2005 Chrysler 300 Fuel system Problems

Strong fuel smell in cabin and outside of car when gas tank is full. Discovered gas in the cabin sitting on top of the fuel tank under the passenger-rear seat. Multiple posts in online forums confirm this is a known issue. Vehicle owner ordered a new o-ring to attempt repair. Area around fuel pump under driver's-rear seat was not affected. No warning lights, notices or performance issues. Only indication is strong gas fumes in car after filling up the gas tank (auto shutoff at pump, not topped off) which persists for several days. Problem seems minimized if gas tank is shorted 2-3 gallons from max capacity on fillup (about 14 gallons when car is close to empty per the gas gauge in dashboard.) Car was not inspected by dealer, insurance agent, police, independent service center, or anyone else other than owner.

NHTSA ID

11495459

Incident

Jun 1, 2022

ENGINE STALLS AFTER FUELING TANK. THIS HAS BEEN CONFIRMED BY AN INDEPENDENT SERVICE CENTER. SPENT MONTHS AND LOTS OF DOLLARS TRYING TO FIX PROBLEM. DID RESEARCH ON INTERNET AND FOUND CHRYSLER HAD ISSUED BULLETIN 14-002-14 SHOWING THERE A PROBLEM WITH CHRYSER 2005 AND 2006 300'S STALLING. THE FUEL PUMP IS IN THE TANK AND NOT MONITORED BY ENGINE COMPUTER. THE FUEL PUMP HAD GONE BAD CAUSING THE CAR TO STALL. CALLED CHRYSLER AND THEY SAID THAT THE BULLETIN DID NOT COVER MY MODEL. CAN NOT USE CAR NOW BECAUSE IT IS A SAFETY HAZARD. NEED HELP ON THIS ISSUE.

NHTSA ID

11463655

Incident

Jan 3, 2022

Our 2005 Chrysler 300 stalls and will not restart for many minutes after we refuel it. Chrysler stated they have extended the warranty to a life time coverage if you are experiencing this issue you are able to get it covered under said warranty. We have contacted them and they state this one is not covered. How can we go about getting this covered. It obviously has the issue they have recalled and should be covered!! Thank you, Shannon Hainzlsperger

NHTSA ID

11421131

Incident

May 1, 2021

My 2005 Chrysler 300 has been having an issue with the fuel tank. When you get fuel in it then it won’t stay started. It keeps stalling out repeatedly. It also stalls out randomly under 25mph. Both are dangerous as it may cause you to get T-boned leaving gas station as it repeatedly stalls. Also it stalled out on the freeway on-ramp under 25mph. This is also dangerous as you lose your steering at the same time. Someone could have been injured or killed. And Chrysler needs to take this more seriously than they did just with the 2005 300c. It’s happening to more models of that year as well. Their offered remedy was telling me not to fuel it all the way up anymore past 3/4 of a tank. A dealership confirmed it needs a full fuel tank replacement and has had it since Memorial Day. They still have it currently. Chrysler told me and the dealership I’m on my own after treating me horribly most of the time on the phone calls with customer care center as I was jumping through hoops for them over and over for around 2 months. Whenever I get someone kind and helpful they won’t let me speak to them again. I have this all written down. And will get the estimate when I get my car back. But I don’t have $2800 ($2000 alone is just the fuel tank) to fix this on my own. Especially not when there is a known issue. Fuel tanks just don’t break and need full replacement as a common issue in vehicles. But Chrysler says my vehicle is too old. Which they knew the year of my vehicle when I called in the first place. And they know there is a known issue which is why they have lifetime fuel tank replacements on others of the same year. It’s too bad they weren’t pushed to do a total recall rather than just a safety bulletin. It left the rest of us that end up having issues with the fuel tanks in danger. It’s not just coincidental. It’s been acting up for awhile and I couldn’t find anyone that had ever heard of this until the Chrysler forums. It got worse in 2020 to present. Thank you.

NHTSA ID

11420210

Incident

Jan 1, 2020

IN THE BEGINING MY CAR STALL AFTER FILLING THE TANK UP WITH GAS. IT WOULD STALL AT LOW IDLE LIKE FOR INSTANCE WHEN I COME TO A STOP. BUT IT ALSO HAVE DONE IT WHEN I'VE BEEN ON THE HIGHWAY WHEN I RELEASE THE GAS PEDAL WHICH IS VERY DANGEROUS TO ME AND EVERYONE AROUND ME. ESPECIALLY ON A MAJOR CITY HIGHWAY LIKE ATLANTA. I;VE BEEN TRYING TO GET THIS RESOLVE SINCE EARLY LAST YEAR.

