Owner-reported complaints naming the fuel system system, filed with NHTSA
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Reports naming fuel storage or delivery — tanks, pumps, lines, injectors and fuel leaks. Every record below is an owner-reported complaint about the 2005 Dodge Grand Caravan submitted to NHTSA — not a confirmed defect, not a recall and not a manufacturer bulletin. 64 reports on file name it.
Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.
The 25 most recent of 64, in the owner's own words
For some reason my caravan has started leaking gas from on top of the gas tank. not sure why, but I heard the was a recall but it was over 15 years ago so you people don't list anything older. i've only had the car a couple months, and also having a catalytic converter problem as well..
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/
REPEATEDLY THE VEHICLE WILL LOOSE POWER AND STALLS OUT AFTER FILLING THE TANK WITH FUEL. IT WILL OCCUR WITHIN LESS AND 1/8TH OF MILE AFTER PULLING OUT OF THE GAS STATION. THE VEHICLE HAS DONE THIS REPEATEDLY IN INOPPORTUNE SITUATIONS, LIKE TRAVELING UP A STEEP HILL AND AT A BUSY INTERSECTION. WE ARE ORIGINAL OWNERS AND HAD NEVER HAD AN ACCIDENT WITH IT . IT HAS JUST UNDER 120K MILES ON IT.
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.
FACTORY FUEL PUMP IS CRACKED, WRIGHT ON THE CONNECTION TO THE FUEL LINE ,ITS A HAIR LINE CRACK,
I JUST ACQUIRED THIS VEHICLE. I UNDERSTAND GAS 6 RECALLS BASED IN THE NHTSA. DOORS READ MODEL 2004. I CALLED CHRYSLER DODGE DEALER IN HEMET, CALIFORNIA AND THE SERVICE RECEPTIONIST STATED THERE IS NOTHING TO DO THAT ARE NO RECALLS FOR THIS VAN. PLEASE HELP. THE LIGHT ENGINE IS ON. THE POWER TRAIN KICKS SOMETIMES (DRAGS) SUDDENLY. AND I SEE THE 6 RECALLS APPLICABLE TO THIS MODEL
I HAVE A FUEL LEAK UNDERNEATH FROM THE TOP OF FUEL TANK. I BELIEVE IT IS COMING FROM THE FUEL PUMP. LEAKS WHEN ENGINE IS RUNNING ONLY. DOES NOT LEAK WHEN AUTO IS NOT RUNNING.
MY VAN ALONG WITH MANY MANY OTHERS SHUTS OFF AFTER REFUELING SPUTTERS RUNS LIKE GARBAGE ALMOST CAUSING ME TO GET INTO A ACCIDENT PULLING OUT OF A GAS STATION ON A ROTARY TODAY
HAVE FUEL SMELL AT BACK MIDDLE OF VAN, FOUND FUEL LEAKING AT MIDDLE OF FUEL TANK, REPLACED FUEL LINE CONNECTED TO FUEL PUMP OUTPUT CONNECTOR. DID NOT STOP FUEL LEAK, FOUND CRACKED FUEL PUMP AT THE OUTPUT AREA. LEAKS AS LONG AS THE HIGH PRESSURE SIDE OF FUEL PUMP IS PRESSURIZED.
NOTICED GASOLINE SMELL EVERY TIME I STOP/PARK CAR & GET OUT. AFTER FEW WEEKS, CHECKED UNDERNEATH VAN & SAW GAS SLOWLY DRIPPING FROM ABOUT MIDDLE OF GAS TANK. IT WAS RUNNING DOWN THE SIDE FROMN THE TOP OF TANK. STOPPED DRIPPIONG AFTER STOPPED FOR FEW MINUTES, BUT FOUND OUT THAT WHILE VAN WAS RUNNING IT DRIPPED CONSTANTLY. GOOGLED THIS PROBLEM & OTHER ARE HAVING SAME PROBLEM WITH CRACKS IN FUEL PUMP. THIS COULD BE A SERIOUS PROBLEM WITH A SPARK/HOT EXHAUST PIPE/MUFFLER CLOSE BY.
2205 DODGE GRAND CARAVAN STALLS AFTER REFUELING. MULTIPLE OCCURENCES. HAPPENS IN MOTION STRAIGHT LINE, WHILE ACCELERATING.
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.
