Tank Assembly Problems of Dodge Grand Caravan - part 1

Our 2007 Grand Caravan sxt has about 44,000 miles on it and it has begun stalling after refueling. This only happens when the fuel tank is refueled to full capacity. The problem started about a month ago. Today, my wife (with kids in car) stalled on the highway. The danger was that she was on a turn and the steering wheel became impossible for her to turn it. This is a major safety issue, and my hope is that Chrysler makes good on a defective part. (I see they did that after a gov't investigation of a similar nature for other cars. . . After an investigation by NHTSA!) ***this is a widespread issue for vehicles from 2004 to 2013. . Read more...

See all problems of the 2007 Dodge Grand Caravan 🔎.

Fuel leaking from the fuel tank and the injection base. Start January 20 ,2014. I am a new owner.

See all problems of the 1996 Dodge Grand Caravan 🔎.

Vehicle stalls immediately after filling gas tank completely. I let pump turn off automatically and do not overfill. Has happened repeatedly in traffic and is dangerous. After a few miles, no more stalling or sputtering. Lots of reports of this problem with Dodge/Chrysler vehicles online but company claims no knowledge of problem. Fix is to replace fuel tank and attached parts.

For at least a year now (dates and mileage above are some sort of approximation) our car has been having trouble upon refueling. As I drive away from the fueling station, within about the first mile the car hesitates, chokes and either threatens to stall or actually stalls. After a few moments, or upon restarting, the car does fine. I have asked the dealer about this and they expressed no knowledge of Chrysler notices about it or what might be causing it. They said it would be expensive to pull the gas tank, so I have left it for now. But having the car do this is dangerous. I googled the problem and found that there are numerous people with this 4th generation caravan that have the exact same problem. Dodge's mediator suggested that it's a problem with topping off the tank, but I have found that not topping it makes no difference, and as you can see from the online strings I am attaching, there are others who never top off their tank and have the same problem as we do. This is apparently a design flaw that creates a danger. It is expensive for the consumer to fix, and my impression is that it will steadily get worse. We were part of the headlight problem with these cars too. The headlights on the car were unstable from the time we bought the car. After years of complaining, our dealer finally seemed to have fixed the problem, but we had to pay part of it. Since then we have received a notice that Chrysler is taking responsibility for the problem. I hope this gas tank problem will not take so many years to correct as the headlight problem.

See all problems of the 2005 Dodge Grand Caravan 🔎.

My gas tank dropped on the ground because both brackets holding the gas tank to the vehicle had rusted through. This could have been a very bad incident if I had been traveling faster on a road with heavy traffic.

See all problems of the 2000 Dodge Grand Caravan 🔎.

Van stalls a few minutes after re-fueling tank to full level. Tank is not topped off beyond what auto shut-off nozzle at station allows. Stalling quite often happens when driving back onto main streets from gas station. All power braking and steering is lost when this happens which presents a very dangerous situation especially in heavier traffic conditions. Van must be completely stopped and restarted. Once restarted, vehicle does not exhibit problem until next fill up.

See all problems of the 2006 Dodge Grand Caravan 🔎.

!999 Dodge Grand Caravan. One gas tank support strap fell off driving on smooth pavement, 2nd strap disintegrated with slight manual twist, got it back onto driveway & supported tank before replacing both. Have both parts same as reported; Ford pickups recall.

See all problems of the 1999 Dodge Grand Caravan 🔎.

Our 2004 Dodge Grand Caravan will stall out driving down the road if you fill the gas tank until the gas pump nozzles stops automatically. The only way to stop this is to replace the gas tank because of a bad valve in the top of the tank in the emissions system. I found this information on line. It has done it several times and we now under fill the tank which is not easy to do.

See all problems of the 2004 Dodge Grand Caravan 🔎.

Shortly after filling up with gas, I often experience difficulty with the vehicle. It sometimes stalls. It acts up within a minute or two by trying to stall. I try to give it as much gas as I can and it eventually stops acting up if it doesn't stall first. The dealer says they cannot replace the fuel filter, because it is part of the whole gas tank setup. It is not replaceable like most fuel filters are. It seems to me that it is the fuel filter needing to be cleaned. I do believe it is ruining my fuel pump slowly. I am concerned about when it stalls that someone may run into the back of me.

The first problem was the automatic door locks failed to function when reaching the required speed. Even would not lock with the key took it to mechanic was advised that would have to replace the computer, but by disconnecting the battery that it would reset the computer, it is only a temporary solution. Second problem was the door motor stop working had that replaced. Third problem was the front axle broke with no apparent wear, had that replaced. Now it's the gas tank, car wants to stall was advised by mechanic that the gas tank would have to be replaced, that it is a defective valve that has since been corrected in the newer models.