NHTSA ID

11405871

Incident

Mar 1, 2020

Mileage

15,000 mi

I WAS DRIVING DOWN THE ROAD AND MY VEHICLE DIED. NOW IT DOES EVERY TIME I COME TO A COMPLETE STOP. THE STEERING MAKES A CLICKING NOISE WHEN I TURN

NHTSA ID

11364836

Incident

Oct 15, 2020

Mileage

181,000 mi

GAS TANK LEAKS. NO HOLES, CAR STALLS LOSES GAS TANK LEAKS CONTUINLY WAS CHECKED FOR HOLES NONE WE COULD SEE. SMELLS LIKE GAS ALL THE TIME. CAR HAS 101.000. MILES

NHTSA ID

11341745

Incident

Jul 1, 2020

Mileage

101,000 mi

II OWN A 2005 300C WITH 1001,500 MILES. I HAD A PROBLEM WITH THE CAR RUNNING OUT OF GAS WHEN THE GAGE WAS STILL SHOWING GAS IN THE TANK WILE DRIVING IN CITY STREETS, AND ONCE IN HIGHWAY. LUCKILY I WAS IN THE RIGHT LANE. I COMPLAINED TO THE DEALER IN TWO OCCASIONS OF THIS OCCURRENCE. FINALLY THE TANK WAS REPLACED AROUND 2014. AFTER THAT, I WENT BACK TO THE DEALER ON SEVERAL OCCASIONS COMPLAINING THAT AFTER FILLING MY TANK WITH GAS THERE WAS A STRONG SMELL OF FUEL. THEY KEEP TELLING ME THERE WAS NOTHING WRONG. FINALLY IN OCTOBER 2019. I TOOK CAR BACK AND WAS TOLD THERE WAS A CRACK ON THE AT TOP OF FUEL TANK PUMP HOUSING R/H, AND GAS WAS LEAKING FROM THE ATTACHING RING AND THE RUBBER HOSE AND ACCUMULATING ON SOME CAVITIES AT TOP OF PUMP. THE DEALER QUOTED ME ABOUT A THOUSAND DOLLAR FOR THE JOB, AND NEEDED KEEP MY CAR FOR 3 DAYS. I GOT A SECOND OPINION AND WAS TOLD THIS HAS BEING HAPPENING FOR A LONG TIME. I EVENTUALLY HAD THE CAR REPAIRED AT THE SECOND LOCATION FOR LESS THAN $450 DOLLAR INCLUDING PARTS, AND THE WAS CAR FIXED IN 4 HOURS NOT 3 DAYS AND A THOUSAND DOLLARS. ALSO! I HAD AN INCIDENT WERE THE FACTORY BATTERY IN THE CAR EXPLODED IN THE TRUNK OF THE CAR WILE I WAS DRIVING. APPROXIMATELY 2011.

NHTSA ID

11287753

Incident

Oct 1, 2019

Mileage

100,600 mi

CAR SHUT OFF WHILE DRIIVING 30MPH ALSO WITH FULL WILL JERK AND STALL

NHTSA ID

11277783

Incident

Oct 22, 2019

Mileage

102,845 mi

I WAS DRIVING SLOWLY, UNDER 10 MILES PER HOUR, WHEN IT JUST UP AND DIED ON ME. TRIED TO RESTART, BUT WOULD NOT. LET IT SIT FOR 5 MINUTES, PUSHED THE GAS PEDAL AND HELD IT HALF WAY DOWN AND VEHICLE STARTED. BUT WOULD NOT IDLE. TRIED TO HOLD PEDAL AND PUT IT IN DRIVE.TO LIMP IT HOME, BUT DIED WHEN ENGAGING DRIVE. LONG STORY SHORT, IT WONT START OR RUN UNLESS YOU GIVE IT GAS, WILL NOT IDLE IN PARK, NEUTRAL, REVERSE OR DRIVE, AND THERE HAVE BEEN HUNDREDS OF COMPLAINTS FOR THIS. THAT BEING SAID, I'M ASSUMING SOMEONE HAS TO DIE IN AN ACCIDENT, MAYBE SEVERAL LIVES LOST BEFORE YOU DECIDE TO TAKE THIS SERIOUSLY. YOU PEOPLE DO REALIZE WHAT HAPPENS WHEN AN ENGINE STALLS WHILE DRIVING YES? LOSS OF BRAKES FOR THE MOST PART, POWER STEERING, ACCELERATION, THE LIST GOES ON...NOW PUT SOMEONE BEHIND THE WHEEL THAT DOESN'T KNOW HOW TO REACT. BUT I GUESS Y'ALL MISSED THAT PORTION OF THE CLASS, OR YOU JUST DONT GIVE A [XXX]. INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