SMELLED RAW GASOLINE SMELL OUTSIDE OF VEHICLE AFTER RUNNING VEHICLE. OCCURRED ON TWO OCCASIONS ON AUG 23, 2016. LOOKED UNDER VEHICLE ON 8/30/16 AND SAW AND FELT LIQUID FUEL ON FUEL TANK IN VICINITY WHERE FUEL PUMP GOES INTO GAS TANK. LEAK OCCURS WHEN IGNITION IS IN THE ON (RUNNING) POSITION. DID ONLINE RESEARCH AND FOUND THAT OTHERS HAVE HAD SAME PROBLEM WITH FATIGUE CRACKS IN PLASTIC TOP OF FUEL PUMP, WHERE FUEL HOSE ATTACHES. WHEN KEY TURNED ON AND FUEL PUMP IS PRESSURIZED, FUEL BEGINS TO LEAK THROUGH THE HAIRLINE CRACK. DANGEROUS, AS MUFFLER AND EXHAUST PIPE ARE LOCATED LESS THAN ONE FOOT FROM THE SOURCE OF THE LEAK!! TOOK VEHICLE TO REPAIR FACILITY, WHO DETERMINED FUEL PUMP MODULE WAS LEAKING AS DESCRIBED ABOVE. COST OVER $500 TO HAVE NEW PUMP INSTALLED, EVEN THOUGH THE OLD FUEL PUMP WAS STILL WORKING, THOUGH LEAKING.
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.
VAN STALLS AFTER FUELING. EVERY TIME YOU FILL UP THE VAN, THE VAN WILL STALL FOR NO REASON. IT WILL RESTART WITHIN A MINUTE OR 2. IT WILL THEN HAVE NO PROBLEMS UNTIL THE NEXT FILL UP. READING REPORTS ON THE WEB, THIS IS HAPPENING ON ALL DODGE AND CHRYSLER VEHICLES EVEN CAUSING SOME TO STALL ON TRAIN TRACKS. NEVER HAD A PROBLEM WITH THE VAN UNTIL I HIT AROUND 100K MILES. ALL OTHER REPORTS ON THE WEB ARE IDENTICAL. CHRYSLER DODGE SHOULD RECALL BEFORE SOMEONE DIES
2005 DODGE GRAND CARAVAN STALLS AFTER REFUELING. THIS ISSUE HAS BEEN HAPPENING FOR ABOUT 3 YEARS WHEN THE FUEL TANK GETS LOW AND THEN REFILLED. MOST OF THE TIME THE STALL HAPPENS SHORTLY AFTER REFILLING AND I COME TO A STOP LIGHT OR STOP SIGN. THERE HAVE BEEN FEW OCCASIONS WHERE THE CARAVAN HAS STALLED WHILE IN MOTION WHILE TRAVEL UNDER 20 MPH. I CAN USUALLY RESTART THE CARAVAN IMMEDIATELY AFTER THE STALL. THE ONLY SOLUTION FROM ONLINE FORUMS SEEMS TO BE TO REPLACE THE FUEL TANK AND PURGE THE VALVE AND CHARCOAL CANISTER OF ANY RAW FUEL. SEEMS LIKE A COMMON PROBLEM WITHIN SIMILAR MODELS.
CAR WILL STALL A COUPLE OF TIMES AFTER FILLING UP TANK PROBABLY WILL GO AWAY AFTER DRIVING A COUPLE OF BLOCKS
EVERYTIME THE VAN IS REFUELED, IT WILL STALL ON ACCELERATION. THIS OCCURS FOR THE FIRST FEW MINUTES AFTER REFUEL AND THEN THE VAN RETURNS TO NORMAL OPERATION. THE PROBLEM IS THE FAILURE USUALLY OCCURS WHEN PULL OUT ON THE ROAD BECAUSE THAT IS THE FIRST POINT OF ACCELERATION.
