Other Fuel System Tank Assembly problems of the 2007 Dodge Grand Caravan

Car stalls and sometimes dies after refueling. This always happens after pulling onto road into traffic. So far I have avoided being hit by another car! this has been happening for a long time. Dealer says replace fuel tank,poor design.

Stalling after refueling when I fill up my gas tank, almost immediately afterward pulling out of the gas station my van sputters, misses, hesitates, call it what you will. The past couple of times the engine has actually stalled as well.

After refueling the car will stall for short period. This is extremely dangerous as it may stall while pulling into he roadway. Nhtsa worked with Dodge on other models to extend the warranty to lifetime. My vehicle has the same issue and the repair is to replace the fuel tank at a cost in excess of $700. Dodge should have redesigned the fuel system to correct this issue as the same issue was lifetime warranties in prior year models.

The contact owns a 2007 Dodge Grand Caravan. While slowing down the vehicle to stop, the vehicle shut down without warning. The vehicle restarted, but the failure recurred several times. The vehicle restarted after each failure. The vehicle was taken to an independent mechanic who diagnosed that the fuel tank needed to be replaced. The manufacturer was made aware of the failure and stated that there were no recalls. The failure mileage was 74,000.

Every time the fuel tank is filled up, and after we start driving, the engine will just stall. It could lead to an accident if this happens in traffic. Luckily this hasn't happened yet. . Read more...

The last few times I have completely filled up my gas tank - the vehicle has stalled. I have had to tried to stop and restart the ignition/engine a number of times for the vehicle to run. This is happening with full gas full-up and happened to me again last night. I have seen this as being a common problem for Chrysler/Dodge minivans in a few on-line forums. Some reports have the vehicles stalling on highways and/or when driving. My vehicle is a 2007 Dodge Grand Caravan sxt.

The engine stalled twice within 5 minutes of refueling. The vehicle was filled with unleaded 87 octane gas to full. The gas pump auto stopped when full, and the tank was not topped off. The first stall happened while the vehicle was idling at a stop sign approximately 1 minute after fueling. The engine restarted, but stalled again approximately 2 minutes later. The second stall occurred while the vehicle was in motion at approximately 15-20 mph and turning left. The stall left the vehicle without power steering, and the vehicle coasted into a driveway. There was no accident because of light traffic. Under different circumstances or traffic patterns, a stalled engine leaving a moving vehicle powerless likely would cause an accident resulting in possible injury or death. This same problem has occurred approximately 5-6 times in the last 2 years, however I can not be specific on dates. It was only when my wife and I were together this last time that we both commented on the problem, and found that it has happened to each of us several times. I believe any manufacturer defect which causes a moving vehicle to lose power and become uncontrollable while in motion is an extremely serious and potentially deadly problem.

The contact owns a 2007 Dodge Grand Caravan. While refueling the vehicle, the fuel stopped flowing through the vehicle without warning. The vehicle was taken to the dealer to be diagnosed. The technician diagnosed that the fuel tank needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 115,000.

The vehicle stalls after re-fueling. We re-fuel at different gas stations (brands) and the issue remains. Every time we fill the tank and pull out of the gas station into traffic, the engine sputters after driving approximately two blocks, as if it is not receiving enough fuel. The engine then stalls. The engine can be restarted and will not sputter or stall until the next time we re-fuel it. We encounter this issue weekly, after every fill up. It is a potentially dangerous issue because the vehicle stalls in traffic and could cause a traffic accident.

Several times following a fill up, the van has stalled out, usually just a few hundred feet from the pumps. Unfortunately, this usually as we are pulling into traffic. From what I've read online, the only fix to this problem is to replace the entire gas tank system.

I filled the fuel tank & then proceded to drive home. After leaving the gas station the van stalled in traffic 4 times. This has happened every time I have filled the gas tank since 8/6/2014.

When it first began the van would stall and skip upon acceleration between 20-50 mph. Now the van stalls and/or skips at any point of acceleration. The engine light comes on right after there is fuel added to the tank and this is when the stalling is the worse. The engine light also comes on when there is1/4 tank of gas left and the distance to empty number jumps around when there is less than 1/4 of a tank.

In may 2014, at approximately 55mph, after refueling and driven 50 miles. The engine light came on. Stopped vehicle and checked everything that I could check, as I had just had it serviced approx. 300 miles prior. Continued on trip, after spending night in motel, took vehicle to repair facility and they did diagnostics. . . Came up with code 461, which was fuel lever sensor in gas tank. Continued on trip, (1300 miles), after that two times when I had filled up with gas again the vehicle died within 2 miles. . . No engine light ever came back on. This continued throughout the summer, occuring 80% of the time I refueled. . . Took to dealer as I have extended warranty, they are looking into it, but said because the engine light doesn't come back on, they can't evaluate it. Read somewhere since I took it back to the dealer, that if I don't fill the tank up fully, that will cure the problem? the engine dying happens while driving less than 20mph, so far. . . Could be a problem pulling out in traffic? this is now October, still experiencing problem.

On approximately 04/07/2014 the van was filled up with gas, I took the nozzle out when it shut off and did not put any extra gas into tank. I started up the van to exit the station we drove about 100 yards and the van jerked with a knocking sound twice and stalled. I started the van back up, when it did start the idle was rough and low. I held my foot on the gas peddle to slightly raise the rpm's for about 30 seconds before we proceeded. It took a couple of miles before the van seemed to be about normal. This has happened two other times since then. Another complaint, the front brakes squeek every time you apply them.

After fueling the vehicle, pulling out from the gas station, the van stalls violently: loses power, lurches & surges. This has become increasingly severe, most recently nearly causing a collision when the van stalled out as we were leaving the gas station in heavy traffic. The problem is the vapor/liquid separator valve located at the top of the fuel tank. The valve is designed to prevent liquid fuel from entering the charcoal canister/emissions system. When the valve fails, liquid gas can enter the line and fill the charcoal canister. After refueling the pcm on the vehicle detects a change in fuel level. Then, when the engine meets certain temperature and driving criteria, the pcm issues a purge command to the charcoal canister to remove the stored gas vapors. It’s at that point that all the liquid gas in the line gets sucked into the charcoal canister. The pcm expects to see gas vapors entering the intake manifold and it is prepared to adjust air/fuel mixtures to compensate. However, it is not prepared to see liquid gas coming into the intake. That’s what causes the engine to stall. Unfortunately, the only fix is to replace the entire gas tank. Chrysler does not sell the vapor/liquid valve as a separate unit. We are now at nearly 100,000 miles, and the problem persists and continues to get more severe. I have called Dodge, but they say there is no extended warranty on the fuel tank/evaporation canister.

Vehicle runs fine until you refuel and get back on the road then it's starts spitting and sputtering you have to completely let off the gas to keep from stalling it out. Also it dies when sitting on a hill with less than a half a tank of gas and won't crank back until it's on flat ground.

Right after gas tank fill up engine stalls,and on several occasions was on highway ,and power went off after stalling with loss of control of steering,and rapid deceleration with near miss of being rear ended. Someone is going to be killed,and according to the reported incidences on the internet someone will eventually be killed or severely injured.