NHTSA ID

11277281

Incident

Oct 31, 2019

Mileage

192,000 mi

STALLS AFTER GETTING FUEL BOTH STATIONARY AND IN MOTION 109000 MILES

NHTSA ID

11171447

Incident

Jan 22, 2019

Mileage

109,664 mi

TL* THE CONTACT OWNS A 2005 CHRYSLER 300. THE CONTACT STATED THAT THERE WAS AN ABNORMAL NOISE AND A BURNING ODOR COMING FROM THE VEHICLE. ALSO, THE VEHICLE FAILED TO CRANK INITIALLY AND WOULD STALL INTERMITTENTLY. THE MANUFACTURER INDICATED THAT THE VEHICLE HAD BEEN SERVICED ON AUGUST 3, 2010 FOR A FUEL SYSTEM RECALL CAMPAIGN IN WHICH BOTH FUEL PUMP MODULES WERE REPLACED. SAHARA CHRYSLER JEEP DODGE RAM (5050 W SAHARA AVE, LAS VEGAS, NV 89146, (800) 506-5050) DIAGNOSED THAT BOTH FUEL PUMP MODULES NEEDED TO BE REPLACED AGAIN. THE CONTACT FELT THAT BY REPLACING THE SAME OEM FUEL PUMP MODULES, THE FAILURE WOULD RECUR. THE DEALER HAD NOT BEEN AUTHORIZED TO SERVICE THE VEHICLE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND THE CONTACT WAS WAITING ON A RESPONSE TO DETERMINE THEIR GUIDELINES FOR THE DEALER'S REPAIR. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

11161982

Incident

Aug 3, 2010

AFTER FILLING GAS TANK, WHEN WEATHER IS BELOW 40 DEGREES F, VEHICLE STUMBLES, STALLS AND IS HARD TO RESTART WHILE DRIVING IN TRAFFIC.

NHTSA ID

11156446

Incident

Nov 30, 2018

Mileage

52,090 mi

VEHICLE STALLS EVERY TIME AFTER FILLING UP GAS TANK. STALLS WHEN DRIVING SLOWLY OR AT IDLE WHEN TURNING EX. WHEN TURNING AT INTERSECTION OR TURNING INTO DRIVEWAY. THIS IS A DEFINITE SAFETY ISSUE AS THE CAR CAN SHUT OFF IN THE MIDDLE OF A BUSY INTERSECTION AND COULD POSSIBLY CAUSE AN ACCIDENT. VEHICLE CAN SOMETIMES BE TURNED ON RIGHT AFTER IT HAS SHUT OFF OR CAN TAKE UP TO 10 MINUTES FOR IT TO CRANK UP. 10 MINUTES IN A BUSY INTERSECTION IS A LONG TIME WAITING FOR A VEHICLE TO CRANK UP.

NHTSA ID

11145371

Incident

Oct 16, 2018

Mileage

134,000 mi

TL* THE CONTACT OWNS A 2005 CHRYSLER 300. WHEN THE VEHICLE'S FUEL TANK WAS FILLED, THE VEHICLE WOULD ABRUPTLY STALL. THE CONTACT STATED THAT THE FAILURE OCCURRED WHILE EXITING THE SERVICE STATION, WHEN ATTEMPTING TO ACCELERATE AFTER A COMPLETE STOP, OR WHILE DRIVING AT LOW SPEEDS. THE FAILURE ONLY OCCURRED WHEN THE FUEL TAKEN WAS FILLED. IF THE VEHICLE WAS DRIVEN FOR SEVERAL HOURS, THE STALLING FAILURE WOULD NOT OCCUR. THERE WERE NO WARNING INDICATORS ILLUMINATED BEFORE, DURING, OR AFTER THE FAILURE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING OR REPAIRS. THE FAILURE MILEAGE WAS 154,000.

