Tank Assembly problems of the 1996 Chrysler Town & Country - part 1

Last week, 17 Aug 05, I had to replace the fuel tank on my '96 Chrysler t&c (VIN 1c4gp64l8tb146902) due to a fatigue crack that was spilling fuel. Chrysler has refused to accept any responsibility since my vehicle is out of warranty. Are there any requirements regarding the longevity and performance of plastic fuel tanks? other than the obvious safety concerns, the replacement cost exceeded $800. At the time of failure my vehicle had 180,885 original miles and has been meticulously maintained. The location of the crack (top, front, left corner) precludes any accidental impact of the undercarriage. According to the servicing dealer, hayes Chrysler, lawrenceville, GA, the defective tank was destroyed per environmental requirements. Please advise if there is a course of action I can take to ameliorate this problem.

1996 Chrysler town and country had a split seam on the top side of the gas tank. Vehicle had a strong odor of gasoline due to the split. Replaced the gas tank, was charged for new tank and labor. Manufacturer said due to mileage on vehicle, there would be no consideration for reimbursement.

Fuel was leaking from the fuel tank, which could be dangerous because it could cause a fire. Manufacturer was contacted by consumer.

The VIN for this vehicle 1c4gp54r9tb326968 car suffered fuel line breakage after driving through a large puddle. Was towed to o'hara Chrysler-Plymouth dealer(clinton, mi) for repairs, which the fuel line damage was determined. Inquired with the service rep, jake, as to why since owning the vehicle. The maximum tank fill-up was 13. 0 - 13. 4 gallons, whereas the service manual states 18 gallons. "jake" stated that there was a tendency of the tank to bow-in, that would either reduce the fuel sensor accuracy or reduce the volume. A new tank carried a different part number than the original. Since this vehicle was assembled on January 11, 1996 and there is a NHTSA technical service bulletin #140895 issued on January 1, 1996. Am I covered by this and was I charged for a known defect? I had brought the TSB number to the service manager chris, who indicated that the TSB number was something he was not familiar with and did not meet d-c recall three digit numbers.

The vehicles plastic tank collapsed on the inside. This resulted in incorrect fuel level reading. The dealer replaced the pump at no charge but the sending unit in the tank has the same reading. The dealer had the fuel tank down, and stated that the tank was sagged, and possibly caused the false reading. Chrysler sent out letters about the problem but when the consumer called the dealer, they stated that this was a manufacturer problem.

Consumer smelled gas, dealer found that fuel was leaking from the vent seal at the top of the tank, dealer replaced fuel tank, the consumer is requesting reimbursement for this repair since it appears to be safety related. Nlm.

While driving at any speed and with no warning fuel tank had cracked, causing fluid to leak out. Consumer will have to refill tank more then usual. Dealer notified.

Welding on gas tank cracked, and vehicle started to leak some fuel. Contacted dealer, and the dealer replaced the tank.

Fuel leaking from gas tank. Took vehicle to Chrysler dealer to be checked. Was advised that fuel tank was leaking at a seam. This vehicle had an earlier recall concerning fuel leaking where the fuel pump was mounted to the tank. Repairs were made according to the recall. It seems that a fuel tank should not just start leaking for no apparent reason (there was no physical damage to the fuel tank). The tank is to be replaced by the local Chrysler dealer for a sum of $700 plus. This is a very serious safety issue in which a fire could easily occur. If this is a common occurence, it should be taken care of by the Chrysler corporation. Thank you for your time and consideration in this matter.

The fuel tank has compressed due to fuel leakage. The dealer refused to do recall 99v216000 because of this problem.

Consumer states fuel is leaking from the top of the fuel tank, dealer notifed.

The van experienced a leak at the gas tank, which had worsen over time. The dealership was unable to fix problem.

Plastic fuel tank is warping, this will be the third time the tank needed to be replaced due to this condition. Dealer notified. Consumer states this condition is dangerous because all of the weight in the rear of the tank rests in two small spots.

Plastic fuel tank has developed a crack along the top (per dealer). I did notice on one or two occasions that the tank bottom developed a concave appearance. The dealer has offered to replace the fuel tank for approx. $800 with no guarantee that the replacement tank won't fail for the same reason the original tank has. I would be intereseted in hearing from you about the safety record and longevity of plastic gas tanks. I have never owned a vehicle in which the gas tank has developed a crack.

Vehicle is leaking fuel from the fuel rail. Consumer was smelling some fuel inside cab when driving before taking vehicle into a dealer.