LAST NIGHT - FOR THE 4TH TIME NOW - AFTER FILLING THE TANK AT THE GAS STATION, MY CAR JUST DIED. THE FIRST 3 TIMES IT WAS WHEN I STOPPED AT THE STOP SIGN LEAVING THE GAS STATION PARKING LOT. LAST NIGHT, IT WAS AFTER I WAS OUT ON THE MAIN ROAD AND IN HEAVY TRAFFIC. IT WAS STOP AND GO RUSH HOUR TRAFFIC, SO I WAS THANKFULLY ONLY GOING APPROX 15-20 MILES AN HOUR. POWER STEERING WAS LOST, BRAKES WERE PRACTICALLY NON EXISTENT. BARELY MANAGED TO PULL OFF INTO A PARKING LOT AND WAS ABLE TO SET THE PARKING BRAKE TO FINISH STOPPING. ONCE STOPPED AND IN PARK, WAS ABLE TO START IT RIGHT BACK UP. EVERY TIME THIS HAS HAPPENED IT HAS BEEN RIGHT AFTER FUELING UP. I NEVER THOUGHT MUCH ABOUT IT THE OTHER 3 TIMES, BUT THIS TIME WAS DIFFERENT, AND VERY DANGEROUS. I WAS ALMOST HIT FROM BEHIND BECAUSE I INSTANTLY LOST POWER, THEN I ALMOST HIT ANOTHER CAR TO MY LEFT BECAUSE OF THE UNEXPECTED LOSS OF POWER STEERING. I COULD HARDLY MANAGE TO GET INTO THE PARKING LOT AND ALMOST HIT THE CURB/SIGN/ANOTHER CAR. WAS SCARED TO DRIVE HOME THE REST OF THE WAY. NOW AFTER READING THE OTHER POSTS HERE, I'M AFRAID TO EVER GET GAS AGAIN!!! THIS IS UNACCEPTABLE DODGE...YOU OBVIOUSLY KNOW ABOUT THIS PROBLEM AND DO NOT CARE ABOUT YOUR CUSTOMERS. WELL, THIS IS ONE CUSTOMER YOU WILL NEVER HAVE AGAIN. I'M IN THE MARKET FOR A NEW CAR, AND GUESS WHAT WILL NOT BE SITTING IN MY DRIVEWAY EVER AGAIN?
FILLED UP WITH GAS, DROVE ABOUT 2 MINS, SLOWED TO TURN LEFT AT INTERSECTION WITH STOP LIGHT. MY MINIVAN THEN STALLED WHILE IN THE MIDDLE OF THE INTERSECTION. THIS IS THE THIRD TIME THE CAR HAS DIED AFTER FUELING. I REPLACED MY BATTERY AND ALTERNATOR UPON RECOMMENDATION BY LOCAL AUTO PARTS STORE, BUT THE PROBLEM PERSISTS. DODGE DEALER SERVICE TECHNICIAN SAYS "IT'S A COMMON PROBLEM AND BEING INVESTIGATED" AND SAID I NEED A NEW GAS TANK DUE TO A BAD VALVE AND RECOMMENDED REPLACING THE FUEL PUMP AND FILTER WHILE DOING THE MAINTENANCE, OVER $1000. I DREAD GETTING GAS AND WON'T LET MY WIFE DRIVE THE KIDS IN THE VAN ANYMORE. IT'S A DEATH TRAP WAITING TO HAPPEN.
TURNED VEHICLE ON, VEHICLE WOULD NOT TURN OVER AT FIRST, LIKE IT WASN'T CATCHING. UPON SECOND TRY TO TURN OVER ENGINE IT DID FINALLY TURNED OVER AND VEHICLE WAS RUNNING. THAT'S WHEN I NOTICED A STRONG SMELL OF GAS ON THE DRIVER'S BACK PASSENGER SIDE. INSPECTED UNDERCARRIAGE AND NOTICED WHAT APPEARED TO BE FUEL HAD RUN DOWN TANK AND WAS SLOWLY DRIBBLING. THERE WAS A SMALL PUDDLE OF FUEL ON GROUND DIRECTLY WHERE DRIBBLE WAS. THE FAMILY WAS ON THE WAY HOME FROM BEING OUT OF TOWN AND WE DECIDED THAT WE WOULD DRIVE IT HOME BEFORE DEALING WITH ISSUE. ONCE VEHICLE WAS BROUGHT HOME I PULLED FUEL PUMP OUT OF GAS TANK AND NOTICED SMALL HAIR LINE CRACKS. THEY APPEARED TO LOOK LIKE DIRT OR DUST HAD JUST SETTLED INTO A "SEAM" OF WHERE THE TWO PARTS OF THE PLASTIC/MATERIAL MET, BUT WAS IN FACT A HAIR LINE CRACK. THE FUEL PUMP WAS LEAKING. THE NEW FUEL PUMP HAS CURRENTLY BEEN ORDERED AND I WILL REPLACE IT FIRST THING IN THE MORNING. THE MILEAGE ON THE VAN IS AT AROUND 137,000 MILES. THIS JUST SEEMS TO BE PRETTY IMPORTANT AS IT'S LEAKING FUEL WHICH IS A POTENTIAL FIRE HAZARD.