Gas gauge failure on 2005 Dodge Grand Caravan. Gage reads full when vehicle is serviced with gas and tank is filled. As gas is used the gage will decrease correctly until 1/4 tank is remaining. Gauge then hangs up, showing 1/4 tank, and does not decrease as gas is used below 1/4 tank. This resulted in my daughter-in-law running out of gas while in heavy evening traffic. Luckily, she was able to coast to the side of the road. I have found out from reliable sources (authorized Dodge repair shops) that this gas gage failure is common among the Dodge caravan's and Grand Caravan's. I feel this is a safety issue and should be investigated for possible recall to prevent any possible injury or death resulting from running out of gas while in heavy traffic.

Fuel tank leaks.

See all problems of the 2001 Dodge Grand Caravan 🔎.

The contact stated that gas tank had to be replaced. It was falling apart at the top of the tank. When filling the vehicle up with gas it spilled everywhere. The gas was seeping out of the top. He called the dealer and it was not under recall. Updated 11/29/05.

1994 Dodge caravan le, v6, 3. 8 l. Leaking fuel tank. Fuel leaks when vehicleã‚??s tank is filled. Fuel run off from the top side of fuel tank between the floor and top of gas tank. Vehicle fuel does not leak after 2-4 gallons of fuel is burned. Vehicle has no accident history.

Occasional fuel smell from car for many months. After filling and parking car with rear end on up hill incline noticed gas pouring out from under car from top of gas tank. Took to dealer they said all recalls were performed. They dropped tank and informed me the plastic tank was splitting at the seam on top. Not a Dodge problem . My cost to replace $900. 00. I think this is a manufacturer defect since I have been informed by several outside mechanics that they have replaced quite a few of these Chrysler fuel tanks. The potential for fire is great for some one passing by and flipping a cigarette.

The consumer stated vehicle was leaking fuel from fuel tank, and has already had three fuel related recalls. There was a defective roll over valve. The vehicle is currently at the dealership. They have not stated why the problem was happening. Also called the manufacturer. The fuel leaked when the tank was relatively full. The problem was noticed four or five months ago. On July 21, 2005 there was fuel under the vehicle. Consumer stated it was his wife's vehicle.

Dt: the consumer stated the location of the fuel tank causes it to be susceptible to damage and cause leaking which can lead to a fire hazard.

Heavy fuel vapors in passenger compartment, and under hood. Occurred during normal driving. Has occurred in the past but then went away the next day. All occurrences were during cold weather (20-30f). Driver and passengers experienced nausea. Mechanic said that the fuel tank rollover valve is malfunctioning allowing fuel into the vapor canister. This sounds alot like the recall for 1996 models of this van.

See all problems of the 1997 Dodge Grand Caravan 🔎.

Gas pump malfunctioned, causing overfill of gas tank. Gas tank system allows for capture and evaporation of overfill. Vents for air flow in vehicle allow gasoline fumes/vapors into passenger compartment of vehicle. This creates a problem if you have passengers or need to use the vehicle. All occupants are forced to sit inside of an enclosed vehicle with gasoline vapors. Brought concern to dealer and dealer said vehicle was operating within design parameters and advised not to overfill tank. Overfill was not intentional and dealer advise does not correct problem. Dealer stated that the evaporative system was mandated by federal government regulations. Dealer also stated that all new cars have similar systems and if they are overfilled fumes/vapors will be present in passenger compartment as well. I believe that this is a design/manufacture problem that needs to be corrected. Dealer will not work with me but only states that the system is working the way it was designed. I am not comfortable putting my family/children into the vehicle and driving it while it is full of gasoline fumes/vapors. As a career firefighter I recognize that gasoline is most volitile in the vapor state. I have brought this information to the manufacturers/dealers attention and have been told that there is nothing that they can/will do.

See all problems of the 2002 Dodge Grand Caravan 🔎.

While filling up the fuel tank valve joint separated from gas tank, causing gasoline to pour out. Consumer had vehicle towed to the dealer for analysis, and mechanic recommended that the fuel be replaced due to a crack.

See all problems of the 2003 Dodge Grand Caravan 🔎.

When driving over some debris in the road, the fuel tank ruptured.

My vehicle is 28 months old and I am already on my third fuel tank cap. The previous two caps began leaking which was detected by my computer. The first cap was replaced just this past November, 2002. This cap had to be replaced only 8 months later. This last replacement was not under warranty because my vehicle had reached it's 36,000 miles since the first time the cap was replaced in November of 2002.

The fuel tank cracked and leaked fuel. The consumer was told that the problem was due to the fuel tank assembly which had additional brackets. The consumer felt that this was a design flaw. Scc.

Fuel tank leaked profusely when full. Tank had a leaky vent on top repaired cost $300. I noticed several of these tanks setting around the dealers repair area that have been replaced. Dt.

