Other Fuel System Tank Filling/charging Problems of Dodge Grand Caravan

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.

See all problems of the 2005 Dodge Grand Caravan 🔎.

After filling the fuel tank the vehicle stalls, and sputters when pulling into traffic, and driving down the road for up to 1 minute.

See all problems of the 2007 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.

See all problems of the 2006 Dodge Grand Caravan 🔎.

After filling the gas tank, within a few miles the vehicle will stall. Dodge already has extended the warranty on the fuel tank of vehicle built after September 2003 but mine was built August 5 2003 so it is outside their window. This is a very dangerous issue because it has happened to me on the highway at 55 miles an hour and I then have no power and need to get out of the way of traffic that is going to run me over.

See all problems of the 2004 Dodge Grand Caravan 🔎.

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.

After filling up the tank with gas, the car, almost always, stalls, a few minutes into driving. I've been concerned about this, since my wife mostly uses this car, and has stalled on the highway several times. I have had it stall in the middle of a busy intersection. Of course, the power steering also cuts out when the engine shuts down which compounds the danger. When I "googled" the words "2007 Grand Caravan stalls", a very long list of people with the same complaint immediately came up. Apparently, the small part causing this malfunction is part of the entire gas tank and cannot be replaced without replacing the entire gas tank. This is a very expensive repair, and not affordable to many. Chrysler should be recalling these vehicles and repairing what is obviously a major design flaw, before someone is seriously hurt or killed. This is not a defect in some innocuous interior part of the car, it affects the safe operation of a moving vehicle!.

Engine stalls out 10 or 15 seconds after filling the gas tank. Usually on the highway you are turning on to. Its been doing this for a couple of years.

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?.

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 broadsided. 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.

While making left the vehicle stalled while in motion in the middle of major intersection. After a 20 or so seconds, the vehicle engine turned on. Another incident, approximately a year ago, while traveling 60+ miles on major interstate, the vehicle again shut down while in motion. I had to coast the vehicle, with loss of power, to median on the interstate. After about a minute or so, the vehicle turned on. Always upon filling the gas tank, the vehicle stalls while exiting the gas station or shortly thereafter. After a minute, the vehicle is able to turn back on.

Car shuts off after filling the gas tank. This has happened several times. Always on the road and in traffic.

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.

After filling my '04 Grand Caravan with fuel and attempting to leave the pump my caravan shuts off. This has been on an ongoing issue for over 2 years. After several repair attempts I was told today that the vapor separator valve located on top of the gas tank is faulty. A valve that Dodge does not make available for repair. The only "fix" that is offered is to replace the entire tank of which I was told today would be $1600.

Approximately three months ago, my 2007 Dodge Grand Caravan stalled as I came to a stop sign in a parking lot. I was able to start right back up after putting my van in park. Being unsure why this happened, I drove around the parking lot a few minutes before getting on the road. It stalled one more time, but then I had no other problems and drove home. This occurred immediately after filling my van with gas, but I did not associate the problem with fueling at the time. Since that incident, this has become a recurring issue of the engine stalling only after filling my tank. When refueling now, I drive around near the gas station to insure the van is going to run. After getting gas, when I slow to come to a stop or I have stopped, the car may stall out. I have been able to restart my van by putting it in park, starting and pumping the gas peddle for a few seconds before proceeding. Fortunately, when my van has stalled, I have not been trying to cross traffic or traveling at a high rate of speed; however, the potential for serious injury does exist. Before taking my car to a dealership, I decided to look online to see if anyone else has encountered the same issue. My search found this to be a common enough problem that a defect petition dp14-002 was filed in September 2014 with doi. According to online resources, the remedy is to replace the entire tank. The problem is the vapor/liquid separator valve located at the top of the fuel tank and the valve is not sold separately. This appears to be a design flaw and I wonder why a recall has not been issued.

