Other Fuel System Tank Mounting Problems of Dodge Grand Caravan

Repeatedly the vehicle will loose power and stalls out after filling the tank with fuel. It will occur within less and 1/8th of mile after pulling out of the gas station. The vehicle has done this repeatedly in inopportune situations, like traveling up a steep hill and at a busy intersection. We are original owners and had never had an accident with it . It has just under 120k miles on it.

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Tl-the contact owns a 2004 Dodge Grand Caravan. The contact stated when the vehicle was being refueled to capacity the fuel level indicator would not register the amount of fuel in the vehicle. The vehicle was taken to the dealer, who stated that they would have to replace the fuel tank. The manufacturer was notified of the failure. The failure mileage was 87,000. Kmj.

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The 3. 8l engine stalls after almost every fuel fill-up and began in early 2010. Within 1-2 miles after a fuel up, the vehicle will buck and sputter and often turn off completely. It gets better after 3-5 miles. It apparently is a known issue with many Dodge owners, not just minivans. I had two 2006 Dodge chargers (r/t and srt8) that both did the same thing. I no longer own the chargers but still have the 2004 caravan. This a dangerous and unpredictable issue that has something to do with the tank mounted vapor separation valve and the vapor return system. The vehicle is not "topped off" when fueling which has been known to create the issue. Thanks.

Purchased vehicle new. Have always topped gas past initial click. Sometime from the beginning of this year, after topping off the gas tank, vehicle started bucking and engine quit. First couple of times, couldn't figure out problem. Then remembered it always happened after fill up. Started varying topping off, and was able to notice length of problem related to amount of top off. Last couple of fill ups, went to first click and stopped. Did not resolve problem, but kept sequence of vehicle bucking and engine quitting. Engine had also died while driving on the highway. On last fill up, was preparing to take vehicle to dealer for check of problem. After filling tank (to first click), was at signal light, waiting to make a turn. Vehicle started bucking, engine died. Put transmission in neutral, started motor, then a sound like carburetor backfire occurred. Engine went to high idle, signal light changed, so proceeded to drive. Had sound like a/c coolant low. Speed was barely controllable. Had to use brakes. Gas pedal control was erratic. Seemed to stay at level applied. Took to dealer next morning. Had failure code (#po507), and eventually they said "pvc valve hose to upper peliunm" had came off. Never had a "check engine" light. Have not had fill up since, but will sometime this week. Have been looking in haynes repair manual, and noticed there was some type of check valve to keep fuel from entering air intake. Dealer did not bring up this idea, but did mention another customer had a similar problem by topping off. Looked under vehicle and noticed two valves/connections at lower level of gas tank.