REFUELING THE VEHICLE, THE ENGINE STARTED AND STALLED. THE OIL WARNING INDICATOR ILLUMINATED ON THE INSTRUMENT PANEL. THE FAILURE WAS INTERMITTENT. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 105,000.

ENGINE SPUTTERS OR STALLS SHORTLY AFTER FILLING THE TANK. IT TYPICALLY HAPPENS WHEN TAKING OFF AT ONE OF THE FIRST INTERSECTIONS AFTER FILLING THE TANK. IT PUT ME IN DANGER, BECAUSE IT STALLS IN THE MIDDLE OF THE ROAD WITHOUT WARNING. THIS HAS HAPPENED SEVERAL TIME IN 2015. THE DATE BELOW IS APPROXIMATE FOR THE TIME THE VAN WAS LAST FILLED UP.

THE VEHICLE STALL IMMEDIATELY AFTER 1ST STARTUP FILL UP OF THE GAS TANK. THE STEERING LOCKS AND CAR ENGINE HESITATES AND DIES. AFTER WAITING COUPLE OF MINUTES, THE CAR WILL START UP AND NOT HAVE THE PROBLEM UNTIL NEXT REFILL OF THE GAS TANK. I NEVER OVERFILL THE GAS TANK. THE PROBLEM IS SIMILAR TO AN EXISTING RECALL ON 19 GALLON GAS TANKS ON DODGE CHARGERS.

THE ENGINE STALLS WHILE DRIVING WITHIN FIVE OR SIX MINUTES AFTER FILLING THE GAS TANK. THIS HAS HAPPENED MULTIPLE TIMES. *TR

CAR STALLS WHEN I FILL THE TANK UP WITH GAS. THE CAR STALL OUT SHORTLY AFTERWARDS WHILE DRIVING. *TR

VEHICLE STALLS OUT AFTER FILLING UP WITH GAS. IT WILL RUN ROUGH AFTER A FILL UP AND STALL OUT AT THE NEXT STOP YOU HAVE TO MAKE. *TR

AFTER I FILL UP THE GAS TANK THE VAN STALLS WITHIN A COUPLE OF MINUTES. THIS HAS HAPPENED NUMEROUS TIMES AND HAS ALMOST CAUSED SEVERAL ACCIDENTS. *TR

2005 DODGE CARAVAN SXT STALLS UNEXPECTEDLY AT HIGHWAY SPEEDS AND AT LOW SPEEDS SHORTLY AFTER BEING FUELED TO A FULL TANK OF GAS. THIS HAS BEEN HAPPENING MORE OFTEN AFTER THE MILEAGE HAS GONE OVER 100000 MILE. IT HAS BEEN STARTING BACK UP AFTER IT STALLED BUT HAS TAKEN LONGER TO START WITH EACH PASSING STALL. IF I DISCONNECT THE NEGATIVE BATTERY POST WAIT A FEW MOMENTS AND RECONNECT THE VAN WILL GET ME HOME TILL THE NEXT DAY WHEN THE STALLING START AGAIN. AFTER THE GAS TANK IS BELOW 3/4 THE STALLING ISSUE GOES AWAY. IN IT'S CURRENT CONDITION NOT A VERY RELIABLE OR SAFE AUTOMOBILE FOR ANY FAMILY TO BE USING ON THE HIGHWAYS. *TR

WHEN PARKING AND SHUTTING THE ENGINE OFF, I GET OUT AND WALK TOWARD REAR OF THE VAN, I CAN SMELL GAS BUT I CAN NOT FIND ANY GAS LEAKING ON THE GROUND AND THE GAS CAP IS ON TIGHT. I HAD A FRIEND TELL ME THAT THEY HAD SIMILAR PROBLEM ON THEIR DODGE GRAND CARAVAN AND THEY HAD TO DROP THE GAS TANK AND FOUND A LEAK ON TOP OF THE TANK. IT IS A STRONG ODOR AND I AM AFRAID A SMOKER TOSSING A BUTT NEAR THE VAN MIGHT CAUSE AN EXPLOSION. THIS IS AN E85 FUEL ENGINE BUT THAT IS HARD TO FIND SO I USE UNLEADED REGULAR. I HAVE NOT HAD CHANCE TO GET THIS IN TO HAVE IT CHECKED AND REPAIRED. JUST CHECKING ON RECALL POSSIBILITIES FIRST. *TR

