Tank Assembly problems of the 1996 Plymouth Voyager - part 1

The contact owns a 1996 Plymouth Voyager. The contact stated that while driving 30 mph, he smelled a fuel odor. The contact noticed a fuel leak from the rear of the fuel tank. The dealer stated that the fuel module needed to be replaced. The vehicle had not been repaired. The current and failure mileages were approximately 92,000.

Consumer states that while driving the vehcle had stop for gas after picking up the vehicle the day before from the dealer ship where the recall for fuel leakage was done, was pumping gas when the gas spilled all over the ground at the gas station. Dealer notified. Nlm.

While driving at any speed and with no warning fuel tank cracked, causing fluid to leak out. Dealer notified.

Fuel tank leak occurred at a platisc weld point on the top of the tank where a line went in. This tank is essentially a static component and a leak at a weld joint I consider is a manufacturing defect. I've taken a few autos beyond this amount of mileage and years without any fuel tanks failures of this type. This failure appeared during vacation when parked on a grade with thefront of the van pointed downhill. This caused a rather large pool of fuel to sit on the ground, enough for the local officials to send a fire truck to the scene. When I returned to our van it was determined by the fire offical that it not be driven. The van was towed to a Chrysler dealer ship and the next day the leak was found. They could not supply a tank but since the leak was on top said it was safe to drive as long as I filled the tank no more than three quarters full. I proceeded home and had the local moncks coner dealership repair the van. I called the Chrysler customer service 800 number to see if this was a covered recall or alert bulletin. It was not. They would not even consider paying for a portion of the repairs. Like I said before a failure of this type is unacceptable and can be very unsafe do to the great possiblity of fire. Please look into this for me. Thanks leif.

My wife was driving our five year old Plymouth Voyager minivan in town and another driver warned her that gasoline was spraying from the vehicle. She stopped in a parking lot and looked under the minivan. Gasoline was gushing from the gas tank at a very high rate. Had this ignited, there would have been an explosion that would have enveloped the whole vehicle. My wife called me at work. Because of the serious safety and explosion hazard, I told her not to restart the car and I had the car towed to our local Chrysler dealer (naylor Chrysler in ann arbor, michigan). Their service department found that the fuel tank had collapsed and deformed separating the fuel pump and gasket from the fuel tank and creating a large gap. The vehicle is a well maintained vehicle with only normal highway usage and with no modifications, no accidents of any kind, and with all the original factory installed fuel system parts. The naylor Chrysler service department replaced the defective fuel tank and associated parts. The cost was approximately $610. I called Chrysler corp. At (800) 992-1997 and stated that if a safely-related defect exists in a motor vehicle, the manufacture must fix it at no cost to the owner. The Chrysler representative verified with the dealer that the takn had collapsed and separated from the fuel pump and that the vehicle was unmodified and original and not in an accident. The Chrysler report filed is file no. 8907052, dated Jul 25, 2001. Chrysler stated that they would not pay for this safety repair because tha vehicle exceeded the 3 yr. , 30,000 mile warrantee and there was no recall. I do not expect a five year old, well maitained, original equipment, accident free vehicle to have a serious fuel system failure that could easily cause a fatal explosion. I requested the dealer to save all defective and replaced parts and make them available for inspection by Chrysler corp. Chrylser corp. Declined to inspect the parts.

A distinctive gasoline odor occurs when the fuel tank is filled to it's maximum capacity. Teh dealer was aware and indicated the entire tank needed replacing. Consumer suspects the problem was only with the o ring and not the whole tank.

Bracket bolt came off gas tank, dropping the gas tank and bracket to the ground.

My engine has had several problems, and every time they "fix" it, something else happens. It is still sputtering and the check engine light came on again even after I spent 650. 00 to have it fixed a few weeks ago. Now, yesterday they did yet another fuel system recall, and today (4/15/00) the check engine light came on and it is sputtering again. I am sick of sinking money into this van and it is not even paid for. Also, the number of fuel system and engine recalls they have had is dangerous. Most of their recalls have had to do with the possibility of the van catching fire. I hate to think about what could happen to my children while riding in this vehicle. They need desperately to put out a recall on the head gasket leaking oil. I had to have a $1,000. 00 head gasket job at 60,000. That is ridiculous. I think it was due to improper repair of the oil galley plug recall, but they say that is not related, even though in the recall notice it states that "engine cylinder head oil galley plug does not seal properly and engine cylinder head oil is not adequately retained. Inadequate sealing and retention of the plug can result in oil leakage. . . " how can they say my van leaking oil from the cylinder head was not related? please respond. I need some help on this matter.