NHTSA ID

11099527

Incident

Feb 1, 2018

Mileage

154,000 mi

CHRONIC ODOR OF RAW FUE BOTH WITHIN AND AROUND THE VEHICLE .. DIFFICULT TO ISOLATE. WHEN THE VEHICLE IS IN AN ENCLOSED SPACE THE FUMES ARE OVERPOWERING AND EXTREMELY FLAMMABLE. I HAVE BEEN ABLE TO IDENTIFY THE SOURCE TO A CONNECTOR ON THE FUEL LINE.. THIS IS CLEARLY A POOR ENGINEERING DESIGN WHICH, WHILE EXPEDIENT IN MANUFACTURING IS HAZARDOUS TO OWNERS AS FUEL IS EXPELLED ONTO THE ADJACENT EXHAUST SYSTEM

NHTSA ID

11092014

Incident

May 2, 2018

Mileage

160,000 mi

TL* THE CONTACT OWNS A 2005 CHRYSLER 300. THE CONTACT STATED THAT WHILE DRIVING AT 10 MPH, THE VEHICLE STALLED. THE CONTACT MENTIONED THAT THE OIL PRESSURE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WERE NO ERROR CODES WERE DETECTED DURING DIAGNOSTIC TESTING. THE CONTACT STATED THAT THE VEHICLE WAS THEN TAKEN TO JIM SHORKEY AUTO GROUP DEALER LOCATED AT 13339 LINCOLN HWY, NORTH HUNTINGDON, PA 15642, PHONE NUMBER: (724) 616-0083, WHERE THE DIAGNOSES WAS UNKNOWN. THE CONTACT STATED THAT HE FOUND A X53 EXTENDED WARRANTY (FUEL TANKS) FOR 2005-2006 CHRYSLER 300, THAT PRESENTED THE SAME FAILURE AS HIS VEHICLE OF ENGINE STALLING AT LOW SPEEDS. THE MANUFACTURER WAS NOTIFIED AND CONFIRMED THAT THE VEHICLE WAS NOT INCLUDED DUE TO THE FACT THAT THE VEHICLE FUEL TANK WAS NOT THE CORRECT SIZE AND OFFERED NO FURTHER ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 45,000.

NHTSA ID

11012441

Incident

Jun 26, 2017

Mileage

45,000 mi

TL* THE CONTACT OWNS A 2005 CHRYSLER 300. WHILE DRIVING APPROXIMATELY 50 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD, PLACED THE GEAR SHIFTER INTO NEUTRAL AND WAS ABLE TO RESTART THE VEHICLE. THE VEHICLE WAS TAKEN TO A DEALER, BUT WAS NOT DIAGNOSED OR REPAIRED. THE CONTACT TOOK THE VEHICLE TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT EITHER THE VALVE OR THE FUEL TANK WITH A NEW VALVE WOULD NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER INFORMED THE CONTACT THAT THE VEHICLE WAS COVERED UNDER AN EXTENDED WARRANTY, BUT THEY DID NOT HAVE THE CAPACITY TO SERVICE THE VEHICLE. THE APPROXIMATE FAILURE MILEAGE WAS 147,000. UPDATED 07/13/17*LJ UPDATED 08/29/2017*JS

NHTSA ID

10990930

Incident

May 23, 2016

Mileage

147,000 mi

AFTER FILLING GAS TANK CAR REPEATEDLY STALLS CREATING A SERIOUS TRAFFIC HAZARD.