Fuel tank has a rubber vent ring on the top of the tank around the line which feeds fuel out of the tank. The vent dry rotted and deteriorated. The van was parked on our slanted driveway and gas began pouring out of the tank onto the driveway. The dealership and corporate headquarters have been contacted. They are firm with their position that the warranty has expired and the van was not repaired at one of their service centers, therefore they will not help with the costs of the repairs. ($737. 00) the service manager at the dealership did admit this problem has never been seen before. He stated he has been asked to complete an engineering report for Dodge corporate headquarters. Should this car have been involved in an accident with this defective part, gas would have easily leaked from the tank causing an extreme safety hazard. Dodge seems to be turning a blind eye to this problem and refusing to admit they sold me a car with a defective fuel tank. A response regarding this matter would be appreciated. Dt.

The fuel tank was leaking fuel. Ts.

Fuel tank developed a crack and caused fuel leakages. Dealer notifed. Feel free to provide any further information.

Vehicle has a hole on top of gas tank, and tank is leaking gasoline. Dealership is aware of problem.

The top of the gas tank came off and witin 40 miles I lost 10 galons of gas.

The consumer requested reimbursement for fuel tank replacement. . The consumer noticed a leak under the van, and seeing the leak become worse after filling up the vehicle, the consumer discovered the van was leaking gasoline. The fuel tank was replaced.

The consumer states taking the vehicle in for the fuel leak recall(NHTSA id#00-v-268-000 manufacturer recall id# 895). The vehicle had a leak at the top seam of the fuel tank. The consumer states each time the tank was filled the smell of gas lingered for at least two days. The problem did not start until the recall was performed. The dealer was notified.

This is my second 2002 Grand Caravan. . . The first was purchased on 10/23/2001 and on the way home we smelled strong fuel vapors, the check engine light came on, and it started running rough. Dealer could not determine problem and we were given a replacement 2002 Grand Caravan on 10/24/2001. . . . I later found out that this replacement vehicle was built on the same day and same production line as the previous 2002 I had. . . And only one other vehicle was produced between them. The vehicle I have just started to have the same problem as the previous one (strong vapors, check engine lite), and was diagnosed as having gas tank/pressure relief valve problems. Since the vehicles were built on the same line/day, and since it is a gas tank/vapor problem, am concerned about the safety of all Grand Caravans built on that line on/around that day.

This is a followup on odi 757393 submitted on 1/24/2002 and amended 1/27/2002. Upon towed return of vehicle to service agent repair shop, service agent investigated visible gasoline leak. Upon careful examination of the replacement vent assembly, service agent reported that while the part "looked" like the right part; it indeed was an incorrect part. The service agent said the part was previously packaged and shipped in a box with the correct part number; however in conversations with daimlerchrysler, it was only then determined to be an incorrect part. They could only distinquish the part by its vendor manufacturer's "casting number" cast into the assembly. Chrysler verified that this was indeed an incorrect part; and a replacement vent assembly was ordered and replaced. This alleviated the prevous leak. Service agent reports his technician could not distinguish the incorrect part from the real part, and felt it was securely tightened, but the apparent clearances and slight size differences allowed the gasoline leak to develop. No leak was further noted with the complete fill-up of the gas tank by the owner. It is noted that the service agent had no "special" procedure for testing the gas-tightness of the gas tank as he had not previously filled the tank to overflow to check same. This appears to be a "deficiency" in tank replacement procedure, as it was only when the owner subsequently filled the tank that the original leak was ever detected.

Owner reported raw fuel odor after filling fuel tank. Previous TSB #845 recall (o-ring) was performed 04/21/2000 and verified ok. Service agent reports vent assembly on gas tank defective and leaking. Fix involved complete replacement of gas tank with new model, as present vent assembly is no longer manufactured nor compatible with original tank. Dodge post warranty participated for 50% of matl cost of tank only. Dissatisfied owner made to incur $302 matl/$100 labor + tax to incur fix. Owner requested defective part; Dodge service agent refused citing not applicable to extended post warranty offer and need for service rep to account for same. Would only release part if owner fully paid for fix. (sounded like a ruse. ) owner was forced to accept offer in light of safety concerns. Suggest investigation of defective part, as currently held by service agent and why original part is no longer available to accommodate repair making the fix to manufacturer's new designs(desires)? owner has expressed his total dissatisfaction to service agent with no results, short of suggested withdrawal of offer. Service manager suggested if owner did not wish to participate in the "fix" he would suggest that the owner not completely fill up the gas tank. Owner notes an extremely close proximitiy of the defective original (and replaced) plastic vent assembly to rear muffler assembly. The replacement tank is also plastic. The original gas tank was reported to be "good" at time of recall, and at time of replacement. Service manager alluded to free replacement of tanks shown to buckle or bow at time of recall #845. Similar offer was not extended at present time of replacement of gas tank.

This vehicle is experiencing same problem as mentioned in recall 00-v-268-00. But vehicle is not included in recall due to VIN. Vehicle leaked out almost instantly 28 gallons of fuel. Contacted dealer, and the dealer was taking a look at the problem.