Other Fuel System Tank Filling/charging problems of the 2006 Dodge Grand Caravan

We purchased van new from Dodge dealer in September of 2006. About 5 months ago my wife (normally drives) stalled pulling toward an intersection shortly after she drove from filling the gas tank. The van runs fine otherwise and now has about 112k miles. This happened to her a few more times (very stressful losing power steering and brakes). Therefore, one fill-up to check it I drove the car and it did the same a couple minutes after fill-up driving 1/4 mile slowly in nearby home depot parking lot (afraid I would hit someone trying to turn (similar conditions as my wife had). The van will restart after trying a couple of times and then run fine for the rest of the tank. We have been forced to stop filling the tank above 3/4, an inconvenience to plan for but seems to eliminate that problem; but I am not sure how much longer that will work. In doing research I understand other Dodge van owners in that year range have had this problem. Apparently, due to the design of the valve that is failing the entire gas tank must also be replaced which is very costly. I feel that Chrysler used a very poor design or part where if only the valve fails that the entire gas tank must be replaced. The van runs fine, we like the van and were planning to drive it many more miles but at this point the costly repair involved is a good portion of the vehicle value. I think that Chrysler should help us in repairing this issue. It is obviously a safety issue when driving the car, and a design flaw in my opinion in that failure of a small component requires the whole gas tank system to be replaced. Please let us know Chrysler's position on this issue. We realize that the vehicle is out of Chrysler's warranty but feel this is something that should have been rectified when the issue became known a number of years ago. Thanks in advance.

After filling the tank with gas, the van engine runs rough and then stalls out. This has happened numerous times over the past three to four years. When it happened on tues, October 7, 2014, I had just pulled out of the gas station and was getting ready to cross a busy intersection when the car stalled. I had to quickly put it in to park and restart. Scared me to death. Again, this has happened at least fifty times to me. We have taken it to the dealership and they can never get the problem to happen for them which makes sense because it is only going to happen after refueling.

The contact owns a 2006 Dodge Grand Caravan. The contact stated while driving approximately 30 mph immediately after refueling, the vehicle suddenly stalled. After restarting the vehicle resumed normal function. The contact indicated that the defect had occurred on two separate occasions and the defect only occurred after filling the fuel tank. The vehicle was taken to the dealer. The technician diagnosed that the roll over valve inside the fuel tank was defective. The vehicle was currently being repaired by the dealer. The manufacturer was notified of the defect. The failure mileage was 143,000.

Investigation: dp 14-002; prompted defect petition; date opened: 09/05/2014; investigator: [xxx]; reviewer: [xxx]; approver: [xxx]; subject: engine stall after refueling. Please include me in the above mentioned complaint/investigation # dp 14-002. After refueling, my engine stalls about 1 to 2 minutes after starting almost every time I fill-up with fuel. When the fueling nozzle trips for the first time, I do not attempt to continue adding more fuel and possibly overfilling the fuel tank. I have been caught in heavy traffic at times with the engine stalling and it takes 2 to 3 attempts to restart the vehicle. This is very dangerous! now after refueling, I pull away from the pumps and park out of the way and allow the engine to stall. After attempting to restart several times, the engine will misfire for about 30 to 45 seconds, then the engine will smooth out and run fine until the next refueling. I want to thank you in advance for all of your help in this matter. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Filled fuel tank right off i24 in TN. Car stalled on entrance ramp to highway. Drifted to side and engine restarted quickly. This now happens almost every time the tank is filled. Around town I can cope by not filling the tank, but very inconvenient and very dangerous on trips especially on highways. We are not talking about overfilling the tank, but just filling to point when pump shuts off. When engine stalls, not only is there an immediate loss of momentum, the power steering system quits, but the brakes become useless. Every time this happens, I just wait for someone behind me to not slow down in time and rear-end me. Luckily, I have not been in the fast or middle lane when it stalls, because of possibly not being able to get to the shoulder to restart it. I am also paranoid that if I try to mess with putting it into neutral and fooling around with the key, I will become a very distracted driver. Chrysler's answer is to replace fuel tank at a cost of $1200. If I could afford that then I wouldn't be driving a 2006 automobile.

After filling the gas tank with gasoline, the car will often stall temporarily after traveling approximately 1/4 mile. This has happened numerous times, but the car has always restarted. I thought that I was using a poor brand of gasoline, but I just received notice of a recall for sticking fuel fill valve on my other vehicle, which has never (to my knowledge) experienced this problem.

After filling my gas tank, I drove approximately 2 miles and the car totally lost power and stalled. The entire dash panel died and I lost all steering capabilities. This has happened multiple times and I no longer fill my gas tank to the fullest capacity for fear that the car will stop.