AFTER FILLING THE FUEL TANK UP, THE VEHICLE STALLS, STUTTERS, OR SHUTS DOWN AFTER ENTERING INTO TRAFFIC. AFTER IT DOES SHUT DOWN, IT IS TYPICALLY DIFFICULT TO RESTART. THE TYPE OF DRIVING ENVIRONMENT DOES NOT MATTER - CITY/COMMUNITY STOP AND GO TRAFFIC OR HIGHWAY SPEEDS FOR EXTENDED PERIODS OF TIME. AFTER THE VEHICLE IS RESTARTED, WE DO NOT HAVE A PROBLEM AGAIN UNTIL THE NEXT TIME THE VEHICLE NEEDS TO BE REFUELED. THE GAS TANK, FUEL FILTER, AND FUEL PUMP WERE ALL REPLACED BY THE DEALER PRIOR TO 100,000 MILES TO ELIMINATED A HIGH PITCHED WHINE COMING FROM THE FUEL TANK AREA EVERY TIME THE FUEL LEVEL DIPPED BELOW HALF A TANK. MOST OF THE TIME, THE VEHICLE DECIDES TO STALL OR SHUT OFF AS WE ARE ACCELERATING TO JOIN TRAFFIC - LEAVING FROM THE GAS STATION. ON MULTIPLE OCCASIONS WE HAVE ALMOST BEEN HIT FROM BEHIND BECAUSE THE VEHICLE JUST STOPS. THE EXHAUST MANIFOLD, CATALYTIC CONVERTER, UPSTREAM AND DOWNSTREAM O2 SENSORS HAVE ALL BEEN REPLACED WITH OEM/MANUFACTURER STANDARD PARTS.
ON TWO SEPARATE OCCASIONS WITHIN THE PAST MONTH, THE ENGINE ON MY 2005 DODGE GRAND CARAVAN STOPPED RUNNING WHILE I WAS DRIVING. ON BOTH OCCASIONS, IT WAS WITHIN A MILE AFTER FILLING THE GAS TANK. ON ONE OCCASION, IT OCCURRED WHILE I WAS MAKING A LEFT TURN ACROSS ONCOMING TRAFFIC; I WAS LUCKY TO BE ABLE TO COAST OUT OF THE INTERSECTION WITHOUT BEING BROAD-SIDED. SINCE THE ENGINE STOPPED RUNNING, ALL POWER ASSIST ALSO STOPPED, SO THE CAR WAS VERY DIFFICULT TO CONTROL. I HAVE SINCE READ ONLINE THAT THIS IS A RELATIVELY COMMON OCCURRENCE WITH DODGE CARAVANS, PARTICULARLY WITH OLDER CARS. AFTER FILLING UP THE GAS TANK, THE ENGINE MAY SUDDENLY STOP RUNNING WITHIN A SHORT DISTANCE OF THE GAS STATION. APPARENTLY IT HAS SOMETHING TO DO WITH THE GAS TANK VENTING, AND THE ONLY REMEDY IS TO REPLACE THE GAS TANK. THIS IS AN EXTREMELY DANGEROUS SITUATION; IT IS JUST A MATTER OF TIME BEFORE SOMEONE GETS KILLED. THERE SHOULD BE AN ALERT AND A RECALL TO CORRECT THIS PROBLEM. UPDATED 9/25/15 *LN
TL* THE CONTACT OWNS A 2005 DODGE GRAND CARAVAN. THE CONTACT STATED THAT THE FUEL TANK WAS CRACKED AND CAUSED FUEL TO LEAK OUTSIDE OF THE VEHICLE. AS A RESULT, THERE WAS A STRONG FUEL ODOR INSIDE AND OUTSIDE THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THERE WAS A HAIRLINE FRACTURE THAT NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 132,000.
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.
Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers.
Categories with enough reports to have a page of their own
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