Inside sidewall on left front wheel suddenly split away. On four different occasions while driving the transmission suddenly downshipt without any warning to a lower gear causing the speed of the car to immediately drop from 65-70 mph to 50mph or less and on other occassion the transmission lockup, problem diagnosed as relay control for tcm, replaced, to no avail. Transmission leaks oil and other fluid, replace shat seal,gasket and resealed pan. Replace fuel gas tank to achieve reliable fuel gauge measurement. Steering locks up especially on hard left turn, replace rack and pinion.

Vehicle started leaking gasoline when it was on a hill. Dealership was aware of problem. Mechanic told the consumer that she had a crack inside of gasoline tank.

There was a gas leak coming from gas tank. Took vehicle to dealer, and they replaced seal. It only lasted 60,000 miles, and leaked again, vehicle had been back to dealer 3 times for same problem. Consumer felt this was very dangerous, it could cause a fire. Consumer also stated the transmission went out.

Consumer was traveling about 8mph on street and smelled gasoline fumes coming from underneath engine. Gasoline was coming from fuel rail. Dealership will repair it at consumer's expense.

The consumer was smelling gasoline, and vehicle was leaking gasoline. Fuel tank was made out of plastic and it warped. Vehicle is at the dealership getting repaired.

Consumer drove vehicle inside of garage, and was complaining about a gasoline smell inside of vehicle. Took vehicle to dealership. Mechanic said that fuel tank, which was plastic, leaked fuel.

When van was parked a huge amount of fuel leaked onto the garage floor. When van was checked by a mechanic, he discovered that fuel tank was cracked at the seam. Fuel tank will be replaced. Please provide any further information.

Smelling gas inside vehicle. Consumer took vehicle to shop,and mechanic told conusmer that there was a recall 00v268000 which dealt with same problem. Contacted dealer and the dealer fixed the problem.

We have only owned this vehicle for one and a half years for these safety issues to arise leads us to believe there has been more problems with the vehicle than we are aware of. Also in checking other complaints the safety issues seem to be similar to others that have been posted. No safety defec(s) listed in summary.

Too much weight in the fuel tank caused fuel tank to warp and fumes to enter into vehicle. Please provide further information.

The fuel tank senser is not operating correctly. I experienced symptoms that suggested I had run out of gas with the gas gauge reading 1/4 tank and the distance to empty reading on the internal computer at 76 miles. I pulled into a gas station and was able to put in 20. 5 gallons of gas. The tank capacity is listed at 20 gallons. I monitored the gas consumption over the next tank. I drove 330 miles and the gauge read between 1/4 and 3/8 of a tank and the distance to empty reading was 106 miles. I was able to put in 17. 7 gallons which indicates about 2. 3 gallons were remaining in the tank. That is no where near 1/4 or 3/8 of a tank. I understand that some 1996 jeeps were recalled for a similar defect. It may be possible that the Jeep and Chrysler products share some of the same componants. This is the third gas tank that the van has had. The first tank was replaced due to a faulty sensor which always showed much less gas remaining than was actually in the tank. That tank was replaced. The next tank leaked and also was replaced. The latest tank now appears to show much more gas remaining than is actually in the tank. I have informed my local Chrysler dealer. They inspected the external wiring of the sensor and said it looked normal. My comments have been noted in the vehicle maintainence records. However, I was informed that any sensor problem will require disassembly of the gas tank.

While the vehicle was in park gasoline leak out of the tank, which had a leakage.

Fuel tank was leaking from a seam across the top noticed when tank was completely filled.

Parked vehicle overnight in driveway. When consumer returned the next day fuel was leaking from the fuel tank. Please provide further information.

Possible design flaw of gas tank leaking from the top of the tank out of the circular gasket.

Van was parked on level surface in hot weather with full gas tank, noticed a gas leakage. Consumer has contacted dealer.

I was told that this assembly is plastic in composition and can have cracks or punctures in every day use; this seems to be an unacceptable option and should be considered a design flaw. I have a 1987 automobile with over 140,000 miles and it has never had its gas tank replaced. This vehicle has been driven in the same areas as my Mini-van.

Fuel tank began leaking gasoline when tank is filled. Gasoline fumes present most of the time. Dealer says that fuel tank filler overflow valve is defective and entire gas tank must be replaced as there is no way to repair the valve itself. This seems like a safety issue and a design flaw if the entire gas tank ust be replaced for a defective valve in the filler tube.

Whenever fuel tank is filled fuel will leak from the top of the tank. Dealer was notified about the problem. The dealer stated that the reason why the fuel tank was leaking was because it was plastic and bowed. The problem has not been corrected.

After filling the tank to a certain level fuel begins to to quickly flow from the front top edge of the tank onto the ground. Owner literally gets under the vehicle and sees the fuel gushing. Dealer was notified.