WHILE DRIVING THE CAR HOME AT ONLY 35 MPH, MY WIFE HEARD A LARGE BANG AND IMMEDIATELY LOST THE POWER STEERING, BUT WAS ABLE TO PULL OFF THE ROAD. WHEN I WAS ABLE TO CHECK UNDER THE HOOD OF THE VEHICLE, I FOUND THAT THE ALUMINUM CASTING HAD BROKEN THAT HOLDS THE BRACKET FOR THE ALTERNATOR. THE ALTERNATOR AND SERPENTINE BELTS WERE LAYING NEAR THE LEFT SIDE OF THE ENGINE COMPARTMENT. I TOOK PHOTOS OF THE PROBLEM SINCE I KNOW IT IS NOT USUAL FOR THE CASTING TO BREAK. I HAD THE CAR TOWED TO THE CHRYSLER DEALER THAT WE HAVE HAD ALL THE SERVICE FOR THE VEHICLE PERFORMED. I EXPLAINED THAT I WAS CONCERNED THAT THE CASTING BROKE AND THEY SEEMED CONCERNED ALSO AT THAT POINT. THEY STATED THAT THEY HAD NOT SEEN THIS PROBLEM BEFORE. I HAD THE REPAIRS MADE AT A COST OF OVER $1500.00. THEY HAD TO REPLACE THE CVR PKG-ENGINE BECAUSE THE BREAK WAS PART OF THE CASTING FOR THE COVER OF THAT PART. I THEN CONTACTED THE CHRYSLER DODGE CUSTOMER SERVICE DEPARTMENT AND TOLD THEM I WAS CONCERNED ABOUT THE SAFETY OF THE VEHICLE AND THAT IF MY WIFE HAD BEEN GOING 75 ON THE EXPRESSWAY AND ROUNDING A CURVE IN HEAVY TRAFFIC, SUCH A BREAK COULD EASILY CAUSE CATASTROPHIC DAMAGE, INJURY, OR DEATH. I TOLD THEM THAT I BELIEVE THAT THIS IS NOT A NORMAL WEAR AND TEAR OR MAINTENANCE ITEM, BUT A MANUFACTURING DEFECT SINCE THE ALUMINUM CASTING BROKE AND NOT THE BRACKET. THE CUSTOMER SERVICE CASE MANAGER ONLY CAME BACK WITH A STATEMENT THAT THE VEHICLE HAD 138000 MILES AND THEY COULD OFFER ME ONLY $465.00 TOWARD THE REPAIRS. THERE WAS NO ACKNOWLEDGEMENT, OR CONCERN THAT THIS WAS A SAFETY ISSUE. WHILE I BELIEVE THAT CHRYSLER SHOULD PAY FOR THE ENTIRE REPAIRS, I AM MORE CONCERNED THAT THIS COULD BE A POTENTIAL LIFE THREATENING SITUATION FOR OTHER UNKNOWING DRIVERS. I HAVE THE PICTURES AND I HAVE THE PART IN MY POSSESSION IF ANYONE NEEDS TO INVESTIGATE THIS! *TR

CHECK ENGINE LIGHT ON. NEEDS CATALYTIC CONVERTER/ERG VALVE. *TR

I HAVE A 2005 DODGE GRAND CARAVAN SX. I HAVE HAD TROUBLE SINCE ONE MONTH OF BUYING IT. I TAKE IT BACK TO THE DEALERSHIP WHO SAID THEY COULDN'T FIND ANYTHING WRONG WITH IT. SINCE THEN, I'VE TAKEN IT BACK NUMEROUS TIMES. THEY EVEN KEPT IT FOR A WEEK AND SAID THEY FOUND NOTHING WRONG WITH IT. I WOULD HAVE TO GET IT BACK TO THEM WHEN IT HAD STOPPED. THE PROBLEM IS WHEN I'M DRIVING ALL THE INSTRUMENT NEEDLES GO TO NULL. SHORTLY THEREAFTER, IT STARTS TO LOSE POWER. I ONCE WAS IN THE FAST LANE ON A BUSY HIGHWAY WHEN I HAPPENED TO LOOK DOWN AND EVERY NEEDLE HAD GONE DOWN. I GOT IN THE LOW LANE AND PULLED OFF THE HIGHWAY FOR SAFETY PRECAUTIONS WHEN IT WENT DEAD IMMEDIATELY! I CALLED ROADSIDE SERVICE. WHEN I TURNED THE KEY TO CHECK MY MILEAGE IT STARTED UP IMMEDIATELY. THAT WAS SCARY, BECAUSE IF I HADN'T LOOKED DOWN WHEN I DID AND IT LOST POWER BEFORE I COULD GET IT OFF THE HIGHWAY, I BELIEVE THE OUTCOME WOULD'VE BEEN TRAGIC. THIS ONLY HAPPENED ONCE A YEAR OR ONCE EVERY SIX MONTHS. HOWEVER, ONE NEVER KNEW WHEN IT WOULD HAPPEN NEXT! THE LAST TIME I DROVE IT FOR SOME DISTANCE I HAD ALMOST GOTTEN HOME (WITHIN TWO MILES) IT DID IT AGAIN, THIS TIME THREE TIMES BEFORE I COULD GET HOME. I FEEL BLESSED. TO SAY THE LEASE, I DON'T FEEL SAFE IN IT AND I'M STILL PAYING FOR THIS TRAP. I WAS CHECKING TO SEE IF THERE WERE ANY RECALLS WHEN I FOUND A DAIMLER CHRYSLER PROBLEM WEBSITE STATING THAT THEY'RE NOT LIABLE FOR ANYTHING THAT HAPPENS TO SOMEONE INJURED OR KILLED BY THESE VEHICLES AND THEY DON'T EVEN TRY TO FIX THE PROBLEM. I NEED AN INTERVENTION OF SOME SORT. I CAN'T AFFORD THIS! *TR