Fuel tank: rollover valve located on top of plastic fuel tank is welded into fuel tank at manufacture. First tank failed at 6000 miles on vehicle, tank cracked around weld at rollover valve site. Fuel leakage and vapor leakage ensued until tank replaced by dealer (quality Chrysler Jeep Plymouth eagle, albuquerque, nm in Aug 1996). The replacement tank developed a leak at the same site, weld of rollover valve to tank body, in December 1998. Both tanks failed in similar manner, both failures cause raw fuel and vapor to leak continuously from tank. Problem with multi-function switch (turn signals, high/low beam, wiper, washer switch, steering column mounted. When driving, the front and rear windshield wipers will automatically turn on by themselves. First multifunction switch replaced by quality Chrysler Plymouth Jeep eagle, albuquerque nm, late 1996. Dealer replaced multifunction switch. Problem recurred in November 1998. Dealer replaced multifunction switch a second time. Fuel tank leak at rollover valve site, and multifunction switch both failed two times in same vehicle. It is apparent that the tank manufacturing process is deficient, and that there is a basic design flaw in the multifunction switch.

A crack developed on top of the gas tank is causing gas to leak when tank is full.

Ther was a strong fuel odor outside of vehicle, consumer had taken vehicle to dealer, who noticed a leak at rollover valves. Dealer stated that entire fuel tank needed replacement. Consumer stated problem seems to have been in existance for a number of years, also air condition not cooling properly, and the fan motor blower seems to be inoperative.

Fuel tank failure.

While parked overnight, gasoline leaked from fuel tank onto driveway caused by crack on top/seams and side of tank. Replaced by dealership.

Gas tank leaks at seams, also cracked on top.

Fuel tank continuously overflows and leaks onto the ground.

Vehicle wa sleaking gas after the tank wa sfilled up due to a break in the fuel tank collar asembly.

Failure of the fuel tank, the fuel tank has a crack, causing fuel to leak.

Had been smelling gasoline all the time and now it is leaking . Contacted dealer who was aware of a recall for the fuel tank . There is a stress fracture in the tank caused by defect in the tank.

Fuel tank valve failed, causing fuel leak, owner not notified of recall.

Gas tank leaks at seal.

Filled up tank, 10 minutes later, noticed gasoline dripping out of tank, stopped, started leaking again, whole system will be replaced by dealer.

Fuel tank actually contracts inside itself. The gauge actually is on 3/4 tanks of gas when the tank is empty. Please describe details.

Gas tank leaks somewhere on top surface, leaks when tank is filled onto bottom of tank. Orignal tank replaced by Chrysler with new tank.

Smelled an odor, fuel tank developed leakage around the "o" ring on vent pipe.

While parked on incline approximately 7 gallons of fuel leaked out onto ground, caused by improperly welded seam, dealer found no problem, replaced tank. Owner sold vehicle.

Recall still has not been completed after many attempts.

Gas tank replaced under recall, however fuel gauge not changed to new tank, causing tank to run out of gas while registering 1/4 tank.

Gas tank leaks.

Driver's side sliding door latch failed, door came open while driving, also rear window wiper blade motor failed and fuel tank was leaking on top.

Fuel overflow and filler neck is leaking. Tt gasoline leak from feul return line near gas tank, leak apparently at fill up, gasoline tank replaced with attached fuel return line, binding throttle linkage reported to dealer, repair attempted throttle linkage still binds after warranty service.

When parking on an incline the vehicle stalls repeatedly 4 times, possibly due to gas tank problems. Tt.

Fuel tank manufactured improperly, would not hold fuel, replaced; subsequently, fuel started leaking from fuel filler pipe whenever full tank; dealer tightend clamp that holds filler tank to fuel line.

Gas tank was replaced once because of leaking, now new one is leaking. Tt.

When turning off the vehicle one can hear the gas gurgling in the fuel tank, the tank has been replaced three times first time because it was deformed and second ans third times because of gurgling sound.

Gas tank would leak if parked facing downhill. Tt.