Other Fuel System Tank Assembly problems of the 2004 Dodge Caravan

Fuel leaking from top of fuel tank.

Engine often hesitates after you have driven a few blocks after refueling. This form asks for a single specific date but this problem has happened every few weeks for the last year or so. Depending upon the traffic situation when the hesitation occurs, and accident could easily occur. My mechanic says that the liquid/vapor separator valve on the gas tank is not operating properly. This valve is a part of the tank and cannot be replaced as a separate item, so the cost of the repair is substantial. A brief search on the internet indicates that many other owners of Dodge Caravans manufactured between about 2004 and 2007 are reporting this same problem.

I purchased my vehicle in the fall of 2013 and am starting to come to the conclusion that every time I fill my gas tank up my vehicle shuts off! today I filled up my gas tank. My children were in the back seat and when I pulled out into the highway the van shut off and the steering wheel locked up! I had no control over the vehicle. This seems to be a common problem with these vans and something needs to be done before someone gets hurt! I can't fill my gas tank up because of this issue.

As mentioned by several other postings, the Caravan engine will stall out after the gas tank is filled. This happens almost every time the vehicle is fueled. It will stall out within a few minutes of driving after leaving the gas station. It has stalled out in traffic, at stop lights, and now I avoid traveling on the roadway for several minutes after fueling if possible, choosing instead to travel through parking lots or back roads before entering any main arteries. A service repairman at the dealership said he had never heard of such a thing and had no idea what the problem could be. Another mechanic mentioned it might be a valve in the top of the tank that is defective but the only repair is to replace the whole gas tank as the part is not a separate piece. Based on my own online research, I think this is a defect with this make and model.

When one drives away after refueling the gas tank the vehicle quits running. It will restart. This will happen for the first ten miles or so. Other Dodges are having the same problem.

Not 100% but probably 40% - 60% of the time I refuel - especially a full tank - the car will tend to hesitate and stall within the first 90 seconds of getting back on the road. Seems like it has not done it a lot lately but I just had some work done by the local Dodge dealer including new wires and plugs. When I left the dealership it ran fine. I put in probably 3/4 tank of gas in it and it began hesitating and stalling worse than it had in some time. The weather was also quite a bit cooler than it had been in 6 months. I also read an article in USA today about this issue which I have been experiencing since 2007 when I purchased the car used. I have had the dealer look at it in the past and the could identify nothing specific. Figured I would register the complaint since I heard others were having the same issue.

The contact owns a 2004 Dodge Caravan. The contact stated that over the course of five years, whenever he filled the fuel tank the vehicle would stall immediately after. The failure recurred numerous times. The vehicle was taken to a dealer on three different occasions but the no cause for the failure was determined. The vehicle was not repaired. The failure mileage was 38,000 and the current mileage was 91,000.