Vehicle hesitated first time while going 50 mph after refueling - regular gas. Checked the tach, went to almost zero, then back up again. Rode rough for a while. Stalled first time after refueling w/ regular gas, @ 35 mph, almost causing me to hit a curb - loss of power steering and brakes. Restarted okay. Stalled a 2nd time after refueling at red light, just 500 ft from gas station. Took 2 times to start it. When we figured it was not a bad tank of gas, we had our local mechanic check it, and we paid over $200. 00 for a crankshaft position sensor to be replaced. But we refueled the van soon after, and it stalled out again. That was when I decided to look online to see if anyone else has encountered the same problem. I was amazed at how many people had complained, and were told it’s not a known issue. It sounds to me like Dodge/Chrysler doesn’t want to accept responsibility for the problem. . Read more...

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).

Upon refueling the vehicle, vehicle stalls for a few seconds upon first acceleration. This has happened several times (about 1 out of every 4 refuels). Several times, the vehicle has stalled while pulling into traffic. Upon doing research, we have learned of many complaints already voiced about a faulty valve. . Read more...

See all problems of the 2003 Dodge Grand Caravan 🔎.

The vehicle stalls out after filling at the gas station. Reportedly due to an issue with the check valve and requires the entire fuel tank to be replaced.

Engine stalls within a mile or so after filling fuel tank. Issue began at 31,000 miles and vehicle currently has 35,280 miles. Has occurred every time fuel tank is filled since the first incident at 31,000 miles.

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 taking on gas, engine will sometimes stumble and most of the time quit running. Tried not over filling it and it still will just die sometime after taking on gas. On two occasions, it did this after hitting highway speeds. It would suddenly lose power and you had to pull off the road. It would normally start back up and have no more problems until next fill up. Because of this, we don't fill up and hit the road. We drive around before driving at highway speeds. Once, it died in front of several cars and a big truck had to brake hard and swerve off the road. So far, there has not been any known accidents but feel it is a matter of time before someone gets hurt. The mechanic said it was something wrong with a valve in gas tank and that you can't buy the part. We don't loan our van to the kids anymore since my oldest daughter almost caused a wreck and almost got hit when the van lost power.

Recurring issue of engine stalling after refueling. Usually within 5 minutes of filling, and when driving slowly. Internet search indicates this is a rampant problem, not only with caravans, but with other Chrysler/Dodge vehicles. Apparently the entire gas tank requires replacement, which indicates to me it is a design flaw and should be recalled.

2005 Dodge Grand Caravan stalls after filling up with gas. Is now occurring everytime we fill up the vehicle (3 times so far). After filling the tank, the vehicle starts fine, we drive up to 1/4 mile and the vehicle stalls. Restarts after a couple of tries and no problems noted. . . Until we fill up again.

For the past four years or so, almost every time after filling up the gas tank, the 2004 Dodge Grand Caravan anniversary edition stalls. I can be just pulling away from the pump when it happens, or stopped at a stop light within a few minutes from leaving the gas station. You can feel the car 'jump' like someone is pressing the gas pedal quickly and it jerks the van a bit forward. Then it stalls. It takes a few turns of the key and pressing the gas pedal very quickly and forcefully to get it started again. I have gotten into the habit of driving the van around a parking lot for a few minutes until it feels back to normal before pulling out into traffic, as I'm concerned it will stall out in the middle of traffic. This only happens right after filling up the gas tank. It concerns me now more than ever since my son is learning how to drive and I want him to be safe.

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.

After filling the gas tank on our 2007 Dodge Grand Caravan, it stalls regularly after driving a few hundred yards. Most recently it stalled as my family was merging in traffic.

After filling gas tank, engine hesitated and killed. After researching, determined this is a fuel tank valve issue common to minivans. Not covered under warranty, obvious manufacture defect. Valve allows liquid gas into vapor system. Issue still exists, temporary fix is to not fill tank completely when refueling. Expensive repair.

My 2005 Dodge Grand Caravan has been stalling after filling up the gas tank. It has been going on since mid Dec. 2008. I took it in to the dealer and they couldn't find anything wrong (no codes in the car computer). They increased the idle. It only hesitated after I filled it up after they increased the idle, but it has stalled the last 2 fill ups since then. It has stalled while trying to pull out into traffic and while stopping or slowing down.