NHTSA ID

10990864

Incident

May 21, 2017

Mileage

196,423 mi

X53 EXTENDED WARRANTY FUEL TANKS. VEHICLE STALLS WHILE MOVING ESPECIALLY AFTER REFUELING. VEHICLE WILL STALL AT ANYTIME ESPECIALLY AFTER TANK HAS BEEN COMPLETELY REFUELED, WHETHER IT BE ON SIDE STREETS AT SLOWER SPEEDS OR ON FREEWAY AT HIGHER SPEEDS. ACCORDING TO FIAT/CHRYSLER X53 EXTENDED WARRANTY IS ONLY APPLICABLE TO CERTAIN VEHICLES MANUFACTURED AT SPECIFIC MANUFACTURING FACILITIES, BUT DOES NOT INCLUDE CHRYSLER 300 VEHICLES THAT WERE MANUFACTURED AT OTHER FACILITIES OTHER THAN ONES SPECIFIED. THIS PARTICULAR VEHICLE WAS MANUFACTURED AT ANOTHER CHRYSLER FACILITY THAT WAS NOT AT ONE OF THE SPECIFIED MANUFACTURING FACILITIES. REGARDLESS OF WHICH FACILITY THIS VEHICLE WAS MANUFACTURED, IT STILL IS EXPERIENCING THE SAME ISSUE. THE VEHICLE STALLS AFTER FUEL FILL UPS. THIS PRESENTS A SAFETY HAZARD TO VEHICLE OCCUPANTS. REAR END COLLISIONS COULD OCCUR ENDANGERING THE SAFETY OF THOSE IN THE VEHICLE, ESPECIALLY IF VEHICLE IS MOVING AT HIGH FREEWAY SPEEDS. THIS PARTICULAR VEHICLE BELONGS TO AN INDIVIDUAL WHO IS INVALID AND HASN'T BEEN USED EXTENSIVELY. CURRENT MILEAGE IS APPROXIMATELY 29,000MILES AND STALLING HAS BEEN A RE-OCCURRING SINCE IT WAS PURCHASED. THE LATEST INCIDENT HAPPEND ON 03/08/2017.

NHTSA ID

10967271

Incident

Mar 8, 2017

Mileage

29,000 mi

TL* THE CONTACT OWNS A 2005 CHRYSLER 300. WHILE DRIVING 15 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE FAILURE OCCURRED AFTER THE VEHICLE WAS FILLED WITH FUEL. THE VEHICLE WAS TAKEN TO BE REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 42,000.

NHTSA ID

10946378

Incident

Jan 5, 2017

Mileage

42,000 mi

AFTER I FUELED MY VEHICLE MY CAR STALLED IN THE MIDDLE OF ROAD..I HAD IT TOWED TO REPAIR CENTER BUT COULDNT FIND THE PROBLEM..LUCKILY NO ONE WAS BEHIND ME.

NHTSA ID

10927589

Incident

Nov 16, 2016

Mileage

120,000 mi

Y'ALL HAD A RECALL ON THE GAS TANK EVER SINCE I HAD A GAS TANK REPLACED I CONTINUE TO SMELL GAS FUMES COMING FROM THE FUEL LINE HAS A LEAK IN IT AND I'M TRYING TO FIND OUT DO Y'ALL HAVE A RECALL ON IT AT ALL AND I HAVE A VIBRATION COMING IN FROM MY BRAKE SYSTEM AND I CAN'T SEEM TO FIND OUT WHAT IS COMING FROM BUT IT SAYS POSSIBILITY THAT I HAVE AN ISSUE WITH THE BREAK LINE.

NHTSA ID

10887794

Incident

Jun 24, 2016

TL* THE CONTACT OWNS A 2005 CHRYSLER 300. THE CONTACT STATED THAT IMMEDIATELY AFTER REFUELING AND DRIVING AT VARIOUS SPEEDS, THE VEHICLE STALLED. THE CONTACT WAS ABLE TO RESTART THE VEHICLE. THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE VEHICLE WAS TAKEN TO A DEALER WHO DIAGNOSED THE VEHICLE. HOWEVER, THE CONTACT WAS UNSURE ABOUT WHAT PART NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.

NHTSA ID

10852859

Incident

Aug 15, 2005

TL* THE CONTACT OWNS A 2005 CHRYSLER 300. WHILE DRIVING 10 MPH, THE VEHICLE JERKED AS IF IT WERE RUNNING OUT OF FUEL AND STALLED WITHOUT WARNING. THE FAILURE ONLY OCCURRED AFTER THE VEHICLE HAD BEEN FILLED UP WITH FUEL. THE FAILURE OCCURRED SEVERAL TIMES. THE VEHICLE WAS NOT TAKEN TO A DEALER. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 129,000. UPDATED 05/10/16*LJ *CN

NHTSA ID

10849748

Incident

Feb 17, 2016

Mileage

129,000 mi