THE OIL LIGHT WENT ON. I CONTACTED DEALER, THEY ADVISED ME I NEED AN OIL CHANGE. I MADE AN APPOINTMENT FOR THE NEXT AVAILABLE TIME WHICH WAS A WEEK AWAY. I CALLED BACK NEXT DAY COMPLAINING OF A KNOCKING I HEARD. THEY FINALLY ADVISED ME TO GET THE VAN TO DEALER AND THEY WILL RENT A CAR FOR ME. I CHECKED THE OIL. IT WAS FULL. MY WIFE DROVE IT TO DEALER IN THE MORNING. THERE WAS NO OIL IN MOTOR. THE DEALER CLAIMS I AM RESPONSIBLE SINCE I DID NOT CHANGE THE OIL IN 6 MONTHS AND 7000 MILES. CHRYSLER RUDELY DENIES COVERAGE EVEN THOUGH I AM UNDER WARRANTY, I PURCHASED THE CAR MARCH 2008 WITH 35000 MILES OR SO..IT HAS BEEN IN FOR SERVICE BEFORE FOR A REPLACEMENT OF RACK AND PINION SYSTEM AND AN ENGINE LIGHT INCIDENT. *TR

2005 DODGE GRAND CARAVAN WITH 45,000 MILES. NEEDS EVAPORATOR, REAR EXPANSION VALVE AND REAR LINES FOR AC. TOLD THAT MOST CHRYSLER MINIVANS HAVE THIS PROBLEM AFTER JUST 3 YEARS. WITH THIS MANY PROBLEMS, WHY NO RECALL? TOTAL COST FOR REPAIRS IS $1,250.00. *TR

CLUNKING NOISE FROM UNDER VAN WHEN BREAKING HARD. ONLY HEARD 1 TIME IN EITHER DIRECTION. MISSING BOLTS IN CENTER OF CRADLE (ENGINE MOUNT). BOLTS WERE REPLACED AND TIRE ALIGNMENT WAS ADJUSTED AS IT HAD ALSO CHANGED. CHRYSLER, AS A GOOD WILL GESTURE, REFUNDED THE COST OF THE REPAIR, WHEEL ALIGNMENT AND PARTIAL COST OF THE 4 TIRES WORN ON THE OUTSIDE EDGE SIDE EDGE. *TR

TL*THE CONTACT OWNS A 2005 DODGE GRAND CARAVAN. EVER SINCE THE VEHICLE WAS PURCHASED, THE CONTACT HEARS A THUMPING AND KNOCKING SOUND WHEN THE TRANSMISSION IS PLACED INTO DRIVE. THERE IS ALSO TAPPING IN THE ENGINE. HE TOOK THE VEHICLE TO THE DEALER SEVERAL TIMES, BUT THE FAILURE PERSISTS. ON JANUARY 15, 2008, THE DEALER STATED THAT THE ENGINE LIFTERS FAILED AND ALL OF THEM NEEDED TO BE REPLACED. THE DEALER REPLACED ONE LIFTER AND DECLARED THE VEHICLE REPAIRED. AFTER LEAVING THE DEALER, THE NOISE WAS STILL PRESENT. THE CURRENT MILEAGE WAS 66,128 AND FAILURE MILEAGE WAS 61,287. UPDATED 02/11/08 *TR